DOMETIC TEC 40D Diesel Generator Instruction Manual

TEC 40d
DIESEL GENERATOR

TEC 40D Diesel Generator

Operation, maintenance and installation manual

With Dometic at home everywhere. Thank you for your decision to buy an Dometic product. They all have been specially conceived for your vehicle, matching totally the requirements of leisure on wheels – with more than 75 years of experience, the most advanced technology, first-rate materials, superb workmanship, functional design and a care for the environment. The unique Dometic EuroService Guarantee offers you additional peace of mind – ensuring that you will derive comfort everywhere from your Dometic products

©DOMETIC – 2007 All rights reserved – Printed in Italy –
No part of this manual may be reproduced, copied or transmitted in any form or by any means without prior written permission from DOMETIC.
Figures, descriptions, references and technical data contained in this manual are given as mere example and are not binding.
In pursuing a policy of constant product and safety improvement, DOMETIC reserves the right to effect changes at any time without undertaking to give prior notice or to update this manual every time.
Keep this document for future reference.

“The product is warranted in accordance with the enforced Law and regulations implementing the Directive 1999/44/EC.”
The Manufacturer’s warranty does not extend to Product failures, defects or damage arising from and/or attributable to a wrong installation.
The Consumer is entitled to let the Product be installed by an authorised dealer, not bound by Dometic.
The warranty extends to failures or defects in the gen-sets which shall become apparent within the warranty period. The warranty shall cease to have effect if, during the two-year warranty period, the gen-set is used for more than 1,000 hours or if the recommended service schedule is not completed.

Operation, Maintenance and
Installation manual
Generator

General informations

1.1 Purpose of the manual
This manual has been made up by the Manufacturer and is an integrated part of the generator’s equipment.
The information, if respected, will guarantee the correct use of the generator.
The part of the manual reserved for the users is indicated by the symbol while the part reserved for the experts installing the generator is indicated by the symbol
The following symbols have been used to highlight some parts of the text:

**** The operation can be dangerous.
Useful suggestions.
Information on the protection of the environment.

1.2 Data plate

The company Dometic is not responsible for any damage caused by generator malfunctions.

1.3 Safety
The generator is installed in a closed casing. Therefore, there is no danger of accidental contacts with moving parts or wires under voltage. The door is fitted with a key lock which shall be kept out of reach by children or non- authorised people.

Warning

• Check the generator before using it every time. In this way it is possible to prevent accidents or damage to the motor.
• To prevent fire hazards and to keep the generator in an efficient working condition, do not close the same in a case or an enclosed space such as an alcove but install it in a well-ventilated area.
• Keep children and animals away from the generator when it is running, as it can heat up and cause burns and injuries, both directly and through the systems it is supplying.
• Learn how to turn the generator off quickly and how to use the controls. Never leave the generator in the hands of people who are not trained to use it.
• The generator must only be used with the generator door closed.
• Keep flammable substances away from the generator such as for example: petrol, paints, solvents etc.
• Make sure that the hot parts of the generator do not come into contact with materials that could catch fire.
• Fill the generator with fuel in a well-ventilated area with the generator turned off. Petrol is highly flammable and can explode.
• Never overfill the fuel tank. There should not be fuel in the tank filling throat. Check that the cap is tightly closed.
• If you spill any fuel, clean it up thoroughly and wait for the fumes to evaporate before starting the engine.
• Exhaust gases contain carbon monoxide, an extremely poisonous gas, which is odourless and colourless. Avoid inhaling exhaust gases. Do not run the engine of the generator in a closed garage or room without very good ventilations.
• Do not touch the generator or the connections with wet hands.
• Do not replace fuses or thermal cutouts with others of a higher amperage.
• Any checks carried out on the electric parts should be done by authorised personnel with the engine turned off.
• Install the generator in a stable area. Do not incline the generator by more than 20° with respect to the vertical plane.
• Sudden braking or acceleration, or curves taken abruptly with the vehicle can cause problems in the pumping system of the generator and make it stall.
• When storing the generator up for a long period of time, start it at least once every 30 days and leave it running for at least 15 minutes.
• Leave the generator on for a few minutes without charge after use before switching it off.

The generator is made to meet the safety regulations indicated in the declaration of conformity.
1.4 Noise
The generator has been tested for noise emissions at the qualified independent laboratory DNV Modulo Uno which has issued the EECcertificate based on EC- DIRECTIVE 2000/14.
GUARANTEED AND MEASURED SOUND POWER LEVEL:
TEC 40D …………………………………………………………… LwA 89
SOUND POWER LEVEL measured from 7mt …. dB(A) 64

1.5 Description of the generator
Warning
The TEC 40D generator has been designed and produced to be used only on caravans, motor homes and commercial vehicles.
Therefore it has not been designed to be used on other types of vehicles or on any kind of watercraft. The company Dometic, as it is impossible to envisage every possible use and type of installation, declines any responsibility for every type of use and installation which is not explicitly mentioned.
The generator has been designed to produce alternating current at 230V and 50 Hz, capable of supplying power to various systems.
Therefore it is fitted with an inverter, so that it can supply systems that are very sensitive to the quality of the energy supplied, such as personal computers for example.
The generator is installed in a sheet metal steel casing which is insulated and soundproofed with special soundproofing materials.

