Dca Da Series

8/2/2019 Dca Da Series

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NO. 001 01 675048

INSTRUCTION MANUAL

Engine GeneratorMODEL: DCA - SERIES

MODEL DCA - 13 SPK , DCA -15 SPKDCA - 25 SPK

Denyo Asia Pte Ltd.

HEAD OFFICE27 Pioneer Sector 1, Jurong, Singapore 628433

Tel. : 65-8610058Fax.: 65-7969067


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This Inst ruc tion manual g ives a deta il ed descript ion of the opera tion , rout ine inspec tion ,maintenance, and troubleshooting of the generator, and other item s required forproperoperation.

We th erefore recomm en d that all users read this m an ual carefu lly before actu allyoperating the gene ra to r t o ensure p roper operation .

Fo r deta iled operation , d isas sembly. r ea ssembly and repairof the eng ine, p lease refert o the "Engine Ins truc ti on M anua l" supp lied by the engine manufac tu re r.


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CONTENTS

Page1. INTRODUCTION OF PRODUCTS 12. SAFETY PRECAUTIONS 23. MAJOR SPECIFICATIONS 34. PREPARATION 55. CAUTION FOR Ac. POWER SUPPLY............................................. 66. OPERATING PROCEDURES 77. STARTING AND OPERATING 78. STOPPING THE ENGINE 99. CAUTION WHILE OPERATING 910. EARTH LEAKAGE RELAY 911. MAJOR COMPONENT FUNCTION 1012. INSPECTION AND MAINTENANCE 1113. STORAGE ~ :............ 12

14. TROUBLESHOOTING 1315. GENERATOR WIRING DIAGRAM 1516. ENGINE WIRING DIAGRAM 1917. OUTLINE DRAWING 2018. SAFETY PRECAUTIONS FOR DIESEL GENERATING SET AND

EQUIPMENT 21


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1. INTRODUCTION OF PRODUCT

Thank you very m uch for purchace of our product D E NYO G EN ERATING SE T.T his instructio n m an ual is a gu ide to h andle you r best pu rch ase, D ENYO GENERATINGSET , a n d hop e you w ill r ea d it c ara efu lly f or p ro pe r u se o f th is ma ch in e.

Then it w ill surely serve you for a long period of tim e. The D CA-I3 SPK ,D CA -IS SP K, and D CA -25 SP K, is em ploied a new conception pow er generatingsystem and has features as fo llow s;(1) M ain tenance-Free Des ign

This high-performancebrushlessgeneratoris virtuallymaintenance free .An uniquemain tenance system fac il itates easy da ily chek and rout ine se rv icing .

(2) V oltage R egulation L ess T han 1.5 %A h ig h-p er fo rmanc e Au tomatic Vo lta ge Regu la to r (A .V .R .) ma in ta in s s up erb

ou tpu t s tab il it y by keeping vo lt age var ia ti on to unde r 1.5 %(3) M i nim al W avefo rm D estortion

A dampe r coi l and a new gener ator des ign keep waveform des to rt ion to neg ligibl elev els, e ve n u nd er SCR an d c omp ac t X -R ay u nit lo ad s.

(4) C on tinuo us L on g-T im e O p eratio nLong-Time oper at ion has been accompl ished by emp loying a fue l- saving enginea nd a b ig fu el ta nk .

(5) Standard Em ergency Stop D eviceAn eme rg en cy sto p d ev ic e is b uilt-in . Itmonito rs w ate r temp era tu re , a nd o il

p re ssur e. When a ma lfunct ion i s de te ct ed , eng ine s top s automa ti ca ll y.(6) Compact & Double-P i ling Des ign

T he g en era to r a re frame d stro ng ly e no ug h to b e sta ck ed o ne o n to p o f th e o th erfor effic ient s trong.(7) H igh Q uality D esign

T his g en eratin g se t h as b ee n d esig ne d a s a h ig h q ua lity p orta ble p ower so urcefo r l igh ting faci li ty ,power tools, and o ther indust rial and cons truct ion mach inery .

