INSTRUCTION MANUAL ALTERNATING CURRENT GENERATING SETS DCA-70,-125,-180ESEI

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1 MANUAL No.B A INSTRUCTION MANUAL ALTERNATING CURRENT GENERATING SETS DCA-70,-125,-180ESEI IMPORTANT : READ AND UNDERSTAND THIS MANUAL CAREFULLY BEFORE USE OF THIS MACHINE. KEEP THIS MANUAL FOR YOUR FUTURE REFERENCE Nihonbashi-horidomecho, Chuo-ku, Tokyo, Japan

2 FOREWORD We are very thankful for your special choice of our MACHINE in the market. Please read this manual carefully and understand for proper use this machine. Please keep this manual at your prescribed location where operator can always take this manual. If you have any question or problem on this operation, please contact your nearest Distributors. Pay special attention to statements preceded by the following word. DANGER - indicates an imminently hazardous situation which, if not heeded, will result in death or serious injury. WARNING - indicates a potentially hazardous situation which, if not heeded, could result in death or serious injury. CAUTION - indicates a hazardous situation which, if not heeded, may result in minor or moderate injury or damage to the machine. NOTE - indicates useful information for the machine operations

3 SAFETY PRECAUTIONS FOR GENERATORS In order to ensure safe operation, the following symbols are used for explanation of the machine operation. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. [Note] : This symbols show handling precautions for effective operation and many years of satisfactory operation. Some of the items shown by " CAUTION " may also cause death or serious injury. Be sure to observe all the items, as they are important for safe operation. * If the machine is used by an outsider, you are requested to explain him correct handling and advise him to read this instruction manual carefully. * Do not modify the machine at your discretion, as it affects the safety, performance or the life of the machine. * If the machine is modified or it is used incorrectly against this manual or unauthorized parts are used, the warranty of manufacturer will become invalid

4 Safety label Safety labels are attached to the following positions of the machine. * Keep these safety labels clean at all times. * When safety labels are spoiled or lost, contact distributor or our office specifying the nameplate No. shown below and ask for new ones. Parts name Parts number CAUTION: Instruction manual B D A N G E R : Electric shock B WARNING: Fire/explosion B CAUTION: Burn B CAUTION: Moving parts B CAUTION: Emergency stop B CAUTION: Hot coolant/battery B CAUTION: Engine fan B WARNING: Falling B WARNING: Engine exhaust B CAUTION Instruction manual Do not use machine before reading the instruction manual. Do access to machine in accordance with the instruction manual when machine is in fault. Do consult to authorized person for repair or maintenance to avoid incidents

5 DANGER ELECTRIC SHOCK can kill. Do not touch the output terminals during operation to prevent decease due to electric shock. * Never touch the output terminals during operation. If your hands or the machine are wet, it will result in a death or serious injury. * When a wiring work is required, be sure to turn OFF the circuit breaker and stop the machine. * Keep the output terminal cover closed and the terminal bolts tightened while the machine is running. * A low voltage is generated even when the machine is in low speed idle operation. Be sure to stop the machine completely. Do not touch the electrical parts in the machine during operation, as it may lead to death due to electric shock. * Always close the control panel and tighten the fixing bolts before operating the machine. * Always close the side door and lock it before operating the machine. * When opening the control panel for voltage selection, etc., turn OFF the circuit breaker and stop the machine. DANGER ELECTRIC SHOCK by leak can kill. Improper grounding may lead to death due to electric shock. * Be sure to execute the grounding of the machine and the load according to the local rule. CAUTION MOVING PARTS can cause severe injury. Rotary unit which runs at a high speed is located in the machine. (Note that it is very dangerous if you touch it.) * Be sure to close the door and lock it during operation. * When the door needs to be opened during operation, do not get your hands and head in the machine to prevent them from being caught in the machine which may lead to injury. * When making check or maintenance of the machine, be sure to stop the machine in advance

6 WARNING DIESEL FUEL can cause fire or explosion. Fuel and oil are flammable. Incorrect handling results in danger of ignition or fire. * When fuel needs to be supplied to the machine, be sure to stop the engine. Refrain from smoking. Keep the machine away from fire. * Do not leave flammable objects (paper, wood chips, etc.) and hazardous objects (oil, powder, etc.) near the machine. * Wipe off spilt fuel and oil. CAUTION HOT COOLANT can cause severe scalds. If the radiator cap is opened while the water temperature is high, steam or hot water will spout out. * During operation or immediately after stopping the machine, do not open the radiator cap while the water temperature is high. * When cooling water needs to be checked or supplied, wait until the engine is cooled (50 or less as measured with the water temperature gauge). CAUTION HOT PARTS can burn skin. High temperature units are located in the machine. (Note that these units are very dangerous if they are used incorrectly.) * Be sure to close the door and lock it during operation. * If the door needs to be opened during operation, do not get your hands and head in the machine to prevent unexpected burns. * When making check or maintenance of the machine, be sure to stop the machine. * The bonnet is still hot even after the machine is stopped. Be careful until the engine is completely cooled

