MANUAL No.B28443 01104B

INSTRUCTION MANUAL

ALTERNATING CURRENT GENERATING SETS

DCA-15,-25,-35ESEK

2-8-5 Nihonbashi-horidomecho, Chuo-ku, Tokyo, 103-8566 Japan

IMPORTANT : READ AND UNDERSTAND THIS MANUAL

CAREFULLY BEFORE USE OF THIS MACHINE. KEEP THIS

MANUAL FOR YOUR FUTURE REFERENCE.

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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.

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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.

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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 B9111 0220

CAUTION: Instruction manual B9111 0230

DANGER: Electric shock B4510 0250

WARNING: Fire/explosion B9045 0100

CAUTION: Burn B9111 0240

CAUTION: Moving parts B9040 0050

CAUTION: Emergency stop B9044 0000

CAUTION: Hot coolant/Battery B9041 0020

CAUTION: Engine fan B9040 0060

WARNING: Falling B9111 0250

WARNING: Engine exhaust B9042 0020

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.

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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.

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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.

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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.

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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 (MODEL: DCA-15,25ESEK)

1 DANGER: Electric shock 2 WARNING: Fire/explosion 3 CAUTION: Burn 4 CAUTION: Moving parts 5 CAUTION: Instruction manual 6 CAUTION: Instruction manual 7 CAUTION: Emergency stop 8 CAUTION: Hot coolant/Battery 9 CAUTION: Engine fan 10 WARNING: Falling 11 WARNING: Engine exhaust

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SAFETY LABEL/SICHERHEITSANHAGE (MODEL: DCA-35ESEK) 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

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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.

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Contents

SAFETY PRECAUTIONS FOR GENERATORS ------------------------------------------------------------------------ 2

1. DCA series -------------------------------------------------------------------------------------------- 12

1-1 General ------------------------------------------------------------------------------------------------- 12

1-2 Machine structure -------------------------------------------------------------------------------------- 12

1-3 Machine appearance and internal component devices -------------------------------------------- 12

1-4 Control switches and meters ------------------------------------------------------------------------- 16

1-4-1 Engine start/stop controls ------------------------------------------------------------------- 16 1-4-2 Engine indicators --------------------------------------------------------------------------- 19 1-4-3 Generator controls and indicators ------------------------------------------------------- 21

1-5 Noise ----------------------------------------------------------------------------------------------------- 22

2. Transportation, storage and installation -------------------------------------------------------- 23

2-1 Safety precautions for transportation, storage and installation ------------------------------ 23

2-2 Transportation ------------------------------------------------------------------------------------------ 24

2-3 Storage --------------------------------------------------------------------------------------------------- 25 2-3-1 Storage method ------------------------------------------------------------------------------ 25 2-3-2 Preparing for operation -------------------------------------------------------------------- 26

2-4 Installation ---------------------------------------------------------------------------------------------- 27

2-4-1 Installation ------------------------------------------------------------------------------------ 27 2-4-2 Checking after installation ---------------------------------------------------------------- 30

3. Operation ------------------------------------------------------------------------------------------------ 33

3-1 Safety precautions for operation ------------------------------------------------------------------ 33

3-2 Connecting the load --------------------------------------------------------------------------------- 35

3-2-1 Precautions in connecting the load ----------------------------------------------------- 35 3-2-2 Non-liner and sensitive loads ------------------------------------------------------------ 36 3-2-3 Quality, minimum section and maximum length of cables ----------------------- 36 3-2-4 Connecting the load ------------------------------------------------------------------------ 38

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3-3 Before starting ----------------------------------------------------------------------------------------- 40 3-3-1 Checkup before start-up ------------------------------------------------------------------- 40 3-3-2 Instruction for Fuel Source Changeover Device(Three- Way valve) ------------ 42

3-4 Starting --------------------------------------------------------------------------------------------------- 43

3-5 During operation -------------------------------------------------------------------------------------- 45

3-6 Stopping ------------------------------------------------------------------------------------------------- 46

3-6-1 Stopping method --------------------------------------------------------------------------- 46 3-6-2 Emergency stop ---------------------------------------------------------------------------- 46 3-6-3 Emergency stopping device -------------------------------------------------------------- 46

4. Fuel, coolant and lubricants -------------------------------------------------------------------------- 48

5. Periodic checkup and maintenance ----------------------------------------------------------------- 50

5-1 Safety precautions for periodic checkup and maintenance ------------------------------------- 50

5-2 Periodic checkup --------------------------------------------------------------------------------------- 52