( 8) An automatic a ir e xtr ac tio n d ev ic e fr om fu el is s ta nd ard e qu ipmen t, e na blin g its a n e as yair-extraction

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3. MAJOR SPECIFICATIONSSPEC./MODEl DCA - 13 SPK

MODEL DF -0140 KFrequency (Hz) 50 60Rated output (kVA) 10.5 13Rated Voltage (V) Rated current (A)

200 30.3 37.5215 28.2 34.9220 27.6 34.1230 26.4 32.6

a :: 240 25.3 31.30 380 16.0 19.8. . . . 400 15.2 18.8a :: 415 14.6 18.1w 430 14.1 17.52: 440 13.8 17.0wC ! J 460 13.1 16.3480 12.6 15.6

Number of phases Three-phase, four-wirePower factor 0.8 (lagging)Exitation Brushless type

(with automatic voltage regulator)Number of poles 4Speed (min-') (rpm) 1500 1800Insulation Class FAUX. AC Power (OPTION) Single-Phase 3 kW (1.5 kW x 2)Mod e I D 1403 - KAType Vertical, water-cooled, 4-cycle dieselNumber of cylinders 3w Bore x Stroke (mm) 80 x 92.42: Total displacement (l) 1.393-C ! J Rated output (kW) 10.1 12.4

Z (ps) (13.7) (16.9)w Battery 12 V - 70 Ah x 1Fuel DIESELFUELASTM NO.2 or eq.Fuel tank capacity (l) Approx.62Lubricant quantity (l) Approx 5.6Coolant quantity (l) Approx.4.9length (mm) 1400. . . . Width (mm) 650w Height (mm) 900

(J) Dry weight (kg) Approx.490

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SPEC / MODEL DCA - 15 SPKMODEL OF - 0170Frequency (Hz) 50 60Rated output (kVA) 12.5 15Rated Voltage (V) Rated Current ( A )

200 36.0 43.3215 33.6 40.3

c : : : 220 32.8 39.40 230 31.4 37.7I- 240 30.0 36.0- c 380 18.9 22.8c : : : 400 18.0 21.7w 415 17.3 20.9z 430 16.8 20.1w 440 16.4 19.7o 460 15.7 18.8

480 15.0 18.0Number of phases Three _Qhase four wirePower factor 0.8 (lagging)Exitation Brushless type

(with automatic voltage re_gulator)Number of poles 4Speed (min ) (rpm) 1500 1800Insulation Class FAUX. AC Power (OPTION) Singler:>_hase 3 kW ( 1.5 kW x 2 )Model o 1703 - KAType Vertical, water cooled, 4 ~_cIe dieselw Number of cylinders 4

Z Bore x Stroke (rnrn) 87 x 92.4- Total displacement (L) 1647o Rated output (kW) 12.4 I 14.7z (ps) (16.9) (20)w Batery 12 V - 70 Ah x 1Fuel DIESEL FUEL ASTM NO.2 or e__qFuel tank capacity (L) A.Jm.rox.62Lubricant quantity (L) Approx.5.6Coolant quantity (L) Approx.4.9Length (rnm) 1450I- Width (mrn) 650w Height (rnrn) 900

e n Dry weight (kg) Approx.509

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SPEC.! MODEL DCA - 25 SPKMODEL OF -0270 KFrequency (Hz) 50 60Rated output (kVA) 20 25Rated Voltage (V) Rated current (A)200 57.7 72.2

215 53.7 67.1220 52.5 65.6230 50.2 62.8

0:: 240 48.1 60.10 380 30.4 38.0I- 400 28.9 36.10:: 415 27.8 34.8w 430 26.8 33.62

440 26.2 32.8wC ! J 460 25.1 31.4480 24.1 30.1Number of phases Three-phase, four-wirePower factor 0.8 (lagging)Exitation Brushless type

