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- og installasjonsanvisning
Betjenings-, vedligeholdelses- og installationsvejledning

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 ENGLISH gracias a sus productos Dometic. La garantie Européenne Dometic vous offre, où que vous
With Dometic at home everywhere. Thank you for your decision to buy an Dometic product. soyez, la possibilité de profiter partout de votre matériel.
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, PORTUGUÊS
first-rate materials, superb workmanship, functional design and a care for the environment. Com Dometic, em todo o lado como em casa. Agradecemos a sua escolha. Os produtos
The unique Dometic EuroService Guarantee offers you additional peace of mind - ensuring Dometic foram expressamente concebidos para o seu veículo; satisfazendo totalmente as
that you will derive comfort everywhere from your Dometic products exigências do tempo livre, em meios móveis, com uma experiência de mais de 75 anos, a
tecnologia mais avançada, materiais de primeira qualidade, uma excelente equipa de técnicos
ITALIANO e um design funcional e respeito pelo ambiente. Aproveite o Serviço de Garantia Europeia,
Con Dometic come a casa, ovunque. Vi ringraziamo per averci scelto. I prodotti Dometic sono que lhe oferece uma tranquilidade absoluta e lhe assegura que obterá um grande conforto
stati espressamente concepiti per il Vostro veicolo; soddisfacendo completamente le esigenze em qualquer lugar graças aos seus produtos Dometic.
del tempo libero, sui mezzi mobili, con un’esperienza di oltre 75 anni, la tecnologia più avanzata,
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per l’ambiente. Usufruite del Servizio di Garanzia Europea che Vi offre completa tranquillità Med Dometic är Du hemma överallt. Tack för Ditt beslut att köpa en Dometicprodukt. De
assicurandoVi che trarrete grande comfort ovunque grazie ai “Vostri” prodotti Dometic har utvecklats speciellt för Din husvagn eller husbil och lever upp till alla de krav för fritid på
hjul -med mer än 75 års erfarenhet, avancerad teknologi, förstklassigt material, oöverträffat
DEUTSCH hantverk och design samt omtanke om miljön. Den unika Dometic Europagararantin ger Dig
Mit Dometic überall wie zu Hause. Wir danken Ihnen für Ihre Wahl. Die Dometic-Produkte trygghet om något skulle hända.
wurden speziell für Ihr Fahrzeug entwickelt und tragen den Erfordernissen der Freizeit auf
Rädern voll Rechnung - mit einer mehr als 75-jährigen Erfahrung, modernster Technologie, SUOMI
erstklassigen Materialien, einem hervorragenden Technikerteam, funktionellem Design und Dometic - kotonaan kaikkialla. Olemme iloisia siitä, että olet valinnut Dometic tuotteen.
Umweltfreundlichkeit. Nutzen Sie die EuroService-Garantie, mit der Sie ganz ruhig fahren und Tuotteemme on kehitetty yli 75 vuoden kokemuksella liikkuvan lomanviettäjän tarpeisiin ja
die Ihnen überall dank “Ihren” Dometic-Produkten größten Komfort sichert valmistettu ensiluokkaisista materiaaleista uusimmalla, ympäristöä säästävällä tekniikalla,
toimivalla muotoilulla ja korkealla ammattitaidolla. Dometic tuotteita voit käyttää luottavaisin
FRANÇAIS mielin.Ainutlaatuinen Dometic EuroService -takuu ja laaja huoltoverkosto varmistavat., että
Partout avec Dometic. Merci d’avoir choisi un produit Dometic. Il a été spécialement conçu saat apua ongelmatilanteissa myös matkasi varrella.
pour votre véhicule complétant totalement la gamme d’équipements de votre véhicule de loisirs.
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choix, un design fonctionnel et la protection de l’environnement. La garantie Européenne Med Dometic kan du føle deg hjemme overalt. Takk for at du bestemte deg for å kjøpe
Dometic vous offre, où que vous soyez, la possibilité de profiter partout de votre matériel. et produkt fra Dometic. Alle våre produkter er utviklet spesielt for ditt kjøretøy og lever fullt
opp til alle krav om bekvemmelighet i din fritid - basert på mer enn 75 års erfaring, den mest
NEDERLANDS avanserte teknologi, førsteklasses materialvalg og håndverk, funksjonelt design og omtanke
Met Dometic voelt u zich overal thuis. Wij danken u voor uw besluit een product van Do- for miljøet. Den unike Dometic EuroService-garantien gir deg trygghet og sikrer komfort uansett
metic aan te schaffen. Al onze producten zijn speciaal ontworpen voor uw voertuig en voldoen hvor du måtte befinne deg.
volledig aan de vereisten die worden gesteld aan een vakantie onderweg - met meer dan
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vakmanschap, functioneel design en zorg voor het milieu. Bovendien biedt de unieke Dometic Med Dometic kan du føle dig hjemme overalt. Tak for din beslutning om at købe et Dometic
EuroService Garantie u extra zekerheid - zodat u er zeker van bent dat u overal kunt genieten produkt. De er alle blevet specielt udviklet til dit køretøj og lever fuldt ud op til kravene om
van het comfort die producten van Dometic u bieden. fritid på hjul med mere end 75 års erfaring, den mest avancerede teknologi, førsteklasses
materialer, uovertruffent håndværk, funktionelt design og omtanke for miljøet. Den unikke
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Con Dometic en todas partes como en casa. Le agradecemos su elección. Los productos Dometic produkter vil opleve stor komfort, uanset hvor du befinder dig.
Dometic han sido expresamente concebidos para su vehículo; satisfaciendo totalmente las
exigencias del tiempo libre, en medios móviles, con una experiencia de más de 75 años, la
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le ofrece tranquilidad absoluta, asegurándole que obtendrá gran confort en cualquier lugar