5-2-1 Maintenance schedule ---------------------------------------------------------------------- 52 5-2-2 Check/first 50 hours ---------------------------------------------------------------------- 53 5-2-3 Check/every 100 hours -------------------------------------------------------------------- 54 5-2-4 Check/every 200 hours -------------------------------------------------------------------- 55 5-2-5 Check/every 400 hours -------------------------------------------------------------------- 56 5-2-6 Check/every 500 hours -------------------------------------------------------------------- 57 5-2-7 Check/every 1000 hours ------------------------------------------------------------------ 57 5-2-8 Check/every 2000 hours ------------------------------------------------------------------ 57 5-2-9 Other checks and Maintenance ---------------------------------------------------------- 57 5-2-10 Table of periodical maintenance and checking ------------------------------------- 58

6. Troubleshooting ------------------------------------------------------------------------------------------ 59

7. Principal data ------------------------------------------------------------------------------------------- 60

7-1 Readings on gauges -------------------------------------------------------------------------- 60

7-2 Setting of switches ----------------------------------------------------------------------------- 60

7-3 Reference conditions -------------------------------------------------------------------------- 60

7-4 Limitations -------------------------------------------------------------------------------------- 60

7-5 General specifications ----------------------------------------------------------------------- 61

7-6 Conversion list of S1 units into UK/US units ----------------------------------------- 62

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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 Kubota 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. 1.

1-3 Machine appearance and internal component devices 〇 There are the hanger at the center on the top surface and rope support hooks 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, 2’. 〇 The engine cooling water refilling port and fuel refilling port are located on the top

surface of the machine. 〇 The fuel gage which indicates the residual amount of fuel, is located at the side of the

machine. 〇 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. 〇 For the internal component devices, etc., see Fig. 1 and Fig. 2, 2’. Refer also to “7 Outline

drawing”.

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Fig.1

Model DCA-15ESEK

1. AC generator 2. Diesel engine 3. Control box

4. Fuel tank 5. Radiator 6. Battery 7. Muffler

Model DCA-35ESEK

1. AC generator 2. Diesel engine 3. Control box

4. Fuel tank 5. Radiator 6. Battery 7. Muffler

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Model DCA-25ESEK

Fig. 2

1. 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. Three phase output receptacle 8. Single phase output receptacle

9. Engine exhaust port 10. Cooling air intake port 11. Cooling air exhaust port 12. Side door 13. Drain plug engine cooling water 14. Environment base drain 15. Three-way valve 16. Emergency stop button 17. PE earthing terminal

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Model DCA-35ESEK

Fig. 2’

1. 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. Three phase output receptacle 8. Single phase output receptacle

9. Engine exhaust port 10. Cooling air intake port 11. Cooling air exhaust port 12. Side door 13. Drain plug engine cooling water 14. Environment base drain 15. Three-way valve 16. Emergency stop button 17. RE earthing terminal

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1-4 Control switches and meters 〇 The control switches and meters are located inside the door having a window on the rear

of the machine. 〇 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. 1-4-1 Engine start/stop controls

Model DCA-15,25ESEK

Fig.3

1. Frequency meter 2. Ac ammeter 3. Ac voltmeter 4. Ammeter change over switch 5. Voltage regulator 6. Circuit breaker(for main) 7. Circuit breaker(for 1-phase receptacle)

8. Circuit breaker(for 3-phase receptacle) 9. Earth leakage relay

10. Over current relay(in the control box) 11. Starter switch 12. Emergency stop button 13. Engine monitor

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Model DCA-35ESEK

Fig.3’

1. Frequency meter 2. Ac ammeter 3. Ammeter change over switch 4. Ac voltmeter 5. Voltage regulator 6. Circuit breaker

(3-phase molded case circuit breaker)

7. Earth leakage relay 8. Over current relay (in the control box) 9. Engine indicator

10. Starter switch 11. Emergency stop button

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1. Starter switch The switch is 4-position switch which can be operated with its specific key only. 1) OFF In this position, the key can be inserted in or withdrawn from the switch.

When the key is withdrawn, the switch is locked and the voltage supply from the battery is switched off. When the key is removed, the switch is locked and the current from the battery is turned off. Keep the switch at this position except when running.

2) RUN In this position, the electrical system of the engine, except for the starting

and preheating circuits, is energized. When releasing the key after starting, the switch returns automatically to RUN. Keep the switch at this position during the operation.

3) PREHEAT 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. The PREHEAT position of the switch must only be used when the ambient temperature is low and the engine is cold.

4) START

The switch energizes the starting circuit of the engine when the key is turned to START. The key must be released as soon as the engine fires. The switch then automatically returns to 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.