(with automatic voltage regulator)Number of poles 4Speed (min-') (rpm) 1500 1800lnsulation Class FAUX. AC Power (OPTION) Single-Phase 3 kW (1.5 kW x 2)Mod e I V 2203-KCType Vertical, water-cooled, 4-cycle dieselNumber of cylinders 4w Bore x Stroke (mm) 87 x 92.42 Total displacement (L) 2.197-C ! J Rated output (kW) 18.4 23.72 (ps) (25.0) (32.2)w Battery 12 V - 70 Ah x 1Fuel DIESEL FUEL ASTM NO.2 or eq.Fuel tank capacity (L) Approx.62Lubricant quantity (L) Approx 7.6Coolant quantity (L) Approx.7.9Length (mm) 1580I- Width (mm) 650w Height (mm) 900

t/) Dry weight (kg) Approx.600

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4. PREPARATION

4-1 General Inspection P rior to O perationT his fg en era tor ha s b een th ro ug hly in sp ecte d a nd a cce pte d prio r to sh ipmen t

from the factory. H ow ever, be sure to check for dam aged parts or com ponents,or loose nuts and bolts, w hich could have occured in transit.

4- 2 Lubricating O ilCheck oil level every day. Fill the engine crankcase w ith lubricating oil

through the filler hole, but do not overfill. M ake sure the generating set is level."W ith the dipstick inserted all the w ay, see that the oil level is m aintained betw eenthe tw o notches on the dipstick.

o il p an c ap ac ity ( lite rs )DCA - 13 SPK I DCA - 15 SPK DCA 25 SPK

upper level 5.6 7.6low er level 4.3 5.8

The oil listed below is recommended to ensure proper engine perform ance.U se class CC or higher grade motor oil.

Summer SAE 30Wmter SAE lOW - 30

4-3 FuelC heck the fuel level before engine starting.Fill the fuel tank w ith clean and fresh diesel fuel.D o not overfill the fuel tank.

4-4 Cooling WaterSee the water level in the reserve-tank (sub-tank) and be sure that it is

maintained between "F" and "L " marks. Fill the tank and radiator with cleanwa te r, if n eces sa ry .

-DANGER-N EV ER fill the radiator w hile the engine is rurm ing or it is hot.Hot water m ay spread out from the filler hole.* Drainage Drain the w ater throught the w ater drain and open

the radiator cap for quick drainage.* Antifreeze Use a ntifre ez e in c old o pera ting c on ditio n.

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4- 5 BatteryProper maintenance of the battery is extremely important to ensure smoth

starting and long service life. Check the specific gravity, level of electrolyte andoutput voltage every 50 hours of operation.

If the specific gravity is 1.28 (at 20C), the battery is adequately charged.If itis 1.245 or less, recharging is necessary.The electrolyte must always cover the plates. If the plates are exposed to

air for a long time, damage willresult. Apply a thin a thin coat of grease to ensurea good connection.

5. CAUTION FOR AC POWER SUPPLY5-1 On connecting a 3-phase load to the output terminals, securely tighten locking

bolt with a spanner to prevent it from burning.5 - ; 2 Make sure to switch the circuit breaker to the "OFF" position prior to connecting

the load. Never connect the load with the circuit breaker "ON". Electric shockand possible damage to the generating set may occur.

5-3 Total wattage of the loads should not exceed the rated output capacity ofthegenerating set.

5-4 When connecting a single-phase load to the output terminals, keep all loadswell-balanced. Unbalanced distribution of the loads may cause a instable outputvoltage.

5-5 Connectingtheload

lu V W o O l(0 0 0) .

. . .' i b l i '....3- phase, 200V/2I5V/220V/230V/240V/380VI

400V/4I5V/430V/440V/460V/480V

I-phase, 115VI124V/I27V/133V/139V/220VI230V 1240V1248V1254V1266V1277V

I-phase, 200V 12I5V 1220V 1230V 1240V 1380V I400V/415V/430V/440V/460V/480V.