7 CAUTION Battery Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * Battery should be charged in a well ventilated location. Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and -). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. * For maintenance of the machine, disconnect the ground cable on the ground side. The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. * When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. - In the worst case, it will put out your eyes. For checking or handling of the battery, be sure to stop the engine and turn OFF the battery switch in advance. WARNING ENGINE EXHAUST can kill. Insufficient ventilation may lead to death due to lack of oxygen or poisoning by exhaust gases. * Do not use the machine in a place of poor ventilation or in a place where exhaust gases stays. * Do not use the machine indoors or in storehouse, tunnel, ship hold, tank, etc. of poor ventilation. * If it becomes necessary to use the machine in the above places, the exhaust pipe should be extended to a well ventilated place. In this case, use a ventilator to ensure proper ventilation. * Do not direct the exhaust outlet to nearby pedestrians and houses. CAUTION Operator Do not operate the machine if operator is tired too much or drinks some alcohol or take some drugs. * Otherwise, it may cause unexpected accidents or injury. During checking or maintenance, be sure to put on suitable clothes and protectors. * Do not put on baggy clothes, necklace, etc., because they are easily caught by projections which may cause injuries. CAUTION Noise This machine generates large noise if the door is open. Surrounding to large noise may cause hearing trouble. * Close and lock the door during operation. * If opening the door is necessary during operation, be sure to put on the ear protector

8 CAUTION Connection to house wiring Before connecting this machine to any building's electrical system, a licensed electrician must install an isolation(transfer) switch. * Serious injury or death may result without this transfer switch. CAUTION Transportation Do not lift the machine at the support hook or the ladder because it is not strong enough for lifting and may cause a falling accident. * When lifting the machine, use the hanger located at the roof center. * Keep out under the lifted machine. Do not lift or do not transport the machine during operation, as it may cause damage to the fan or serious trouble. * When loading the machine on the truck or the like, fix the machine firmly by support hooks on the both side. SAFETY LABEL/SICHERHEITSANHAGE 1 DANGER: Electric shock 2 WARNING: Fire/explosion 3 CAUTION: Burn 4 CAUTION: Moving parts 5 CAUTION: Instruction manual 6 CAUTION: Emergency stop 7 CAUTION: Hot coolant/battery 8 CAUTION: Engine fan 9 WARNING: Falling 10 WARNING: Engine exhaust - 7 -

9 This instruction manual describes how to handle the machine with a view to promising safety run, maximum efficiency and long durability. Read the manual attentively before starting the machine operation for correct handling, operation and appropriate maintenance from the beginning. The maintenance schedule consists of a procedure of keeping the machine in good condition. For the user, keep the manual carefully for machine operation and maintenance according to the instructions. Observe all the safety precautions including ones stated in the manual. Entrust the repair to trained personnel of Denyo or its distributor who are capable of contacting us as required. When consulting us, specify the model and serial number indicated on the nameplate. For data not specified in the manual, see Principal data. The company reserves the right to make changes without prior notice

10 Contents SAFETY PRECAUTIONS FOR GENERATORS DCA series General Machine structure Machine appearance and internal component devices Control switches and meters Engine start/stop controls Engine indicators Generator controls and indicators Noise Transportation, storage and installation Safety precautions for transportation, storage and installation Transportation Storage Storage method Preparing for operation Installation Installation Checking after installation Operation Safety precautions for operation Connecting the load Precautions in connecting the load Non-liner and sensitive loads Quality, minimum section and maximum length of cables Connecting the load

11 3-3 Before starting Checkup before start-up Instruction for Fuel Source Changeover Device(Three- Way valve) Starting During operation Stopping Stopping method Emergency stop Protection device Fuel, coolant and lubricants Periodic checkup and maintenance Safety precautions for periodic checkup and maintenance Periodic checkup Maintenance schedule Checking/every 250 hours Checking/every 500 hours Checking/every 1000 hours Table of periodical maintenance and checking Troubleshooting Principal data Readings on gauges Setting of switches Reference conditions Limitations General specifications Conversion list of SI units into UK/US units