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1-4-2 Engine indicators 3. Engine monitor

Fig.4 (1) Fuel level indicator That indicates a fuel level in the fuel tank. Green lamps will turn on with full tank. As the fuel level drops, the numbers of the turn-on lamps decrease and at the sometime the color of lamps changes from green to red. 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.

(2) Hour meter This meter indicates the total running time of the engine.

Fuel level (L) Numbers of lamps turned-on

Color of lamps DCA-15,25ESEK DCA-35ESEK

6 all green 53 to full 75 to full 5 all green 47 to 53 68 to 75 4 all green 41 to 47 63 to 68 3 all green 33 to 41 53 to 63 2 all red 21 to 33 38 to 53 1 all red 0 to 21 0 to 38

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4. Indication/alarm lamp

(1) Preheat lamp When the starter switch is set in the "PREHEAT" position, this lamp goes on. In a little time this lamp goes off, indicating that the machine has been preheated to be ready for startup.

(2) Warning Lamps This monitor indicates the following failures, if any one of them occurs. ① High jacket water temperature This lamp goes on when the water temperature rises abnormally. If this lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. ② Oil pressure failure If this machine is in normal operation, this lamp stays off. When the starter switch is turned to "RUN" position to start the engine, the lamp goes on, and when the oil pressure rises after startup, it goes off. If this lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. ③ Insufficient charge This lamp goes on when the output voltage of the alternator drops unusual value. If this lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically.

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1-4-3 Generator controls and indicators 5. Frequency meter This meter indicates the frequency of the outputted voltage. Make sure that it reads 50Hz when running.

6. Ammeter

This meter indicates the current going to the connected load. It must not exceed the rated current. 7. Voltmeter

The voltmeter indicates the outputted line voltage.

8. 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. 9. Single-phase circuit breaker The circuit breaker is a safety device interrupting the single-phase circuit when an overload or a short circuit occurs at the load side. When tripped, the breaker must be set manually to OFF and then ON after eliminating the cause of the trouble.

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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. 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 31201. 〇 Model DCA-15………. dB(A) 〇 Model DCA-25………. dB(A)

〇 Model DCA-35………. dB(A)

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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.

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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 〇 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.

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Fig. 5 〇 When lifting the machine, use the hanger located at the roof center. Never use the support hook because it is not strong enough to lift. 〇 Before lifting, close and fix the doors, covers, and other moving parts and clear away the machine interior and top. 〇 Do not slip under a lifted machine. 〇 Before transporting by truck or others, wind ropes on the machine to fasten it securely. 〇 Put covers so as to protect the machine from rain or moisture when transporting. 2-3 Storage 2-3-1 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.

Model L W H

DCA-15ESEK 905 345 485

DCA-25ESEK 815 345 485

DCA-35ESEK 1050 430 470

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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. 2-3-2 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.

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2-4 Installation 2-4-1 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.

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If the space required above the machine is not uniform when it is operated indoors, make a decision so that: 〇 The radiator can be refilled with water. 〇 The exhaust pipe can be introduced. 〇 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; 〇 Install an exhaust pipe of sufficient diameter to let the engine exhaust gas out directly. 〇 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 〇 If the machine is earthed in a way different from below, follow the local rule. 〇 The machine is TN system which must conform to IEC 364-3 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.

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Model DCA-15ESEK

Fig. 7

1. 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

Model DCA-35ESEK

Fig.7’

1. 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

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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.

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(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 ㎜. Parts number of fan belt:

Model name Parts number Parts number of manufacture

DCA-15ESEK 06020 11444 17123-97011

DCA-25ESEK 06020 11445 17265-97021 DCA-35ESEK 06020 11440 1G517-97011

(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 ㎜ above the electrodes). Supply distilled water if necessary.

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(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.

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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.

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CAUTION ・ The machine does not provide with panel light. Please provide with light as separate power source to operate each control devices or to verify the measured value on operation panel for proper operation in dark atmosphere. ・ 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.

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3-2 Connecting the load 3-2-1 Precautions in connecting the load 〇 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). 〇 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. 〇 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. 〇 Never connect the generator output voltage to an installation which is also connected to a commercial power supply. 〇 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. 〇 Distribution board (Only DCA-35ESEK) 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. 〇 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. 〇 Before connecting the load, stop the engine and turn off the generator circuit breaker. 〇 The load connecting cable must not get in contact with other output terminals on the terminal board.

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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. 3-2-3 Quality, minimum section and maximum length of cables 〇 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. 〇 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 0298. 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

These values determine the lowest acceptable wire section (in ㎟) 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 0.80.