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6. OPERATING PROCEDURES6-1 B efore Starting

(1) C ircuit B reaker C heckB e sure to disconnect the electrical load and sw itch the circuit

b re ak er to th e "OFF" pos itio n p rio r to s ta rtin g th e e ng in e.Neve r s ta rt th e e ng in e w ith th e c irc uit b re ak er "ON".

(2) O il C heckCheck the lub ri ca ti ng o il l ev el p rior t o s ta rt ing the eng ine, mak ing

s ur e th e g en era in g s et is le ve l. T he o il le ve l mu st b e ma in ta in ed b etwe enth e two notc he s o nth e d ip stic k.

When the re i sno t enough lub ri ca ting o il , f il l t he c rankca se wi th h ighg rad e mo to r o il. U se a h ig h q ua lity d ete rg en t o il c lassified CC o r CD .-CATION-

NEVER sta rt th e en gin e whe n th e o il le ve l is b elow th e lower markon the d ips tick .

(3) Fuel CheckCheck th e f ue l le ve l b y th e f ue l g au ge . When th e f ue l is low , f ill th e

fuel t ank wi th c le an and f re sh d ie se l f ue l.(4) Battery Check

Check the leve lo f e lec tro ly te ,mak ing sure the genera ting se t i s leve l.

7. STARTING AND OPERATING7 -1 Tum the Fuel C ock L evel to the "O N " position7 -2 T urn the B attery Switch to the "ON " p osition. (option )7 - 3 Insert the key into the Starter Sw itch and turn it to th e "RUN" pos itio n.

C heck to see that the O il P ressure L ight and C harg ing L ight tum o n.It th ey d on 't lig ht, c he ck th e lu brica tio n o il sy stem , e ng in e e lec tric s ystem fo rdefective wiring.

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7 - 4 T urn th e k ey to th e "START" p ositio n to sta rt th e e ng in e. A fter startin g, removeth e h and fr om th e k ey immedia te ly . Then th e k ey r etu rn s to "RUN" Po sitio on .'* When th e eng in e w ill n ot s ta rt we ll in cold s ea son:

T urn the key to "H EAT" position. T he P re-heat L am p w ill ~urn o n forabout 5 second. W hen the P re-heat L am p goes off, T urn the key to "START"position to s ta rt the eng ine.

7-5 If the engine does not start w ithin 10 seconds after the key is turned to the"START" position, w ait for about 30 seconds and repeat the procedure asd esc rib ed in ste p 7 -4 a bo ve .

7 -6 When th e e ng in e starts, t he O il P re ssu re L ig ht a nd Charg in g L ig ht sh ou ld g o o ut.If th e lig ht sta ys o n, immed iately s to p th e e ng in e a nd c he ck th e lu bric atio n o ilsystem, engine elect ric system and/or l ights. (referto the engine inst ruct ion manualfor engine e lec tr ic syst em) .

7 - 7 L et th e en gin e idle for fiv em inu tes to w arm -u p7 - 8 Che ck th e e ng in e fo r a bn orm al v ib ratio n, n oise a nd o il le ak ag e.7 - 9 Regula te th e output volta ge by adju stin g th e volta ge Regula to r a nd s et t h e eng in e

sp eed b y th e T hro ttle H an dle a cco rd in g to th e lo ad .- H ow to se t th e T hro ttle H an dle -

(5)

Rele ase th e lo ck ed h an dle b y tu rn in g th e b ottom o fth e T hro ttle H an dleunclockwise (RELEA SE) .D e pre ss in g th e c en te r b utto n o n th e T hro ttle H an dle , p ull th e T hro ttleHandle out s low ly and fully to in cr ea se th e eng in e spe ed .F in e spe ed con tr ol w ill b e done by adju stin g th e Throttle Hand le . ( tu rn itc lo ckw is e to d ec re as e th e eng in e spe ed and unc lo ckw is e to in cr ea se it)L o ck th e T hro ttle H an dle b y tu rn in g th e b ottom o f th e T hro ttle H an dlec lo ckw is e (HOLD ) a fte r s ettin g th e eng in e spe ed a t ra te d spe ed .F or id lin g o f th e e ng in e, re le ase th e lo ck ed Thro ttle H an dle a nd p ush itdown s lowly depres sing the cen te r bu tton .