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 ©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.

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 “The product is warranted in accordance with the enforced Law and regulations implementing the Direc-
tive 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 Dome-
tic.
The warranty extends to failures or defects in the gen-sets which shall become apparent within the war-
ranty 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.

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 Operation, Maintenance and
Index Installation manual GB
Generator
1 General informations Libretto istruzioni per l’uso, la manutenzione e
1.1 Purpose of the manual ................................................... 4 l’installazione I
1.2 Data Plate ....................................................................... 4 Generatore
1.3 Safety..................................................................... 5 Bedienungs- und
1.4
1.5
Noise ........................................................................... 5
Decription of the generator ................................................. 6
Wartungsanleitung D
Generator
1.6 Recommendations for use .............................................. 6
Mise en route, entretien et
1.7 Fuel .............................................................................. 6
1.8 Operating description ............................................ 7
installation F
Generateur
1.9 External control panel ................................................ 8
1.10 Internal control panel ................................................. 8 Handleiding voor bediening,
1.11 Technical data ................................................................ 9 onderhoud en installatie NL
1.12 Display messages ............................................................. 10 Generator
1.13 Routine maintenance .................................................. 11 Manual de instrucciones para el uso, la manutención
1.14 Oil level check ............................................................... 11 y la instalación
Generador
E
2 Installation istructions Livrete de instruções para uso, manutenção
2.1
2.2
Instructions for fixing the generator .........................
Instructions for installing the exhaust system........
12
14
e instalação
Gerador
P
2.3 Instructions for installing the fuel tank ........................ 15 Handbok för drift, underhåll och
2.4 Instructions for the electrical connection ........................ 16 installation
Generator
S
3 Troubleshooting, maintenance, recycling
Käyttö-, huolto- ja
3.1 Faults, causes, solutions .................................................18
3.2 Checks - nature and service intervals...............................19
asennusohje
Generaattori
FIN
3.3 Extraordinary maintenance ............................................ 20
Brukerveiledning og manual
TEC 40D wiring diagram ............................................... 22
til vedlikehold og installasjon
Generator
N
Connection to the external power supply........................ 23
Brugervejledning og manual
til vedligeholdelse og installation
Generaattori
DK

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 1 General informations

1.1 Purpose of the manual 1.2 Data plate

GB
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.