Wire size ㎟ 10 16 25 35 50 70 95

Multiple core 52 70 92 114 138 176 212

Single core 57 77 103 126 153 195 236 Allowable current (A)

H07RN-F 50 76 88 110 138 170 205

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Min. section (in mm2) and max. cable length (in m)

DCA type 35

Rated current (A) 46

Minimum section (mm2) 16

Maximum length (m) 214

Relations between min. section (in ㎟) 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 (㎟)

If connected to receptacles; receptacle (A)

(No.)

32

X 23,24,25

32

X 22

63

X 21

Minimum section (㎟) 6.0 6.0 16

Maximum length (m) 55 115 125

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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). 15,25ESEK 35ESEK

Fig. 8

1. 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

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Model DCA-35ESEK

1. Output terminal L1 2. Output terminal L2 3. Output terminal L3 4. Output terminal N 5. External protection conduct

terminal PE

Fig 9 5. When connecting output terminals (See Fig. 9.) 〇 Remove the protection cover of output terminals. 〇 Loosen the cable clamp and push the wire ends of the load cable through the clamp and rubber cover. 〇 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 〇 Tighten the bolts securely. 〇 Reinstall the protecting cover in front of the output terminal board. 〇 Tighten the clamp to fasten the cable.

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3-3 Before starting The generators are factory-adjusted to operate at 50 Hz, i.e. 1500 r/min. 3-3-1 Checkup before start-up

1. Checking the oil level 〇 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. 〇 If necessary, pour oil up to the specified level through the oil refilling port provided on the engine. 〇 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. 〇 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. 〇 For the oil volume, see the lubricant volume in the specification table. 2. Checking the cooling water in engine radiator 〇 Check that the water level is near the Full mark on the auxiliary tank. Refill if short. 〇 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 anti- freeze 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”. 〇 For making up water, remove the radiator cap. Thereafter, securely install the cap so as to be airtight.

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3. Checking the fan belt tension 〇 Check the fan belt tension and elongation. By a thumb, depress (approx. 6kg) the middle point of the belt. The deflection must be 10-15 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 〇 Check the fuel level. Refill if required. 〇 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. 〇 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 〇 Check whether the electrolyte level is within the specified range or not. If short, add distilled water. 〇 If plates are exposed to air for a long time, the battery life would shorten. Keep them dipped. 〇 Do not pour battery electrolyte beyond the UPPER LEVEL. 〇 After refilling, securely tighten the caps. 〇 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 〇 Check whether the wiring is securely tightened or rubbed. If abnormal, repair or replace. 7. Checking the piping 〇 Check whether the piping is securely tightened or leaky. Make sure that the hoses are not worn. If abnormal, repair or replace.

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8. Checking the bolts and nuts 〇 Check whether bolts and nuts are securely tightened or not especially for the air cleaner, muffler mounting section. If loose, retighten them. 3-3-2 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.9. 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.10. And also switch the lever of three-way valve to the direction of the arrow mark, and close the air bleeding valve as shown in the Fig.11.

Caution : Be sure close the air bleeding valve.(excluded DCA-35ESEK)

③ Where the separate tank is not used and disconnected, be sure to open the air bleeding valve again, reconnect the tank connection plug.

(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.9. 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.10), 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.

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3-4 Starting 1. Insert the key in the starter switch. If the engine is cold and the ambient temperature is below 0℃, turn the key to PREHEAT and the PREHEAT LAMP lights up. When the lamp goes off, turn the key to START. If the engine is warmed up, no preheat is required: turn the key to START directly. The switch automatically returns to RUN. If the key does not automatically return to RUN, manually return it. Otherwise, the starter motor might be damaged. If the engine is warm, do not turn the key to PREHEAT but direct to START. 〇 Do not engage the starter for more than 10 seconds at a time; if the engine does not fire, wait 2 minutes before restarting. 〇 Consult your sales distributor if starting is in extremely cold conditions. 〇 If the engine would not start after several tries, check whether the fuel level is too low, air is not bled sufficiently or the battery is discharged. 2. Make sure that the engine monitor is extinguished. If alight, stop the engine, check the item for which it is alight and eliminate the cause. 〇 Check the engine indicator for normal readings.