(1)(2)(3)(4)

7 -1 0 S et th e c ircu it b re ak er to th e "ON " positio n to su pp ly e le ctric ity to th e lo ad .

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8. STOPPING THE ENGINE8-1 T um the load side circuit b reaker to th e "O F F" p ositio n.8- 2 T um the circuit break er o n the generatin g set to the "O F F" po sition .8 - 3 Le t t he eng in e r un f or fiv e m inute s to coo l-down w ith th e Thro ttle Hand le pushed-

down posi tion . ( id ling opera tion)8-4 Tum the key to the "STO P" position and rem ove the key.

9. CAUTION WHILE OPERATION9-1 Never turn t he Batt ery Swi tch to the "OFF" posi tion during the opera tion (opt ion).9- 2 Check to see the Amm eter and keep the total am perage of the load w ithin the

r ate d ampe rage o f th e g en er atin g s et.9 -3 When th e c irc uit b re ak er trip s, ch eck th e p os sib le c au se s a nd turn it to th e "OFF"

pos itio n onc e and th en turn it to th e "ON " positio n to re se t.9 -4 A lway s ope ra te th e g en er atin g s et w ith th e doo rs in th e c lo sed pos itio n. Oper atio n

w ith th e doo rs open may re su lt in in su ffic ie nt c oo lin g and damage may r esult.9 -5 If a ny a bn orm al n oise , smok e, v ib ra tio n a nd sme ll a re p erd eiv ed , sto p th e e ng in e

immedia te ly and che ck for th e pos sib le c au se s.

10. EARTH LEAKAGE RELAY (OPTION)10 -1 E arth L eak age R elay

The mach ine is equ ipped with an ear th leakage Re lay wh ich det ec ts leakageand b re ak s th e c irc uit to p revent e le ctr ic al s ho ck durin g th e ope ra tio n.B ut m isu se o fth is R elay may b e muc h d an gero us. B e su re to re ad c are fu lly th isins truct ion before operat ing the machine .The s tandard cur rent sensiv ility o f th is b reaker is 30mA.

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Over 50 C J n-:-'-_-,.....,

Earth Terminal(G ro und term in al for leak age R elay )

E arth B arNote: For more safe operation, we recommend the installation of an earth lekage

Relay on the circuit of the load (closer to the each load).10-2 Operation

B e sure to observe the follow ing instructions to ensure safe operation ofthe earth leakage breaker. In case the earth relay actuates, stop the engine andcheck the possible causes and repair it.

(1) E arth ing o n the ge nera to r sid eE arth the m achine by connecting the attached earth pin to the earth

terminal ( gr ou nd te rm in al f or le ak ag e b re ak er ) in sta lle d o n th e con tr ol p an el.(w ith out th is earthin g, the ea rth leak age break er m ay n ot fu nction )A lso earth the bonnet of the machine. Term inal (ground for bonnet) isin sta lle d o n th e re ar p an el.

(2) E arthing on the load sideE arth the bonnet of the box of the load.Note: The provision of earth lekage breaker on the machine can not

elim ate th e nec essity for e arthing th e lo ad.The load m ust be earthed to allow earliest possible detection ofleakage.

11. MAJOR COMPONENT FUNCTION11-1 A.C. Voltmeter

This meter indicates phase to phase voltage of the three phase outputterminals.

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11 -2 Frequency M e terTh is me te r ind ic ate s th e outpu t f requency o f th e gener at ing set .

11 -3 A .C . AmmeterT his m eter in dicate s cu re nt flow to th e lo ad co nn ecte d to th e "U" p ha se

WIre.