12 Safety precaution The user must carry out all safety precautions stated in the manual. If any statement in this book, especially with regard to safety, does not comply with local legislation, the stricter of the two shall apply. 1. DCA Series 1-1 General DCA series generator is intended for generating power source where there is no power source. For further details, see 7 Principal data. 1-2 Machine structure The generator which is directly driven by Isuzu water-cooled diesel engine is mounted on the common frame along with control equipment, radiator, battery, fuel tank and other auxiliary equipment. The altogether is covered by a sound-insulated steel bodywork. See Fig Machine appearance and internal component devices There are the hanger at the center on the top surface and rope hanger on its both sides. When lifting the machine, use the hanger. Do not resort to winding rope because it is not strong enough. See Fig. 2. The engine cooling water refilling port and fuel refilling port are located on the top surface of the machine. The drain plugs for engine oil, cooling water and fuel are located at the base side under the machine. Tags of their respective names are attached there

13 Model DCA-125ESEI Fig.1 1. AC generator 2. Diesel engine 3. Control box 4. Fuel tank 5. Radiator 6. Battery 7. Muffler 8. Intercooler

14 Model DCA-125ESEI Fig Hanger 2. Rope hanger 3. Radiator cooling water refilling port cover 4. Fuel tank refilling port cover 5. Fuel drain plug 6. Oil drain plug 7. Intercooler drain plug 8. Three phase output receptacle 9. Single phase output receptacle 10. Engine exhaust port 11. Cooling air intake port 12. Cooling air exhaust port 13. Side door 14. Drain plug engine cooling water 15. Environmental base drain 16. Three-way valve 17. Emergency stop button 18. PE earthing terminal

15 1-4 Control switches and meters The control switches and meters are located inside the door having a window on the rear of the machine. The control panel is mounted on the bodywork with hinges and is fastened by screws. Loosening the screws has access to repairing or replacing electrical parts in the control box Engine start/stop controls Fig.3 1. Frequency meter 2. AC ammeter 3. Ammeter change over switch 4. AC voltmeter 5. Voltage regulator 6. Circuit breaker(for main) 7. Earth leakage relay 8. Panel light switch 9. Panel light 10. Engine indicator 11. Starter switch 12. Preheat lamp 13. Emergency stop button

16 1. Starter switch The switch is 3-position switch which can be operated with its specific key only. 1) OFF This switch should be set in this position unless the machine is in operation. The key can be inserted or pulled out in this position. 2) RUN This switch should be set in this position when the machine is in operation. In this position, the preheating system is energized. When the preheat indicator lamp lights up, reaching the set temperature, it goes off. Then, turn the key to START. 3) START This is the position to start the engine. When your hand is released from the key after starting, it is automatically set in the position of RUN. 2. Emergency stop button The stop button is a push button to stop the engine in case of an emergency. When the button is pressed, it must be unlocked by turning it anti-clockwise before the engine can be re-started

17 1-4-2 Engine indicators 3. Engine monitor Fig.4 (1) Engine indicator That indicates the numerical values of engine speed, engine oil pressure, run hours, battery charging voltage, or engine coolant temperature. Indicated Items Unit engine speed min -1 engine oil pressure 100kPa battery charging voltage V engine coolant temperature

18 - 1 - Engine Speed Revolutions per minute is indicated. 1500min -1 is indicated at 50Hz Engine Oil Pressure 3.9 to kpa should be indicated at normal engine operation. Higher value would be indicated in cold condition immediately after engine starts. Conduct a warning - up operation until it indicates normal value Battery Charging Voltage That should indicate more than 12.5V at engine running Engine Coolant Temperature That should indicate a temperature between 75 to 95 at engine running. Note ; If that would indicate higher temperature, disconnect all loads, decrease the speed for cool - down operation, and wait until the temperature comes down to normal value. (2) Fuel Level Indicator That Indicates a fuel level in the fuel tank. All the lights are indicated green when the fuel is full. The green lights stop indicating one by one as the fuel level decrease, finally the red light will be indicated when it is only one green light is left. Replenish the tank when there becomes only one lamp turned on. The table below shows the relation between numbers of turn - on lamps and fuel level. Numbers of lamps DCA-70ESEI DCA-125ESEI DCA-180ESEI turned-on Fuel level (L) Fuel level (L) Fuel level (L) to full 210 to full 255 to full to to to to to to to to to to to to to to to to to to to to to to 60 0 to 95 0 to

19 (3) Alarm and Memory at Abnormal Condition When any abnormal condition occurs in engine oil pressure, battery charging voltage, or engine coolant temperature, the indication will change as the following ; The Indicator shows its defect with blinking numbers When the abnormal condition is corrected, the on - and - off indication will stop If engine would stop urgently and automatically or stop manually with the abnormal condition, the abnormal value will be memorized, and then indicated even after engine is started again. In this case, keep on pushing the button RESET for more than 5 seconds, and the abnormal indication will be reset to normal. (4) Hour Meter 1 When you turn the starter switch to RUN position, and push the selector button located on the right side of the Hour Meter, you can see the numbers mentioned below ; ODD Total running hour TRIP A Running hours A on a certain period TRIP B Running hours B on a certain period 2 If you want to reset the Trip Meters, push the selector button for more than 1 second, after selecting each meters