[Fig. 9] [Fig.10] [Fig.11]

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3. Check whether the frequency meter read as shown below or not. Frequency 50-Hz operation 52.5 Hz 〇 Check the voltmeter indication and, when the voltage is deviated from the rated voltage, please contact your nearest Distributor. 4. Check the voltmeter indication and, if required, adjust with the voltage regulator knob. Turning clockwise increases the voltage and vice versa. 5. When three-phase voltage is supplied, switch the three-phase circuit breaker to ON. With single-phase voltage, switch three-phase and single-phase circuit breakers to ON. 6. Test the earth leakage relay for operation. Testing the operation 1) Press the test button of the earth leakage relay. 2) Normally, the earth leakage relay red lamp lights up and the circuit breaker operates. 3) Press the reset button of the earth leakage relay. Switch the circuit breakers to OFF and then to ON. A tripped earth leakage relay is kept tripped until the reset button is pressed or the generator is suspended. 7. Switch on the load and check the frequency meter and voltmeter once more. Adjust voltage

if necessary. Frequency (3-phase) Voltage 50-Hz operation 50 Hz 380~415V 8. After starting, close the rear frame door. During the operation, keep all the doors closed.

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3-5 During operation Periodically check that 〇 Indications of the engine monitor, indicator lamps and meters are normal. 〇 Oil, fuel and cooling water do not spill. 〇 The engine exhaust color is normal. There are no unusual sound and vibration. 〇 A light load is not applied for a long time. Otherwise, the engine output might drop. 〇 Each single-phase load is connected in balance whenever it is used. 〇 The engine oil level checked weekly is normal. Refill if necessary. NOTE ・ If the circuit breakers are tripped during operation, switch off the load and stop the engine. Check and, if necessary, decrease the load.

- 46 -

3-6 Stopping 3-6-1 Stopping method 1. Switch the load circuit breakers to OFF. 2. Switch the generator circuit breaker to OFF. 3. Let the engine run for about 5 minutes to cool down. 4. Stop the engine by turning the key to STOP. 5. If the machine is not used any longer, withdraw and keep the key. 6. Close and lock the rear frame door so as not to be tampered with by third person. 3-6-2 Emergency stop To stop the engine in an emergency, press the emergency stop button. 3-6-3 Protection device

Protection devices and emergency stop devices are provided for protection of the machine against trouble during operation. When the warning lamp lights, stop the engine immediately. Check and remove the cause of trouble.

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Table of protection device

action

warning turn OFF the circuit breaker

stop theengine

indicate by warning lamp function

Oil pressure failure low lubricating oil (OIL PRESS.)

－ 〇 〇

When the oil pressure falls abnormally, the device acts. Set point: 0.049MPa

High jacket water temperature (WATER TEMP.)

－ 〇 〇

When the cooling water temperature rises abnormally, the device acts. Set point: 115℃

Insufficient charge － 〇 〇 When insufficient charge, the device acts.

Fuel level failure (FUEL LEVEL) － － 〇 When fuel runs low,

the device acts.

Over-current of generator 〇 － －

When over-current occurs, the device acts.

Earth leakage 〇 － 〇 When electric leakage, the device acts Current sensitivity: 30mA

■ Engine stop switch

① The engine will not start when the side door is open.

② The engine will stop if the side door is opened during operation.

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4. Fuel, coolant and lubricants This table presents guidelines for the fuel and lubricants best suited for good performance and long life. Proper selection of fuel, coolant and lubricants

RESERVOIR KIND OF FLUIDAMBIENT TEMPERATURE

14 32 50 68 86°F -10 0 10 20 30℃

SAE 30

SAE 10W

SAE 10W 30 SAE 15W 40

Engine oil pan Engine oil

*

ASTM D975 No.2 Fuel tank Diesel fuel

Cooling system Long Life Coolant

* ASTM D975 No.1 NOTE Engine oil : Required API classification Refer to the following table for the suitable American Petroleum Institute (API) classification of

engine oil according to the Fuel Type Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).

Fuel Type Engine oil classification (API classification)

High Sulfur Fuel [0.05 % (500 ppm) ≤

Sulfur Content < 0.50 % (5000 ppm)]

CF

(If the “CF-4, CG-4, CH-4, or CI-4” engine oil is used with a

high-sulfur fuel, change the engine oil at shorter intervals.

(approximately half))

Low Sulfur Fuel [Sulfur Content < 0.05 % (500

ppm)] or Ultra Low Sulfur Fuel [Sulfur

Content < 0.0015 % (15 ppm)]

CF, CF-4, CG-4, CH-4 or CI-4

● CJ4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter)

and is Not Required for use in E3 specification engines. ● Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity

according to the ambient temperatures where the engine is operated.

- 49 -

● With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high sulfur fuel, it is advisable to use a “CF or better” classification engine oil with a high Total Base Number (a minimum TBN of 10 is required).

● When starting the engine in an atmospheric temperature of lower than 0℃, be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to 10℃ more or less in the day time.

