TEC 40d DIESEL GENERATOR Operation, maintenance and installation manual Libretto istruzioni per l’uso, la manutenzione e l’installazione Betriebs-, Wartungs- und Installationsanleitung Manuel d’utilisation, d’entretien et d’installation Bedienings-, onderhouds- en installatiehandleiding Manual de instrucciones para el uso, mantenimiento e instalación Manual de instruções de uso, manutenção e instalação Handbok för användning, underhåll och installation Käyttö-, huolto- ja asennusohje Bruks- vedlikeholds- o
ENGLISH 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.
©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.
“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.
Operation, Maintenance and Installation manual Generator Index 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 General informations Purpose of the manual ................................................... 4 Data Plate ....................................................................... 4 Safety..................................................................... 5 Noise ...........................................................................
1 General informations GB 1.1 Purpose of the manual 1.2 Data plate 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.
General informations 1 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.
1 General informations GB 1.5 Description of the generator 1.7 Fuel 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.
General informations 1 1.8 Operation description GB 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.
1 General informations GB 1.9 External control panel 1.
General informations 1 1.11 Technical data 370 490 455,4 457 320 25 520 41 99,25 467 574 89,25 762,5 DESCRIPTION UNIT OF MEASURE VALUE VOLTAGE SUPPLIED V 230 ± 10% MAX CONTINUOUS POWER W 3500 ± 5% FREQUENCY Hz 50 ± 1% V/A 12 / 10 % 1 g/HPh 190/200 kg 96.
1 General informations GB 1.12 Table describing the alarm messages appearing on the display DISPLAYED MESSAGE LOW BATTERY OIL CHANGE NO FUEL OIL ALERT GENERATOR ALERT! OVERLOAD! SHORT CIRCUIT OVER TEMPERATURE LOW POWER ENGINE RESTART GEN? GEN CAL GEN WAIT GEN ON GEN OFF TEC 40D DESCRIPTION Indicates that the battery voltage is below the minimum value necessary to start the generator. GENERATOR BEHAVIOUR The generator does not start.
General informations 1 1.13 Routine maintenance 1.14 Checking the oil level To perform these checks you should open the door of the generator taking the following precautions: 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.
2 Installation instructions GB 2.
5 6 7 8 GB � � � � � � � user’s manual 13 � TEC 40D
Installation instructions 2 GB 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).
2 Installation instructions 2.3 Instructions for the installation of the tank GB 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. TANK MAXIMUM LOWER EDGE Generator Tank Max 1.
Installation instructions 2 GB 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. 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 Electrical connection to the external network The on board electrical system must be ﬁtted with a relay or switch (e.g.
2 Installation instructions Battery connection GB 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.
Troubleshooting, maintenance, recycling 3 Too much oil in the engine Electric pump unfed/out of order The starter shaft is dirty Low battery charge Load over 3.
3 Troubleshooting, maintenance, recycling 3.2 Check list and time intervals GB Maintenance chart Maintenance work required 8-15 Every 8-15 operating hours, or before each Check oil level daily startup 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.
Troubleshooting, maintenance, recycling 3 3.3 Extraordinary maintenance °F °C 122 50 Changing the oil 40 32 0 14 -10 -4 -20 -22 -30 -40 -40 40 30 10 20W/20 20 50 15W/40 68 10W/40 30 10W/30 86 10W 104 OIL : SAE 5W/40 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.
3 Troubleshooting, maintenance, recycling Air ﬁlter maintenance GB 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.
WIRING DIAGRAM - TEC 40D GB RED 2 YELLOW 21 1 GREY 3 24 26 2 1 2 3 4 5 6 - 25 + 6 + + R3 8 + + + + R3 R2 R1 R2 R1 28 1 2 3 4 5 6 7 8 9 10 11 12 15 + 27 22 RED 23 12 5 4 3 2 1 13 + 9 8 P 20 19 10 M DIESEL PUMP 10 9 8 9 8 7 6 5 4 4 3 3 2 2 1 1 16 18 BLACK BLACK 1 29 2 3 4 14 MOTORE HATZ TEC 40D 22 6 5 4 3 2 1 GRE E N BROW N YELLOW BLACK RED PINK VIOLE T GRE Y WHIT E BLUE YELLOW YELLOW GREY RE D BLACK 7 5 WHITE WHITE 6
CONNECTION TO THE EXTERNAL POWER SUPPLY GB 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.
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