20 4. Indication/alarm lamp (1) Preheat lamp This machine has automatically preheating device. If turn the starter switch to RUN position, it will according to cooling water (coolant) temperature with the preheat lamp goes on. When the preheat lamp goes off, it indicates that preheating is completed. (2) Warning Lamps This monitor indicates the following failures, if any one of them occurs. 1 High jacket water temperature (WATER TEMP) This lamp goes on when the water temperature rises abnormally. If the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. 2 Oil pressure failure (OIL PRESS) If this lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. 3 Air filter blinding (AIR FILTER) When the air element is blinded, this lamp goes on. Indicating that the element should be immediately cleaned or replaced. 4 Over speed of engine (OVER SPEED) This lamp goes on when the engine speed rises abnormally. If the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically

21 5. Electronic Governor Controller (in the control box) Trouble diagnostic functions The engine controller with this unit diagnoses problems that arise with the engine control system and the engine itself. When diagnostic lamp is turned on, there are any failure in the engine control system. Refer to the engine instruction manual. 1. Normally, diagnostic lamp will be lit brightly then the lamp will be turns off, when the starter switch is placed in the RUN position. 2. If engine trouble occurs, diagnostic lamp will become brightly lit as long as the starter switch remains in the RUN position

22 1-4-3 Generator controls and indicators 6. Frequency meter This meter indicates the frequency of the outputted voltage. Make sure that it reads 50Hz when running. 7. Ammeter This meter indicates the current going to the connected load. It must not exceed the rated current. 8. Voltmeter The voltmeter indicates the outputted line voltage. 9. Three-phase circuit breaker The circuit breaker is a safety device interrupting the mains when an overload, a short circuit or a leakage occurs at the load side connected to the receptacles. It also serves as a main switch for supplying energy from the generator to the load connected to the output receptacles. Do not use this circuit breaker to turn on or off the load. When tripped, the breaker must be reset manually by switching it to OFF and then to ON after eliminating the cause of the trouble. 10. Earth leakage relay DANGER :Electric shock by leakage. Be sure to connect the machine to earth. If not connected to earth, the earth leakage relay would not work. Be sure to connect the load also to earth. This relay detects a leakage and trips the mains of the three-phase circuit breaker. The earth leakage relay sensitivity is 30mA. At this time, the red lamp lights indicating a leakage occurrence. Eliminate the cause of the leakage, press the reset button, turn the tripped circuit breaker manually to OFF and then to ON

23 11. Ammeter change over switch The switch allows measuring the outgoing current between each of the phases and also switching the meter off. 12. Voltage regulator knob The output voltage is controlled by a regulator with rotating knob. Turning clockwise increases the voltage and vice versa. 1-5 Noise CAUTION :Injury of ears In room or environment where the sound pressure level reaches or exceeds 90dB(A), use ear protectors. The maximum sound pressure of the machine is the value specified in EN Model DCA db(a) Model DCA-125. db(a) Model DCA-180. db(a)

24 2. Transportation, storage and installation 2-1 Safety precautions for transportation, storage and installation WARNING When lifting or transporting the machine, use only appropriate devices which comply with the local safety codes and regulations. When lifting the machine, use the hanger located at the roof center. Do not resort to rope winding because it is not strong enough. Before lifting, close and fix the doors, covers and other moving parts and clear away the machine interior and top. Do not slip under a lifted machine. The electrical connections shall comply with the local codes. Earth the machine properly. The engine exhaust gas is lethal and toxic. Do not operate in tunnel, indoors or others where the aeration is poor. If it is absolutely obliged to operate in such a place, discharge the exhaust sufficiently by a ventilating system. Never direct the engine exhaust towards passers-by. Do not operate the machine in an atmosphere containing toxic or combustible gas. Otherwise, fire or explosion might occur in the machine. (Example: Near volatilizing paint solvent.) Fuel and oil are combustible and undiluted anti-freeze solution is inflammable. Do not smoke while handling or refilling them. Do not get fire or heated objects near them. Do not spill or leave fuel, oil, anti-freeze solution or cleansing agent in or around the machine. If spilled, be sure to wipe off properly. If necessary, provide a spark arrestor to trap incendiary exhaust sparks