Fuel : ● Cetane Rating : The minimum required Fuel Cetane Rating is 45. A cetane rating greater than 50 is preferred, especially for ambient temperatures below -20℃(-4°F )or elevations above 1500 m (5000 ft). ● Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission regulations for the area in which the engine is operated. ● Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly required. ● DO NOT USE Fuels that have sulfur content greater than 0.5 % (5000 ppm). ● Diesel fuels specified to EN 590 or ASTM D975 are required. 1) SAE : Society of Automotive Engineers 2) EN : European Norm 3) ASTM : American Society of Testing and Materials 4) US EPA : United States Environmental Protection Agency 5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.% No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.% Cooling water : ● Use the mixture of the good quality soft water like city water and the Long Life Coolant(LLC)

of anti-freeze and anti-rust for the aluminum radiator. ● Percentage of LLC must be 30% to 50%, under the 30%, the anti-rust effect will decrease, and

over the 50%, the anti-freeze effect will decrease. ● The following percentages are recommended for each ambient temperature;

30%: -10℃ 40%: -20℃ 50%: -30℃ ● In case of replenishment, use LLC of the same brand and the same density. ● Normally LLC should be replaced every 2 year.

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5. Periodic checkup and maintenance 5-1 Safety precautions for periodic checkup and maintenance

WARNING ・ Before checking or maintaining the machine, stop the engine, wait for it to cool down and remove all loads from the machine. Make sure that the machine would not accidentally start. Otherwise, you might be dead or injured by electric shock, burn, catching of hand or clothing, etc. ・ Do not carry out work which will produce heat near fuel, oil, anti-freeze solution or combustible substances. If such is absolutely required (steam washing, for example), keep away combustible substances. Keep a fire-extinguisher in the vicinity. ・ Take safety precautions against fire. Fuel, oil and anti-freeze solution are combustible. Handle them with care. When handling them, do not smoke or do not get naked flame near them. Keep a fire-extinguisher in the vicinity.

CAUTION ・ Do not use combustible solvents or carbon tetrachloride for cleaning the machine or parts. Take safety precautions against toxic fumes of cleansing agent. ・ When checking or maintaining, protect the air filter, electrical parts, meters, etc. from moisture or humidity. Pay attention so that moisture humidity will not penetrate any part. ・ When checking or maintaining, cover the replacing parts and generator openings with clean cloth, paper, tape, etc. so that the parts and generator interior will not he contaminated or moistened. Particularly, the air cleaner, electrical parts and terminals shall not be splashed with water. ・ Before removing the radiator cap, stop the engine and wait for at least 10 minutes for it to cool down. If done while, or immediately after the end of, running, you might get burnt or injured.

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・ When servicing batteries, always wear protection clothing and glasses. The electrolyte is a 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 being, or just after having been charged. Never make or break live circuits or battery terminals, because a spark usually occurs. ・ Do not leave tools, parts, rags etc. in or on the machine. Do not leave rags, paper, etc. near the air intake port of the machine. ・ All sound-damping materials of the machine shall be normal. If damaged, repair them to prevent the sound pressure level from rising. Do not remove or tamper with them. NOTES ・ Do not reuse gaskets, O-rings, packings, etc. removed for checkup or maintenance. ・ Do not remove, tamper with or remodel covers, protective devices, etc. without our permission. Use only genuine parts for replacement, repair, supply, etc. ・ Use only the correct tools for maintenance and repair work. After checkup or maintenance, carry out a test run to make sure that the generator, controls, circuit breakers, etc. operate properly. The periodic checkup and maintenance are outlined. Read the relevant section beforehand. Only personnel so qualified are allowed to carry out checkup and maintenance. 〇 Routine checkup and maintenance items for the engine are described here. For further details, see the instruction manual for the engine. 〇 The “Long Interval” checks must include the “Shorter Interval” checks. 〇 For checkup and maintenance, wear protecting clothing, glasses, etc.

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5-2 Periodic checkup

5-2-1 Maintenance schedule

50 hours: Check/first 50hours * Replace engine oil * Replace engine oil filter cartridge * Drain the fuel tank

100 hours: Check/every 100 hours

* Clean air cleaner element * Check fan belt * Replace engine oil * Clean fuel filter element

* Clean water separator element 200 hours: Check/every 200 hours

* Replace engine oil filter cartridge 400 hours: Check/every 400 hours

* Check on battery gravity * Replace fuel filter element

* Replace water separator element 500 hours: Check/every 500 hours

* Replace air cleaner element * Clean radiator

1000 hours: Check/every 1000 hours

* Clean inside of fuel tank * Adjust fuel injection nozzle

2000 hours: Check/every 2000 hours * Measure the engine compression pressure * Check valve clearance * Replace radiator water(if LLC is used) * Check on nylon and rubber hose * Checking of terminals and connections

Other Checks and Maintenance

* Check on lining

On the engine system, main checking items only are shown in this manual. For details, refer to the instruction manual for the engine furnished separately.