Manufactured by WTA v.Virgilio,3 Forlì-Italy

Manufacturer’s data
E24 10R-020308
Conformity marking
PRODUCT No. MODEL SERIAL
Model/Serial number 958 500 300 TEC 40D xxxxxxxx
Year of manufacture Date 2007
Voltage V230 Output max W4000
Frequency Hz 50 Output W3500
Technical data Power Factor Cos 1 D.C. 12V A 10
Weight kg 96,5

TEC 40D 4 user’s manual

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 General informations 1

The company Dometic is not responsible for any damage caused by • Exhaust gases contain carbon monoxide, an extremely poisonous
generator malfunctions. gas, which is odourless and colourless. Avoid inhaling exhaust GB
gases. Do not run the engine of the generator in a closed garage
1.3 Safety or room without very good ventilations.
• Do not touch the generator or the connections with wet hands.
The generator is installed in a closed casing. Therefore, there is no dan- • Do not replace fuses or thermal cutouts with others of a higher
ger of accidental contacts with moving parts or wires under voltage. amperage.
The door is fitted with a key lock which shall be kept out of reach by • Any checks carried out on the electric parts should be done by
children or non-authorised people. 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.
Warning • Sudden braking or acceleration, or curves taken abruptly with the
• Check the generator before using it every time. In this way it is vehicle can cause problems in the pumping system of the generator
possible to prevent accidents or damage to the motor. and make it stall.
• To prevent fire hazards and to keep the generator in an efficient • When storing the generator up for a long period of time, start it
working condition, do not close the same in a case or an enclosed at least once every 30 days and leave it running for at least 15
space such as an alcove but install it in a well-ventilated area. minutes.
• Keep children and animals away from the generator when it is • Leave the generator on for a few minutes without charge after use
running, as it can heat up and cause burns and injuries, both before switching it off.
directly and through the systems it is supplying.
• Learn how to turn the generator off quickly and how to use the The generator is made to meet the safety regulations indicated in the
controls. Never leave the generator in the hands of people who declaration of conformity.
are not trained to use it.
• The generator must only be used with the generator door clo- 1.4 Noise
sed.
• Keep flammable substances away from the generator such as for The generator has been tested for noise emissions at the qualified
example: petrol, paints, solvents etc. independent laboratory DNV Modulo Uno which has issued the EEC-
• Make sure that the hot parts of the generator do not come into certificate based on EC-DIRECTIVE 2000/14.
contact with materials that could catch fire.
• Fill the generator with fuel in a well-ventilated area with the gene- GUARANTEED AND MEASURED SOUND POWER LEVEL:
rator turned off. Petrol is highly flammable and can explode.
• Never overfill the fuel tank. There should not be fuel in the tank TEC 40D ..................................................................... LwA 89
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. SOUND POWER LEVEL measured from 7mt .... dB(A) 64

user’s manual 5 TEC 40D

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 1 General informations

1.5 Description of the generator 1.7 Fuel

GB
Warning All diesel oils which satisfy the following specifications are suitable:
The TEC 40D generator has been designed and produced to be used
only on caravans, motor homes and commercial vehicles. EN 590 or
Therefore it has not been designed to be used on other types of vehicles DIN 51601 - DK or
or on any kind of watercraft. The company Dometic, as it is impossible BS 2869 A1 / A2 or
to envisage every possible use and type of installation, declines any ASTM D975 -1D / 2D
responsibility for every type of use and installation which is not explicitly
mentioned. At temperatures below 0°C, winter-grade fuel should be used or paraffin
added to the fuel well in advance.
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. Paraffin content for:
Lowest ambient
The generator is installed in a sheet metal steel casing which is insulated
and soundproofed with special soundproofing materials. temperature when
Summer Winter
starting (°C) fuel fuel
1.6 Recommandations for use
0 a -10 20% -
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. -10 a -15 30% -
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 -15 a -20 50% 20%
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.