11-4 H ourm eterTh is me te r ind ic at es the ope ra ti ng t ime o f the gener at ing set

1 1- 5 C irc uit B re ak erT his c ircu it b rea ker co nn ects o r d isco nn ects g en era to r o utp ut from th e

three phase ou tpu t termina ls . I t a lso pro tec ts the genera ting set f rom shor t c ircu it sor overloads.

11-6 Vo ltage Regu la to rT he volta ge re gu la to r a llows manu al a dju stment o f th e g en era to r o utp ut

voltage.1 1-7 Emerg en cy S hu td own S ystem

This g en era tin g s et is p ro vid ed w ith s afe ty d ev ic es to a utomatic ally s to pthe engine in the event below .low oil p ressu reabnormal ly h igh water tempera tu reinsufficentcharge

This system furn ished engine pro tec tion during operat ion .

12. INSPECTION AND MAINTENANCEA t least daily or prior to each use, the generating set should be cleaned and

in sp ecte d fo r d eficie ncies. C hec k fo r lo ose, m issin g o r d amag ed n uts, b olts o r o th erfa ste ne rs . A ls o c he ck f or fu el o r o il le ak ag e.

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Inspect ion ProcedureItem Procedure Period

Chec k fo r th e fu el lev el a nd refu el dailyfue l sys tem dra in the f ue l tank as necessaryc lean the fue l f il te r e ve ry 100~200 h rs.r ep lace the fue l f il te r ev ery 4 00 h rs.ch ec k fo r th e o il le vel a nd re fill it daily

o il s ys tem dra in t he eng ine c rankcase and r ef il l o il s ee engine manualrep lace the oil s tr aine r s ee eng ine manual

cooling che ck for wa te r l evel and r ef il l dailywater c lean fue l system components every 40 0-50 0 h rsair c lean air c leane r e lement every 10 0-20 0 hrscleaner rep lace i t s ee engine manualelectric c he ck for batt er y e le ctr oly te le ve l every 50 hrs. orsystem and r ep le nis h it o nce a mon thengine s ee ang ine manualothers c le an the r ad ia to r fi ns a s necessaryche ck f an belt t en sion s ee eng ine manual

13. STORAGEFor l ong te rm s to rage o f the gener at ing s et , t he f ol low ing p rocedu re s a re r equ ir ed :

(1) Drain wa te r f rom the radia to r c omple te ly(2) Dra in the f ue l tank comple te ly(3) Dra in the o il fr om the eng ine c rankcase comple te ly and r ef ill w it h fr es h and c le an

oil(4) Rem ove the battery and keep it charged(5) P lease refer to the engine m aintenan ce m anual.

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14. TROUBLESHOOTING

Eng ine fails to s ta rt CHECH PO INT NOStarter rotates 1--------CD ,@, @, , .

Eng ine fails to s ta rt ,@,0,.Someth ing wrong with engine 1----- @, @, , ,@.Insufficient output of engine 1----- , , .Engin e su dd en ly sto ps d urin g o pera tio n ~ CD ,@ ,@ , ,@ ,@ ,@ ,@ ,@ ,(j)

CHECKPOINTCD N o. fuel. Fuel strainer is closed@ Fue l p ip e c lo gg ed o r su ck s in a ir@ Wate r in f ue l tank and in fu el s ys tem .Cogged fuel s trainer Batte ry sw itch tu rned "OFF" (op tion)@ Batt ery cable d isconnectedo Inspect the batte ry e lectroly te leve l and vo ltage@ Check o il leve l Use an o il w ith app rop ria te v iscosity , e spec ia lly in cold ambient tempera tu re@ Clogged a ir c leaner Cir cu it b re ak er is tu rn ed "OFF"@ Genera ting se t i s over-loadedQ ) No w ater in th e radiato r or the w ater lev el is to o low@ F an b elt is lo ose ne d o r b ro ken@ Gen era tin g se t o pe ra tes in e nclo se d o r c on fin ed a re a whe re th e fre e flow

of cool ing a ir i s res tr ic ted .