1.6 Recommandations for use
To use the generator in the best way it is a good idea to pay attention to even small overloads, which if prolonged, will cause the protective thermal cutouts to trip.
When running in it is important not to put the new engine under a load that exceeds 70 % of the nominal load, at least for the first 50 working hours; then we recommend a normal use of the generator with a load equal to roughly 3/4 of the maximum declared continuous load, this in order to prolong the life of the generator and maximize efficiency.

1.7 Fuel
All diesel oils which satisfy the following specifications are suitable:
EN 590 or
DIN 51601 – DK or
BS 2869 A1 / A2 or
ASTM D975 -1D / 2D
At temperatures below 0°C, winter-grade fuel should be used or paraffin added to the fuel well in advance.

1.8 Operation description
The main elements of the TEC 40D generator are: an engine (a), a permanent magnet alternator (b), an inverter (c), an internal control panel (d), a terminal board (e) and an external control panel (f).
When the engine runs it drives the alternator to which it is solidly connected, which in turn generates alternating current that supplies the inverter.
The inverter “converts” the voltage supplied into a higher quality, perfectly stable voltage of 230 V and 50Hz supply.
The terminals, the socket where the extension of the external control panel is connected and the safety switch are located on the internal control panel.

The external control panel is equipped with:

• buttons to start and stop the generator
• a back lit LCD screen showing the main electrical pro-perties, an indicator shows that the generator is working properly and an hour counter is also displayed. In the case of problem the alarm messages are displayed on this screen.
• LED indicators indicate low levels of petrol and oil.

Start sequence:

1. Push the red main switch
2. Wait “GEN OFF” on the display
3. Push and release the START button

Turn-off sequence:

1. Push the red main switch

1.9 External control panel

Operation description
MAIN SWITCH: turns the panel on/stops the generator
START BUTTON: starts the generator
PETROL INDICATOR: indicates that you are using the fuel reserve
OIL INDICATOR: indicates a low oil level and the engine automatically stops
EMERGENCY STOP SWITCH: stops the generator immediately in an emergency
CUT OUT SWITCH: continuous current thermal cut out protection

1.10 Internal control panel

1.11 Technical data

1.12 Table describing the alarm messages appearing on the display

DISPLAYED MESSAGE| DESCRIPTION| GENERATOR BEHAVIOUR| ACTIONS
---|---|---|---
LOW BATTERY| Indicates that the battery voltage is below the minimum value necessary to start the generator.| The generator does not start.| Check the efficiency of the battery before starting the generator.
OIL CHANGE| This message appears every time the hour counter of the machine reaches the service interval pre-set to change the engine oil,| The generator continues to run,| Change the oil (see p.20) before restarting the generator by holding the start button down for longer.
NO FUEL| Indicates that you are using the fuel reserve.| The generator continues to run.| Refuel.
OIL ALERT| There is no more oil in the oil tank.| The generator stops.| Fill up (see page 11).
GENERATOR ALERT!| General alarm message: it is displayed for instance when the check ring of the carburettor throttle (step motor) is defective and the M110 module cannot check the motor speed| The generator stops.| SeeTroubleshooting table on page 18. If the problem persists. address to the nearest service centre.
OVERLOAD!| Indicates an output overload of the supplied sy- stems.| The inverter stops and voltage is no longer supplied. but the engine continues to run for a correct cooling of the internal parts.| Reduce the connected load. wait a few minutes to cool down the generator. Stop the engine by pressing the main switch button. Then restart the generator.
SHORT CIRCUIT| Indicates an output short of the supplied systems.| The inverter stops and voltage is no longer supplied. but the engine continues to run for a correct cooling of the internal parts,| Check all the connected systems. wait a few minutes to cool down the generator. Stop the engine by pressing the main switch button.
OVER TEMPERATURE| This message is displayed in the event of a thermal overload,| The inverter stops and voltage is no longer sup-plied. The engine continues to run for a correct cooling of the internal parts. then stops and the message displayed is “RESTART GENT’.| Let the generator cool down, wait a few minutes and restart the unit.
LOW POWER ENGINE| Signals a reduction of the voltage supplied to the inverter,| The generator stops.| Reduce the connected load and restart the generator.
RESTART GEN?| This message appears after any stop of the generator.| The generator stops.| Turn off and restart the generator.
GEN CAL| This message appears at the generator start-up and indicates the calibration phase preceding any start- up. The generator does not produce current yet.| The generator run but voltage is not supplied.| Wait a few seconds.
GEN WAIT| Message displayed between one start attempt and the other.| The generator not run.| Wait until the message goes off before attempling a new start.
GEN ON| Indicates that the generator is running.| |
GEN OFF| Indicates that the generator not run or is ready to start| The generator not run.| Push the start button if you want to restart the generator