TEC 40D 6 user’s manual

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 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.
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:

ALTERNATOR - buttons to start and stop the generator

UNIT - a back lit LCD screen showing the main electrical pro-
(B)
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
ENGINE (A)
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
INTERNAL
CONTROL
PANEL EXTERNAL
(D) CONTROL
PANEL
(F)

INVERTER CONTROL TERMINAL

CARD BOARD (E)
(C)

user’s manual 7 TEC 40D

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 1 General informations

1.9 External control panel 1.10 Internal control panel

GB

DISPLAY

OIL
INDICATOR
MAIN SWITCH
EMERGENCY
STOP SWITCH

PETROL
START INDICATOR
BUTTON

POWER DELIVERED
VOLTAGE DELIVERED WORKING HOURS CUT OUT SWITCH

BATTERY’S DC GENERATOR
VOLTAGE STATUS

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

TEC 40D 8 user’s manual

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 General informations 1

1.11 Technical data

765
GB

455,4
457

490
320 25
370 41 520
99,25 574 89,25
467
762,5

DESCRIPTION UNIT OF MEASURE VALUE

VOLTAGE SUPPLIED V 230 ± 10%

MAX CONTINUOUS POWER W 3500 ± 5%

FREQUENCY Hz 50 ± 1%

DIRECT CURRENT POWER V/A 12 / 10

THD % 1

CONSUMPTION g/HPh 190/200

WEIGHT kg 96.5

user’s manual 9 TEC 40D

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 1 General informations

1.12 Table describing the alarm messages appearing on the display

GB
DISPLAYED MESSAGE DESCRIPTION GENERATOR BEHAVIOUR ACTIONS

LOW BATTERY Indicates that the battery voltage is below the mini- Check the efficiency of the battery before starting
The generator does not start.
mum value necessary to start the generator. the generator.
This message appears every time the hour counter Change the oil (see p.20) before restarting the
OIL CHANGE
of the machine reaches the service interval pre-set to The generator continues to run. generator by holding the start button down for
change the engine oil. 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).

General alarm message; it is displayed for instance

SeeTroubleshooting table on page 18. If the
GENERATOR ALERT! when the check ring of the carburettor throttle (step
The generator stops. problem persists, address to the nearest service
motor) is defective and the M110 module cannot che-
centre.
ck the motor speed
Reduce the connected load, wait a few minutes
The inverter stops and voltage is no longer
OVERLOAD! Indicates an output overload of the supplied sy- to cool down the generator. Stop the engine by
supplied, but the engine continues to run for a
stems. pressing the main switch button. Then restart
correct cooling of the internal parts.
the generator.
The inverter stops and voltage is no longer Check all the connected systems, wait a few
SHORT CIRCUIT
Indicates an output short of the supplied systems. supplied, but the engine continues to run for a minutes to cool down the generator. Stop the
correct cooling of the internal parts. engine by pressing the main switch button.
The inverter stops and voltage is no longer sup-
OVER TEMPERATURE This message is displayed in the event of a thermal plied. The engine continues to run for a correct Let the generator cool down, wait a few minutes
overload. cooling of the internal parts, then stops and the and restart the unit.
message displayed is “RESTART GEN?”.
LOW POWER ENGINE Signals a reduction of the voltage supplied to the Reduce the connected load and restart the
The generator stops.
inverter. generator.
RESTART GEN? This message appears after any stop of the ge-
The generator stops. Turn off and restart the generator.
nerator.
This message appears at the generator start-up and
GEN CAL
indicates the calibration phase preceding any start- The generator run but voltage is not supplied. Wait a few seconds.
up. The generator does not produce current yet.
GEN WAIT Message displayed between one start attempt and Wait until the message goes off before attemp-
The generator not run.
the other. ting a new start.
GEN ON
Indicates that the generator is running.