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5-2-2 Checking/first 50 hours

(1) Replace engine oil Replace the engine oil at 50 hours only the first time and every 100 hours after. ① Remove the engine oil drain plug and discharge oil

completely. It can be discharged easily when the engine is warm.

② After engine oil is discharged, tighten the plug firmly. ③ Supply new engine oil through the oil filler until it reaches

the notched line of the "H" on the dipstick. ④ After engine oil is supplied, run the engine for a few

minutes. Check if oil remains at the level between H and L.

(2) Replace engine oil filter cartridge Replace the engine oil filter cartridge at 50 hours only first time and every 200 hours after second time. Remove the drain plug and discharge oil completely in advance. ① Remove the cartridge using filter wrench. ② Insert the new cartridge. ③ Screw in the cartridge by hand. Once the gasket comes into

contact with the face of the seal, tighten the cartridge using the filter wrench.

④ Run the engine for a while and check to see if there are any oil leakages. Stop the engine. After the engine has stopped for about 10 minutes, check the oil level gauge.

If there is a shortage of oil, refill the oil.

Parts number of oil filter cartridge :

Model name Parts number Manufacture Parts number of manufacture DCA-15,25ESEK 06020 41173 KUBOTA 17321-32431 DCA-35ESEK 06020 41272 KUBOTA 10020-32430

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5-2-3 Check/every 100 hours

(1) Clean air cleaner element － Dry dust clings on element － Remove the air cleaner element and clean the element with dry and clean compressed air. － Carbon and oil clings on element － ① Use a special element cleaner detergent. ② Soak the dirty air cleaner element in a solution of water

and special element for about 15 minutes. ③ Rinse the air cleaner element using distilled water and let

it dry in a place that is exposed to wind. * While it is being cleaned, check the element for any

damage. Replace if necessary. * Before installing the air cleaner, wipe off dirt on the

element cover. * When insert the element, insert the element completely

pressing equal edge of element. (2) Check fan belt Refer to the instruction manual for the engine furnished separately. (3) Replace engine oil

Refer to「5-2-2.(1) Replacement of engine oil See p.47」. (4) Clean fuel filter element (excluded DCA-35ESEK)

① Turn the fuel filter cock to the close position. Remove the screw ring and take out the filter bowl and element.

② Rinse the element using diesel fuel and also, clean the inside of the filter bowl using diesel fuel.

③ After leaning, fit the fuel filter back to its original position. Make sure when the fuel filter is being refitted that it is not overly dusty.

Parts number of air cleaner cartridge :

Model name Parts number Manufacture Parts number of manufacture DCA-15,25ESEK 06020 46335 WAKO 11304-3002 DCA-35ESEK 06020 46309 DONALDSON P82-2768

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(5) Clean water separator element

①Turn the water separator cock to the close position. Remove the screw ring and take out the filter bowl

and element. ②Rinse the element using diesel fuel and also, clean

the inside of the filter bowl using diesel fuel. ③After leaning, fit the water separator back to its

original position. Make sure when the water separator is being refitted

that it is not overly dusty.

5-2-4 Check/every 200 hours Check/every 100 hours is also required.

(1) Replace engine oil filter cartridge. Refer to ｢5-2-2.(2) Replace engine oil filter cartridge See p.47｣.

5-2-5 Check/every 400 hours

Check/every 100 and 200 hours is also required.

(1) Check on battery gravity. Measure the battery gravity if there is a suspicion that battery leakage has occurred especially where there have been instances where the machine would not start. The relationship between Battery Gravity and Battery Charging at 20℃.

Battery Gravity Battery Charging O v e r 1 . 2 8 Over charged(need adjustment) 1 .25 － 1 .28 Optimal charging 1 .24 － 1 .25 Average B e l o w 1 . 2 4 Low charged(need adjustment)

In determining the specific gravity at a temperature other than 20℃, use the following formula: Ｓ20 = St ＋ ０．０００７(ｔ－２０) where Ｓ20 : is the calculated specific gravity at 20℃.

St : is the measured specific gravity ｔ : is the battery solution temperature reading.

- 56 -

(2) Replace fuel filter element or cartridge 2.1 DCA-15,25ESEK

① Turn the fuel filter cock to the close position. Remove the screw ring and take out the filter bowl and element.