1.13 Routine maintenance
To perform these checks you should open the door of the generator taking the following precautions:
The generator must not be running and all of the parts must be cold.
Set the safety switch on the internal control panel to “O” (OFF).
Disconnect the positive pole (+) of the vehicle’s battery
IMPORTANT: Use only genuine spare parts. The generator may get damaged if other than genuine parts having a different quality standard are used.
IMPORTANT:
Remember to reconnect the positive pole (+) of the vehicle’s battery and set the switch back to “I” (ON) once you have finished the checks.

1.14 Checking the oil level
Remove the oil filler and clean the dipstick with a cloth.
Refit by screwing the dipstick.
Remove the dipstick and check that the oil level is between the two (min. and max.) marks.
Add oil if necessary through the filler. Use only the oil recommended by the manufacturer!
** Refit the plug.
IMPORTANT:**
Perform all of the checks making sure the generator is in a horizontal position.

Installation instructions

2.1 Instructions for fixing the generator

2.2 Instructions for installing the exhaust system

We recommend positioning the elbow of the exhaust pipe in line with the length of the casing (as shown in the figure) so more vibrations can be absorbed.
Use the exhaust extension (AG125) to extend the position of the muffler. Fix the exhaust extension to the vehicle using flexible elements to reduce vibrations (extension fixing is avalaible as accessory upon request – Ref. AG163).
WARNING
Do not make any sharp bends in the hose which could obstruct the exhaust gas.

2.3 Instructions for the installation of the tank
Generator TEC 40D is equipped as standard with an electric pump for pumping fuel. The following should be done.
The fuel tank should be installed with the tank basis at a maximum depth of 1.5 meters below the lower edge of the generator box. For safety reasons ensure not to mount the generator box top edge higher than the tank top edge.

2.4 Instructions for the electrical connection
The Dometic generator is a source of alternate 230V 50Hz tension, able to cope with various power needs.
Electrical connection to the external network
The on board electrical system must be fitted with a relay or switch (e.g. Dometic switch cod. AG113, available on request) to prevent damage to the generator when the external power supply network is connected; in this case, it is suggested that the generator be connected in such a way as to give it priority with respect to the external network.
Electric wiring must be effected in conformity with the existing laws and regulations in force in the user’s country.
For correct installation performed by the final user, use preventive technical assistance by your seller or by a skilled technician.
For the 230 V, use an approved cable with the section indicated in the table. For connection of the Dometic switch cod. AG113 refer to the instructions and diagram on the following pages.
Electrical connection of the battery charger
The unit is set up to provide for automatic battery recharging. If this function is to be used, proceed as follows.
Use a cable finding the correct section in the chart on the right.
Connect the cable to the connecting terminal and to the positive pole of the battery to be charged.
Should the battery be others than that used to start the generator, then connect the negative pole of this battery to the proper mass point of the generator (see picture on page 17).
NB:The negative pole of the battery should be grounded with the vehicle’s frame.

Cross-section mm²
230V
(power cables)| Cross-section mm²
12V
(battery charger)| Cross-section mm²
Lenght up to 6m
(battery connection)| Cross-section mm²
Lenght > 6m
(battery connection)
---|---|---|---
4| 2.5| 16| 25

Connecting the fuel indicator
Only use the indicator connection if there is a fuel level probe in the tank used for the generator. Connect the proble cable (e.g. float) to the relevant terminal (see figure above).

Battery connection
N.B.
To start the generator it is necessary to use a 12VDC battery, with a minmum capacity of 60Ah.
To start the generator, connect it to the positive pole of the vehicle’s battery with a sheathed cable of a suitable cross-section as shown in the table. The ground cable must have the same cross-section and be connected or as shown in the figure to the side or from the inserts to the frame of the vehicle. Make sure that the contact is good. If necessary remove paint or rust from the surface of the frame and protect the connection with grease. To protect the DC wiring use a 100 Amp fuse closed to the plus pole of the battery.

External control panel connection
Choose the desired position inside the vehicle, use the extension lead (supplied) to connect the external control panel to the internal control panel of the generator.