25 CAUTION Install the machine on a well ventilated, horizontal, flat, dry and solid floor. If the floor is not horizontal enough to keep the machine leveled, consult your sales distributor. When installing the machine on a trailer, fasten the trailer and fix the wheels by stoppers. Do not remove or unduly modify safety devices, guards, covers or insulating materials from the machine. When servicing batteries, always wear protecting clothing and glasses. The battery electrolyte is a diluted sulphuric acid which can cause severe burns. Get it away from eye, skin and clothing. When charging batteries, an explosive gas forms above the cells and escapes through the vents. Do not smoke near batteries just after having been charged. Never make or break live circuits or battery terminals, because a spark usually occurs. Before checking the machine, stop the engine and wait for at least 10 minutes so that it will cool down completely. If done while running or immediately after shutdown, you might get burnt or injured. 2-2 Transportation When lifting or transporting the machine, use only appropriate devices which comply with the local safety codes and regulations. For dimensions and weight of the machine, refer to 7 Principal Data. See Fig 5 for the center of gravity

26 Fig. 5 Model L W H DCA-70ESEI DCA-125ESEI DCA-180ESEI When lifting the machine, use the hanger located at the roof center. Never use the rope hanger because it is not strong enough to lift. Before lifting, close and fix the doors, covers, and other moving parts and clear away the machine interior and top. Do not slip under a lifted machine. Before transporting by truck or others, wind ropes on the machine to fasten it securely. Put covers so as to protect the machine from rain or moisture when transporting. 2-3 Storage Storage method 1. Store the generator in a sufficiently ventilated, dry room which is free from frost, salt and dust. Storage environment: Atmospheric temperature -5 to 40, humidity 85% or lower, altitude 1000m or lower. 2. Run the engine once a week until warm

27 3. If it is impossible to run the engine regularly, extra precautions must be taken. 1) Consult the instruction manual for the engine. 2) Remove the battery. Store it in the same environment as for the machine. Keep the battery clean and coat its terminals lightly with petroleum jelly. Recharge the battery regularly. 3) If the electrolyte has dropped to the specified level, refill it. 4) Clean the generator. Oil or fuel spillage is not allowed. Protect all electrical components against penetration by moisture. 5) Place silica gel bags, VCI paper (volatile corrosion inhibitor) or another drying agent inside the generator and close the doors. 6) Close all openings on the bodywork by sticking sheets of VCI paper with adhesive tape. 7) Enclose the generator, except the bottom, with a plastic bag Preparing for operation Before operating again the generator kept unused for a long time, remove the plastic bag, VCI paper from the openings and silica gel from inside and check the generator thoroughly. Further maintain the following items. 1. Consult the instruction manual for the engine. 2. Measure the insulation resistance of the generator with a 500-V insulation resistance tester. The resistance must exceed 1 megohm. In case of measuring with an insulation resistance tester over 500VDC current, disconnect all connectors from the AVR located in the control box before measuring. 3. Replace the fuel filter cartridge and fill the fuel tank. Vent the fuel system. 4. Reinstall and connect the battery. If necessary, recharge it. 5. Check the fan belt condition and tension; adjust if required. 6. Check and, if required, refill cooling water and oil. 7. Submit the generator to a test run

28 2-4 Installation Installation 1. Install the generator on a well ventilated, horizontal, even and solid floor. If the floor is not horizontal enough to keep the machine leveled, consult your sales distributor. When installing the machine on a trailer, fasten the trailer and fix the wheels by stoppers. Avoid a site exposed to rain or high temperature. The operating ambient conditions are atmospheric temperature of -5 to 40, humidity of 85% or lower and altitude of 1000m or lower. If the machine do not conform with the above conditions, consult your sales distributor. 2. Avoid a dusty site. If it is inevitable, provide protective devices. 3. Do not operate the machine in an atmosphere containing toxic or combustible gas. Otherwise fire or explosion might occur in the machine. (Example:Near volatilizing paint solvent.) 4. Leave space for operation, inspection and maintenance; at least 500mm each on machine front and 1000mm each on rear and sides. See Fig. 6. Fig. 6 Note: If the machine is operated in a smaller space than that shown above, the room temperature will rise. Please reduce the generator output in such condition. Therefore proper power reduction is necessary

29 If the space required above the machine is not uniform when it is operated indoors, make a decision so that: The radiator can be refilled with cooling water. The exhaust pipe can be introduced. The exhaust can smoothly be discharged. 5. Do not direct the exhaust towards passers-by or residences, etc. 6. If the generator is operated indoors; Install an exhaust pipe of sufficient diameter to let the engine exhaust gas out directly. Check for sufficient ventilation and position the ventilator so that the exhaust from the machine will not be re-circulated in the room even if the ventilation is proper. 7. Check that the inner earthing system is in compliance with the local regulations. 8. Earthing the machine If the machine is earthed in a way different from below, follow the local rule. The machine is TN system which must conform to IEC and must directly be earthed at one neutral point. 1 Be sure to connect to earth the earthing bar connected to the PE earthing terminal. 2 Avoid earthing at the following places 1. Near underground utilities such as gas pipe, city water pipe, electric wires, underground cables. 2. Within 2m from lightening arrester earthing place. 3. Do not use the high voltage circuit earth commonly earthing the machine. 3 Precautions in earthing 1. Drive the earthing lugs as near the machine as possible in shady and humid soil so that its top end will sufficiently be buried inside. 2. Be sure to connect the lead-wise securely if the hanger is buried in a place of heavy traffic. 9. Also connect the load bodyworks to ground