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EngineStarting

Engine failst o s ta rt

{

battery switch in "O FF" positiondefec tiv e bat te ry swi tchStarter fails discharged batteryto rotate defective starter switch

defective starterbroken leads

(option)(option)(option)

-{broken pre-heat c ircuit

Starter no fuelrotates air i n fuel system

others

{compression leakage

E ngine remains air in fuel systemat low speed clogged fuel strainerclogged air c leaner

Engine speedrises

Enginestarts

Generator failsto generate

malfunct ion ofexciting circuitd efec ti ve rec tif ie r (Re )broken armature windingbroken field windingdefective rotorbroken leadsdefective A.V.R.

~turn it "ON"~replace~ change or replace~replace~replace~repair

~repair~refuel~ repair or bleed~ see engine m anual

~r epa ir e ng ine~repair or bleed~clean~clean

~replace~replace~replace~replace~ replace~repair~repalceidefectiveA.V.R. ~ replaceVoltage too short in a rmature winding ~ replacelow defective rotor ~ replaceengine speed is too low ~ raise enginespeed to ratingdefective voltage regulator-ereplacev oltag e is ad jus ted w ro ng ly ~ adju st it to ra tingVoltage too -[ defecfive A.V.R. ~replacehigh . voltage is adjusted wrongly~ adjust it to ratingBattery

dischargesoon iefective engine alternator-ereplaeedefective engine regulator ~repalcebroken leads ~repairdefective starter switch ~replacedefective battery ~replaceCircuit=r defective breakerdoesn't close short circuit in load

over loadEngine seems _ _ _ c broken leadsloaded damaged bearing

~replace~repair~reduce th load~repair~replace

Abnormal noise1ngine side ~ repairalternator"T damaged bearing ~ replaceside Loosened clamping ~retighten

boltsbonnet side ~ repair

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15. GENERATOR WIRING DIAGRAM15.1 Generator Wiring Diagram (200V Class) ELR

~.. . . ~$ ~",'" ~E '" > e.:;; E g ':" E ' " c:> 5 - ~~~8 . .u~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - 1 Q

w~2!hI-a:a.

. . ,zo. . . .. . . CO ): z : . . .

(,) ~ . . .>- < :i~N UN . . . -"o I ~ '- ~ . . ,: z :I~ U~ it t'l . .>~

."i~ t'l Z be;:, L) eIII . . . ._.jlll

. . . . .o " I !l:0 . . , . , C > lz; IIr,:;--'" 0''' (,J ~L) C Il . .- I I ' -- - I ~ ~ ~ 0 I , . . -I t.l >. . . I. . . . , z(,Jj~ uI z0. . ":-'____ _J~

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15.2 Generator Wiring Diagram (200V Class)

l!;:;;":]

i~.-.j~

1 , I ..I z I~lOt ....L~ .-' ~17

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~~~I. t ; " > C\lZc> N t). . . . . .'-,

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21/27

1 5.3 G en era to r W irin g D ia gram (4 00V C la ss ) ELR

t,8>1 ll.;;

l!;:;;;s]- I I ' sco

. . . . _,

o

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15.4 Generator Wiring Diagram (400V Class)

c: Q { @ ~U.Q

~~to .,

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til. . .C"j0 :~-"'- - I" @n~ ~. --", 5to N U'0 >- - oJ~m . ,>~,I)r : / u/

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16. ENGINE WIRING DIAGRAM

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24/27

17. OUTLINE DRAWING

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18. SAFETY PRECAUTION FOR DIESEL GENERATAINGSETS AND EQUIPMENT

Tobe read attentively before installing, operating or repairing the unit.Inaddition to general safetyruleswhich should b e observedwith diesel generatingsets and equipment, the following safetydirectionsand precautions are of specialimportance.When operating this unit, theoperatoris expectedto employ safeworking practicesand to observe all related local work safety requirements and ordinances.The owner is responsible for maintaining the unit ina safe operating condition.Parts and accessories shall be replaced ifunsuitable for safe operation.Installation, operation, maintenance and repair shall only be performed byauthorized, trained, competent personnel.If any statement in this book, especially with regard to safety, does not complywith local legislation may not apply to the unit (s) described in this book.