Troubleshooting, maintenance, recycling

3.1 Faults, causes and solutions

3.2 Check list and time intervals

| Maintenance chart| Maintenance work required
---|---|---
8-15| Every 8-15 operating hours, or before each daily startup| Check oil level
Check combustion and cooling air intake zone.
250| Every 250 operating hours| Change engine oil (In any case at least once a year)
Check and adjust valve clearances.
Clean cooling air area.
Check screw connections.
500| Every 500 operating hours| Change fuel filter element.
Dry-type air cleaner maintenance.
1000| Every 1000 operating hours| Clean the oil filter
| Once a year| Vibration-proof fixing point

3.3 Extraordinary maintenance

For some maintenance operations there is the possibility of pulling the generator out by sliding the entire bottom of the generator on the guides fixed to the sidewalls of the casing. To set the generator basis free loosen the harness and unscrew the 4 fastening screws. The generator unit will be extractable by ¾ of its depth. To come to a complete extraction put the generator basis on firm ground to protect it against possible falls and unscrew the 2 limit stop screws. Alternatively tighten the generator basis inserting screws in inner position.

Changing the oil
Warning
Hot oil can burn your skin!
Check the oil level with the engine turned off.

Important
Old oil moust not be disposed of in the environment, but left to a station specialised in the disposal and/or recycling of the same, respecting the laws in the country where the operations are carried out.Use oil recommended for 4-stroke Diesel engines of these types:
CCMC-D4-D5-PD2 or API-CD-CE-CF-CG or SHPD (this indication is on the oil can).
SAE 10W-30 oil is recommended for general use at all temperatures.
If you use monograde oil, choose the appropriate viscosity on the basis of the average temperature of the place where the generator is installed.
To drain the old oil easier you should run the generator for roughly 3/5 minutes, in this way the oil is more fluid and will drain better through the drain tube when you remove the drain plug. Refill the generator with oil of the recommended type, through the oil filler.
The quantity of oil is:
1.1 Litres

Air filter maintenance
Warning
Do not use diesel or solvents with a low evaporation point to clean the air filter element as it could catch fire or explode.
Important
If the air filter is dirty this reduces the flow of air to the engine. Therefore, to prevent malfunctions we recommend checking the state of the filter periodically, and more often if you are using the TEC 40D in particularly dusty areas.
Never use the engine without the air filter. The engine would wear quickly.
Operations:
Remove the air cleaner cover.
Unscrew and remove knurled nut and take off air cleaner element.
Clean the filter compartment and the cover.
Dirt and other foreign bodies must not be allowed to enter the engine’s air inlet points.
The filter cartridge should either be renewed or, depending upon the degree of contamination, cleaned, or checked, as follows:

Cleaning the filter cartridge
Dry contamination
Use compressed air to blow through the filter cartridge from the inside outwards, until no further dirt emerges.
Important! The pressure must not exceed 5 bar.
Moist or oily contamination
Renew the filter cartridge.
Checking the filter cartridge
Check filter cartridge’s gasket surface for damage, Check the filter cartridge for cracks or any other type of damage to the paper filter by holding it inclined towards the light or by shining a light source through it.
Important! The slightest damage to the paper filter rules out it being used any longer. Re-assemble the filter cartridge in the reverse order of work.

WIRING DIAGRAM – TEC 40D

DESCRIPTION

1| THREE-PHASE WINDING| 15| THERMAL SWITCH
2| AUXILIARY  WINDING| 16| 12-PIN CONNECTOR
3| AUXILIARY  WINDING| 17| ELECTROSTOP
4| INVERTER MODULE| 18| 10-PIN CONNECTOR
5| 9-PIN CONNECTOR| 19| PREHEATING GLOW PLUG
6| 12V REGULATOR| 20| TEMPERATURE SENSOR
7| 0/1 EMERGENCY STOP SWITCH| 21| 2-PIN CONNECTOR
8| PRESSURE CONTROL DEVICE| 22| VEHICLE CONTROL PANEL
9| START RELAY| 23| 12-PIN CONNECTOR
10| STARTING MOTOR| 24| AUXILIARY  WINDING
11| 9-PIN CONNECTOR| 25| CONNECTOR
12| HATZ 6-PIN CONNECTOR M| 26| PREHEATING RELAY
13| HATZ 6-PIN CONNECTOR F| 27| PUMP RELAY
14| INTERNAL CONTROL PANEL| 28| MOTOR START RELAY
| | 29| 4-PIN CONNECTOR

CONNECTION TO THE EXTERNAL POWER SUPPLY

AG113 SWITCHING ACCESSORY (available on demand)

1. Use cables of suitable section (see table in paragraph “electrical connection”).
2. Fix the AG113 switch in a position that facilitates connection.
3. Break the cable connecting the mains input with the cut-out on the control panel, so that it is possible to make the connections as shown in the wiring diagram.
4. Connect the cables to the switch, it is necessary to insert a jumper between terminal 1 and R1 and between terminal 3 and R3.
5. In positions R2 and R4, connect the cables from the generator 230 V terminal board.

DOMETIC
Via Virgilio, 3 – 47100 Forlì
Tel. 0543/754213
Fax.0543/756631

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