GEN OFF Indicates that the generator not run or is ready to Push the start button if you want to restart the
The generator not run.
start generator

TEC 40D 10 user’s manual

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 General informations 1

1.13 Routine maintenance 1.14 Checking the oil level

GB
To perform these checks you should open the door of the generator Remove the oil filler and clean the dipstick with a cloth.
taking the following precautions: Refit by screwing the dipstick.
Remove the dipstick and check that the oil level is between the two
The generator must not be running and all of the parts must be cold. (min. and max.) marks.
Add oil if necessary through the filler. Use only the oil recommended
Set the safety switch on the internal control panel to “O” (OFF). by the manufacturer!
Disconnect the positive pole (+) of the vehicle’s battery
Refit the plug.
IMPORTANT: Use only genuine spare parts. The generator may
get damaged if other than genuine parts having a different quality IMPORTANT:
standard are used. Perform all of the checks making sure the generator is in a horizontal
position.
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.

user’s manual 11 TEC 40D

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 2 Installation instructions
2.1 Instructions for fixing the generator
GB
1 2

3 4

TEC 40D 12 user’s manual

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 GB
5 6

7
�

�
�

user’s manual 13 TEC 40D

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 Installation instructions 2

2.2 Instructions for installing the exhaust system

GB
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.

EXTENSION FIXING
AG163 (OPTIONAL)

EXHAUST
EXTENSION
AG125

TEC 40D 14 user’s manual

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 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

Max 1.5m Tank

TANK MAXIMUM TOP EDGE

3m Tank
Generator

user’s manual 15 TEC 40D

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 Installation instructions 2

2.4 Instructions for the electrical connection

GB Cross-section mm2
230V
Cross-section mm2
12V
Cross-section mm2
Lenght up to 6m
Cross-section mm2
Lenght > 6m
(power cables) (battery charger) (battery connection) (battery connection)
The Dometic generator is a source of alternate 230V 50Hz tension,
able to cope with various power needs.
4 2.5 16 25
Electrical connection to the external network
230 V
plug
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 Earth wire
to the generator when the external power supply network is connected; External control
in this case, it is suggested that the generator be connected in such a panel socket
way as to give it priority with respect to the external network.
Electric wiring must be effected in conformity with the existing laws and 12 V plug
regulations in force in the user’s country. for battery
For correct installation performed by the final user, use preventive charger
technical assistance by your seller or by a skilled technician.
For the 230 V, use an approved cable with the section indicated in the Socket for
table. For connection of the Dometic switch cod. AG113 refer to the tank float
instructions and diagram on the following pages. wire

Emergency
Electrical connection of the battery charger stop switch
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. Cut out switch
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 Connecting the fuel indicator
generator (see picture on page 17).
NB:The negative pole of the battery should be grounded with the
Only use the indicator connection if there is a fuel level probe in the
vehicle’s frame. tank used for the generator. Connect the proble cable (e.g. float) to the
relevant terminal (see figure above).

TEC 40D 16 user’s manual

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 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. 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.

(-) negative
pole

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.

(+) Plus
pole

user’s manual 17 TEC 40D

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 Troubleshooting, maintenance, recycling 3

3.1 Faults, causes and solutions

GB

The generator earth wire (or fuse) is broken

The emergency stop switch is not to ON

Electric pump unfed/out of order

The electrical cables are broken

No fuel received from injectors

The Air intakes are obstructed

The starter is not powered up
SOLUTION

Operations to be carried

Too much oil in the engine

out by the user Check the load supplied

The starter shaft is dirty

Inverter is damaged
The air filter is dirty

Low battery charge

Operations to be carried

Load over 3.5 kW

out by qualified technicians
No fuel

CAUSE
By operating the main switch, the
panel does not switch on
By pushing the start button, the
generator does not start (the
starting motor does not run)
The starting motor runs but the
generator does not start

The generator tends to stall

The generator runs but it does not

produce current

The generator starts, then stops and

display “generator alert!” message

The produced current oscillates

TEC 40D 18 user’s manual

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 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.

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

user’s manual 19 TEC 40D

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 Troubleshooting, maintenance, recycling 3

3.3 Extraordinary maintenance

GB °F °C OIL : SAE
For some maintenance operations there is the possibility of pulling
122 50
the generator out by sliding the entire bottom of the generator on
104 40
the guides fixed to the sidewalls of the casing. To set the gene-
rator basis free loosen the harness and unscrew the 4 fastening
86 30

40
screws. The generator unit will be extractable by ¾ of its depth.