30 Model DCA-70ESEI Model DCA-125ESEI Fig Oil level gauge 2. Oil refilling port cap 3. Oil filter cartridge 4. Reserve tank cooling water 5. Fan belt 6. Alternator 7. Fuel filter cartridge 8. Air cleaner 9. Water separator

31 2-4-2 Checking after installation (1) Check engine oil (Read the instruction manual for the engine furnished separately.) 1 Check the level of engine oil by the dipstick. Make sure the oil level is always between H and L. 2 When it is below the low limit, supply oil immediately. 3 At the same time, check condition of oil by the dipstick. [Note] : Oil is consumed gradually during operation. When the machine is to be used continuously for a long time, be careful with lack of oil. (2) Check engine cooling water (Read the instruction manual for the engine furnished separately.) 1 Check (to see) that cooling water in the reserve tank is within the range of FULL-LOW. 2 When it is below the low limit, supply (additional) water immediately. 3 Normally, only the water level of the reserve tank needs to be checked. But, the radiator cap should be opened once a week to check that water is full in the radiator. [Note] : When closing the radiator cap after water level is checked or water is supplied, turn the cap fully clockwise so that it can be firmly tightened. Otherwise, cooling water is evaporated which results in serious damage to the engine

32 (3) Check fan belt (Read the instruction manual for the engine furnished separately.) 1 Check the belt for tension and elongation. Also, check it for damage. Replace if necessary. 2 For adjustment or replacement of the belt, refer to the instruction manual for the engine. Press (about 6kg) the position shown by arrow mark (middle of belt) with your thumb. The bend should be within the range of 10 mm. Parts number of fan belt: Model name Parts number Parts number of manufacture DCA-70ESEI DCA-125ESEI DCA-180ESEI (4) Check fuel level 1 Be sure to check the quantity of fuel prior to operation to prevent lack of fuel during operation. 2 Loosen the drain plug of the fuel tank from time to time, and remove sediment's and water at the bottom of the tank. (5) Check battery acid level CAUTION Battery The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. * When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. - In the worst case, it will put out your eyes. Remove the battery acid plug(cap) and check the liquid level (10-12 mm above the electrodes). Supply distilled water if necessary

33 (6) Check for leak of water and oil Check the machine for the trace of leak of oil or water. If a leak is found, check the location of leak and stop it. When the leak cannot be stopped, contact our service factory. (7) Check for loose parts Check for loose bolts and nuts. Loose parts should be tightened firmly. Particularly, make check on (the fitting of air cleaner, muffler, turbo-charger, etc.), disconnection of electric wiring, short-circuit and loose terminals. (8) Removal of foreign objects in machine * Check that tools and cleaning cloth are not left in the machine. Remove if necessary. * Check the surroundings of the muffler and engine for presence of dust and flammable objects. Remove if necessary. * Check that the cooling air inlet and the cooling air outlet of the machine are not clogged with dust or other objects. Remove if necessary

34 3. Operation 3-1 Safety precautions for operation DANGER When the machine is running, never touch output terminals, internal wiring or other electrical parts. Do not use the machine in a humid place. An excessive humidity is very dangerous. Never touch the machine if the machine or your body is wet. Never fail to perform a test running for the earth leakage relay prior to operation. The electrical connections shall comply with the local regulations. Use cables which are not damaged. Make sure that all electrical connections are securely fastened. Damaged cables or loose connections might cause electric shocks. WARNING The engine exhaust gas is lethal and toxic. Do not operate in tunnel, indoors or others where the aeration is poor. If it is absolutely obliged to operate in such a place, discharge the exhaust by a ventilation facility. Do not direct the engine exhaust towards passers-by, residences, etc. Do not operate the machine in an atmosphere containing toxic or combustible gas. Otherwise, fire or explosion might occur in the machine. (Example: Near volatilizing paint solvent.) Do not refill fuel or oil while the machine is running but after stopping the engine. Fuel and oil are combustible and undiluted anti-freeze solution is inflammable. Do not smoke while handling or refilling them. Do not get fire or heated object near them. Do not spill or leave fuel, oil, anti-freeze solution or cleansing agent in or around the machine. Never remove the cover of the output terminals during operation. Before connecting or disconnecting the cables, switch off the load and machine circuit breakers, stop the machine and make sure that the machine cannot be started inadvertently