A. INSTALLATION

Apart from general engineering practices that conform with the local safetyregulations, the following directives are especially stressed:1. Engine exhaust contains noxious elements

Therefore, pay close attention to ventilation when operating the generatorset inside tunnels, building, or other enclosed areas.

2. For outdoor operation, install the generator set that the exhaust is notdischarged in the direction of nearby homes or other enclosed areas.

3. When the generator set is installed in a dusty or corrosive atmosphere,frequently inspect it for radiator clogging and other abnormal conditions

4. Provide adequate space for engine inspection, lubrication, refueling, cableconnection to the load, and operation

5. Never remove or tamper with the safety devices, guards or insulationsfitted on the unit6. Be sure that the generating set is on secure and level ground

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B. OPERATION

1. Select cables ofproper thickness while referring to the load capacity anddistance to the load. Then, securely connect them.Do not use any cable whose cover is broken and degraded.In connecting the cable, be sure to shut down the operation. Cover ortape the connections to prevent leakage and direct contact with the humanbody.

2. Always check voltmeter and frequency meter indicates the rated, ammeterindicates under the rated current.

3. All canopy doors should be shut during operation.4. People staying environments or rooms where the sound pressure level

reaches or exceeds 90 db (A) shall wear ear protectors.5. The following items should be checked before start up:

a) All guards should be in place and securely fastenedb) Water,engine oil or fuel leakagec) That all fasteners are t ightd) That all electrical leads are secure and in good ordere) Oil leveland cleanlinessf) Cooling-water level (radiator and overflow tank) and radiator cap

securely tightenedg) Fuel levelh) Tension ofa llV-belts

6. Provide a switch between the generator and load to operate or stop theload

7. Always keep batteryswitchturned "ON"while operating the engine. Also,always keep it "OFF" when engine isnot running. (option)

8. Do not wire the generator set to the interior circuit.9. Avoid low-load operation for long periods of time.10. Coolant: Use clean water

when the temperature drops to (32F) or below, the following mesuresmust be taken:a) Use antifreezeb) When antifreeze is not used,Open drain cock of the engine and radiator to completely drain off coolingwater after engine operation.

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11. Fill the fuel tank frequentlyP erio dic ally o pe n th e d ra in p lu g to d ra in mois tu re a nd c on tamin an ts .

12. A void high speed operation immediately after starting13. Never turn th e s ta rte r switc h to " Sta rt" p os itio n while th e e ng in e is ru nn in g14. Never stop the engine suddenly except in an em ergency15. N ever touch any rotating, hot and live parts during operation.

c. MAINTENANCEM aintenance and repair work shall only be carried out under supervision ofsom eone q ualified for the jo b

1. U se only the correct tools for maintenance and repair work.2. U se only genuine spare parts.3. A ll maintenance work, other than r ou tine a tt en tion , sha ll only be unde rt aken

w hen the unit is sto pped .4. N ever use flammable solvents or carbon tetrachloride for cleaning parts.

T ak e s afe ty p re ca utio n a ga in st to xic v ap ou rs o f c le an in g liq uid s.5. Scrupulously observe cleanliness during maintenance and repair. Keep

dirt aw ay by covering the parts and exposed openings w ith a clean cloth,paper or tape.

6. M ake sure that no tools, loose parts or rags are left in or on the unit7. P rotect the electrical and regulating com ponents, etc. to prevent m oisture

from e nte rin g th es e p arts, e .g . whe n s te am cle an in g.

A ll re sp on sib ility fo r a ny d amag e o r in jiu ry re su ltin g from n eg le ctin g th es e p re ca utio nsor by non-observance of ordinary caution and due care required in handling, operating,m aintenance or repair, even if not expressly m entioned in this book, w ill be disclaim ed byD enyo A sia P te. L td.

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Dca Da Series

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