15W/40
68

10W/40
20

30
5W/40

10W/30

20W/20
5W/30
To come to a complete extraction put the generator basis on firm 50 10

ground to protect it against possible falls and unscrew the 2 limit 32 0

10W
stop screws. Alternatively tighten the generator basis inserting 14 -10

screws in inner position. -4 -20

-22 -30

Changing the oil -40 -40

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
Oil drain plug

TEC 40D 20 user’s manual

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 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. 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. Air cleaner cover
Dirt and other foreign bodies must not be allowed to enter the engine’s
Knurled nut
air inlet points.
The filter cartridge should either be renewed or, depending upon the Air cleaner element
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.
user’s manual 21 TEC 40D

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 WIRING DIAGRAM - TEC 40D

GB
CYAN
11 4 DESCRIPTION
1 5 1 THREE-PHASE WINDING
9 8 7 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1

CYAN
CYAN
RED
2 AUXILIARY WINDING
BLACK YELLOW 3 AUXILIARY WINDING
BLACK YELLOW
WHITE
4 INVERTER MODULE
WHITE 21 8 5 9-PIN CONNECTOR
RED
2 6 12V REGULATOR
1 2 1 2 3 4 5 6
BLACK 7 0/1 EMERGENCY STOP SWITCH

RED
1 8 PRESSURE CONTROL DEVICE
3 25 2
GREY
GREY

9 START RELAY
- +

BLU

BLU
10 STARTING MOTOR
11 9-PIN CONNECTOR
24
6 12 HATZ 6-PIN CONNECTOR M
13 HATZ 6-PIN CONNECTOR F
14 INTERNAL CONTROL PANEL
1 2 3 4 5 6

+ + + + + + 7 8 9 10 11 12

15 THERMAL SWITCH
R3 R3
26
R2 R2 R1 R1
28 15 16 12-PIN CONNECTOR
+
27 22 17 ELECTROSTOP
RED 18 10-PIN CONNECTOR
23
12 11 10 9 8 7 6 5 4 3 2 1 19 PREHEATING GLOW PLUG
7 - 20 TEMPERATURE SENSOR
21 2-PIN CONNECTOR
YELLOW
BROW N
VIOLE T

GRE E N

BLACK
WHIT E
230

230

GRE Y

BLUE
12

PINK
RED
B

22 VEHICLE CONTROL PANEL

ORANGE
YELLOW
YELLOW
VIOLET
BROWN

BLACK

BLACK

GREY
BLUE

PINK

23 12-PIN CONNECTOR
RE D
PINK

24 AUXILIARY WINDING
PINK 12 11 10 9 8 7 6 5 4 3 2 1 16
ORANGE BLACK 25 CONNECTOR
BLACK
12 6 5 4 3 2 1 6 5 4 3 2 1
13 10 9 8 7 6 5 4 3 2 1
18 26 PREHEATING RELAY
ORANGE
WHITE
WHITE

+ 27 PUMP RELAY
17 8 9 20 29
28 MOTOR START RELAY
YELLOW
BR O WN
GR E E N

VIOLE T
BLA CK

WHIT E

P 19
GR E Y
BLUE

PINK

29 4-PIN CONNECTOR
RE D

1 2 3 4

14
M DIESEL
10 PUMP

MOTORE HATZ

TEC 40D 22

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 CONNECTION TO THE EXTERNAL POWER SUPPLY

GB
AG113 SWITCHING ACCESSORY
(available on demand)

1) Use cables of suitable section (see ta-

ble in paragraph “electrical connection”).
LOAD
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 connec-
tions as shown in the wiring diagram. 1 R1 R3 3 A2
4) Connect the cables to the switch, it is
necessary to insert a jumper between ter-
2 R2 R4 4 A1
minal 1 and R1 and between terminal 3
and R3. MAINS
5) In positions R2 and R4, connect the AG113
cables from the generator 230 V terminal
1
board.
230
BATTERY
230

12

GENERATOR

23 TEC 40D

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 ST095 r0

DOMETIC

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

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