35 CAUTION Avoid overloading the generator. The generator is provided with circuit breakers for overload protection. When a circuit breaker has tripped, reduce the concerned load before re-starting. Do not connect the output voltage from the machine to facilities wired to the commercial power supply. Before connecting a load, turn off a corresponding circuit breaker and make sure that the frequency, voltage and power factor of the load to connect match the generator ratings. Before checking the machine, stop the engine and wait for at least 10 minutes so that it will cool down completely. If done while running or immediately after shutdown, you might get burnt or injured. Do not operate the machine beyond the range given in the main specification table. In room or environment where the sound pressure level reaches or exceeds 90 db (A), use ear protectors. During the operation, keep all doors closed. Periodically check that: 1. All guards are in place and securely fastened. 2. All hoses and/or pipes inside the machine are in good condition, not bent and not rubbing. 3. There are no leaks of fuel, oil, cooling water, etc. 4. All fasteners are tight. 5. All electrical leads are secure and in good order. 6. The electrical cables are not damaged. NOTES Do not remove any of, or tamper with, the sound-damping material. Whenever an abnormal condition arises, e.g., excessive vibration, noise, odour, etc., switch the circuit breakers to OFF and stop the engine. Correct the faulty condition before re-starting

36 3-2 Connecting the load Precautions in connecting the load The switchgear, switching equipment, load and generator in the plant must be connected in compliance with local codes of low voltage power installation (1000 or less). Before starting or before connecting a new load, make sure that the generator is earthed. Use the earthing rod or, if effective, use an existing earthing installation. Any protective devices against electric shock and leakage would be useless if earthing is poor. Avoid overloading the generator. The generator is provided with circuit breakers for overload protection when a breaker has tripped, reduce the concerned load before restarting. Never connect the generator output voltage to an installation which is also connected to a commercial power supply. Before connecting a load, turn off the corresponding circuit breaker, and check whether frequency, voltage and power factor comply with the ratings of the generator. Distribution board If the outlets provided on the machine are insufficient, provide an auxiliary switchgear and connect it with the output terminals. The distribution board must comply with the local rule of power installation. Be sure to provide a load ON/OFF switch between the power outlets and load. Do not use the generator circuit breaker to turn on/off the load. Before connecting the load, stop the engine and turn off the generator circuit breaker. The load connecting cable must not get in contact with other output terminals on the terminal board

37 3-2-2 Non-linear and sensitive loads Non-linear loads draw currents with high contents in harmonics causing distortion in the wave form of the voltage generated by the synchronous generator. In general, non-linear type loads generate a high frequency current which adversely affects the performance of inverters used to feed power voltage to variable speed motors or loads such as thyristor/rectifier controlled UPS. Loads most sensitive to voltage distortion include incandescent lamps, discharge lamps, computers, X-ray equipment, audio amplifiers and elevators. Consult your sales distributors for measures against the adverse influence of non-linear and sensitive loads Quality, minimum section and maximum length of cables The cable connected to the output terminals of the generator must be selected in accordance with local regulations. The type of cable must be determined by its rated voltage and current, current carrying capacity, installation conditions, stress and ambient temperature. For flexible wiring, rubber-sheathed, flexible core conductors of the type H07 RN-F (Cenelec HD. 22) or better must be used. As an example, the following table indicates the maximum allowable 3-phase currents in an ambient of 40 for cable types and wire sections as listed in accordance with VDE Local regulations remain applicable if they are stricter than those proposed below. Max. allowable 3-phase current (in A) for PVC insulated conductors, multiple or single core; H07 RN-F multiple core Wire size mm Multiple core Allowable current (A) Single core H07RN-F These values determine the lowest acceptable wire section (in mm2) of multiple core cable or H07 RN-F and the corresponding maximum length (in m) of cables for a voltage drop of e 5%, at rated current and at a power factor of

38 Min. section (in mm 2 ) and max. cable length (in m) DCA type Rated current (A) Minimum section (mm 2 ) Maximum length (m) Relations between min. section (in mm2) and max. cable length (in m) Equation for voltage drop of 3-phase, 3-wire system obtained from cable length and operating current: voltage drop, e (V) = 30.8 L I 1000 A e = Voltage drop (V) L = Length of one wire (m) I = Generator rated current (A) A = Wire size (mm2) If connected to receptacles; receptacle (A) (No.) 32 X 23,24,25 32 X X21 Minimum section (mm2) Maximum length (m)

39 3-2-4 Connecting the load 1. Check whether frequency, voltage and current conform with the ratings of the generator. 2. Install for the load cable, without excessive length, and lay it out in a safe way without forming coils. 3. In case of three- phase load, engage the specified plugs with the specified receptacles (Fig. 8). 4. In case of single-phase load, engage the specified plugs with the specified receptacles (Fig. 8). 70ESEI 125ESEI Fig Three phase output receptacle (63A) 2. Three phase output receptacle (32A) 3. Single phase output receptacle (32A) 4. Cable clamp 5. Rubber cover 6. PE earthing terminal

40 1. Output terminal L1 2. Output terminal L2 3. Output terminal L3 4. Output terminal N 5. External protection conduct terminal PE Fig When connecting output terminals (See Fig. 9.) Remove the protection cover of output terminals. Loosen the cable clamp and push the wire ends of the load cable through the clamp and rubber cover. Connect the wires to the proper terminals: L1/L2/L3/PE, and if required N, for 3-phase load N/L1, N/L2, N/L3 and PE for single-phase load Tighten the bolts securely. Reinstall the protecting cover in front of the output terminal board. Tighten the clamp to fasten the cable

41 3-3 Before starting The generators are factory-adjusted to operate at 50 Hz, i.e r/min Checkup before start-up 1. Checking the oil level Check the engine oil level or contamination by the dipstick. The oil level must be near to, but not exceed, the high mark on the dipstick. If required, refill or change the oil. If necessary, pour oil up to the specified level through the oil refilling port provided on the engine. For oil change, loosen the oil drain plug from the generator base to drain and, thereafter, pour oil the same as refilling. Dispose of the discharged oil in compliance with the local regulations. After supplying oil, run for several minutes, then stop the engine and make sure that the oil level is between the high and low marks. For the oil volume, see the lubricant volume in the specification table. 2. Checking the cooling water in engine radiator Check that the water level is near the Full mark on the auxiliary tank. Refill if short. Use soft water as engine cooling water. Use anti-freeze solution where the atmospheric temperature is low. Mixing volume of anti-freeze solution = total cooling water volume mixing antifreeze solution concentration. For the total cooling water volume, see the engine specification table. For anti-freeze solution concentration at the temperature, see Fuel coolant and lubricants. For making up water, remove the radiator cap. Thereafter, securely install the cap so as to be airtight

42 3. Checking the fan belt tension Check the fan belt tension and elongation. By a thumb, depress (approx. 6kg) the middle point of the belt. The deflection must be mm. At the same time, check whether the belt is scratched or not. If abnormal, adjust or replace it. For belt checkup, adjustment and replacement. 4. Checking the fuel Check the fuel level. Refill if required. If the fuel remainder is small, dew might be formed in the tank and mix with the fuel. To avoid such inconvenience, it is recommended to refill the tank fully after the day s work. Loosen the drain plug from the fuel tank to drain water and sediment from the tank. Dispose of the sediments, etc. in compliance with the local codes. 5. Checking the battery Check whether the electrolyte level is within the specified range or not. If short, add distilled water. If plates are exposed to air for a long time, the battery life would shorten. Keep them dipped. Do not pour battery electrolyte beyond the UPPER LEVEL. After refilling, securely tighten the caps. Give attention to the connection of battery plus (+) and minus (-) terminals. Reverse wiring of the terminals will cause damage to generator instruments. 6. Checking the wiring Check whether the wiring is securely tightened or rubbed. If abnormal, repair or replace. 7. Checking the piping Check whether the piping is securely tightened or leaky. Make sure that the hoses are not worn. If abnormal, repair or replace

43 8. Checking the bolts and nuts Check whether bolts and nuts are securely tightened or not especially for the air cleaner, muffler mounting section. If loose, retighten them Instruction for Fuel Source Changeover Device (Three-Way valve) (1) Setting Procedure for Separate Tank 1 When the machine is shipped from factory, the three way valve is sets as shown in the Fig.10. In the case that fuel source is the mounted fuel tank, run the machine without changing the setting of the piping and valve lever. 2 Where fuel source is a separate tank placed outside the machine, disconnect the tank connection plug and change the connection as shown in the Fig.11. And also switch the lever of three-way valve to the direction of the arrow mark as shown in the Fig.12. (2) Caution on Setting 1 For the piping, use oil-resistant hose of 8 to 10 mm internal diameter. Under Cold environment, use the hose of lager diameter. 2 Install the separate fuel tank as near the machine as possible. 3 Reconnect the piping for the separate tank while the lever of three-way valve is unswitched as shown in the Fig.10. Switch the lever after completing the reconnection work. 4 Set the suction end in the separate tank at the position of 15 to 20mm upper than the bottom level (as shown in Section-A of the Fig.11), so that water or sediment may not come into the suction. 5 While feeding the fuel into the separate tank, do not allow water or dust to come in. [Fig. 10] [Fig.11] [Fig.12]

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