② After replacement, fit the fuel filter back to its original position. Make sure when the fuel filter is being refitted that it is not overly dusty.

2.2 DCA-35ESEK

① Remove the cartridge using filter wrench.

② Clean the filter base. Coat the packing of new

cartridge with engine oil thin. Then, mount the cartridge.

- When mounting, tighten the cartridge about from 1/2

to 3/4 turn by hand after the packing is fitted to the seal

of the filter base.

③ After the cartridge is replaced, discharge air in the fuel piping.

- For details, refer to the instruction manual for the engine.

(3)Replace water separator element ① Turn the water separator cock to the close position. Remove the screw ring and

take out the filter bowl and element. ② After replacement, fit the water separator back to its original position.

Make sure when the water separator is being refitted that it is not overly dusty. ● Parts number of fuel water separator element Parts number 06020 42750

Parts number of fuel filter element :

Model name Parts number Manufacture Parts number of manufacture DCA-15,25ESEK 06020 42174 KUBOTA 15521-43161

Parts number of fuel filter cartridge :

Model name Parts number Manufacture Parts number of manufacture DCA-35ESEK 06020 42552 KUBOTA 16631-43560

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5-2-6 Check/every 500 hours

(1) Replace air cleaner element The element should be replaced referring to every 500 hours or 2 years. In situations where the generator has not been operated for 500 hours or more, as a general rule, the air cleaner will need to be replaced after it has been cleaned 6 times. (2) Clean radiator When the fin or tube is blinded, it should be cleaned with steam or running water. Do not use a high pressure washer to prevent damage to the fin and tube.

5-2-7 Check/every 1000 hours

(1) Clean inside of fuel tank Drain the fuel in the fuel tank completely, and wash out deposits and water collected inside the tank. (2) Adjust fuel injection nozzle

5-2-8 Check/every 2000 hours

(1) Measure the engine compression pressure (2) Check the valve clearance (3) Replace radiator water (if LLC is used) (4) Check on nylon and rubber hose Check on the nylon and rubber hose whether they are hardened or deteriorate. Contact distributor or our office to replace the nylon hose and rubber hose, if necessary. (5) Checking terminals and connections Check for main and sub circuit whether there are no abnormality such as loosening, corrosion and burning, etc.

5-2-9 Other Checks and Maintenance

(1) Check on lining Check on the lining whether it deteriorates greatly, or it is stained by clinging of oil or the like, or it is removed. Contact distributor or our office to replace the lining, if necessary.

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5-2-10 Table of periodical maintenance and checking ◇:Check or Clean 〇:Replacement ☆:Only first time

List of maintenance and inspection daily first50h

every100h

every200h

every 400h

every 500h

every1000h

every2000h

Check water and oil leakage ◇ Check for looseness of pipe connection and signs of wear ◇ 〇 Check for looseness of wiring connections and signs of wear ◇

Check meters and warning lamps ◇ Check oil level and stain of oil ◇ Check cooling water ◇ Check fuel level ◇ Drain the environment tank ◇ Drain the fuel tank ◇ Check battery acid level ◇ ※3 Replace engine oil ☆ 〇 Replace engine oil filter cartridge ☆ 〇 Clean air cleaner element ◇ Check fan belt ◇ Clean fuel filter element ◇ Clean water separator element ◇ Replace fuel filter element 〇 Replace water separator element 〇 Check battery gravity ◇ Clean radiator ◇ Replace air cleaner element 〇 ※1 Adjust fuel injection nozzle ◇ Clean inside of fuel tank ◇ ※1 Measure the engine compression pressure ◇

※1 Inspection of engine valve clearance ◇ ※2 Replace radiator water 〇 Check rubber suspension ◇

Engi

ne

Replace nylon and rubber hose 〇

Checking for terminal and connection of the circuit ◇

※1 Contact distributor or our office.

※2 Please replace cooling water every two years. When you do not use LLC of it, replace cooling water every six months. ※3 Please replace oil every six months even when you do not reach at replacement time.

In detail, please refer to “Engine Instruction Manual” furnished separately.

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6. Troubleshooting

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7. Principal data 7-1 Readings on gauges

Marking Reading Unit Engine speed 1500 min-1

Hour meter Adding up H

Engine temperature below 95 ℃

Engine oil pressure Between 2 and 7 1) ×100kPa

Generator charge 0 to + value A

Frequency 50 Hz

Load current Below max. rating A

Voltage indicates Phase-to-phase voltage V

1) If the engine is cold, the pressure may be higher during starting. 7-2 Setting of switches

Switch Function Breaks at Unit Engine oil pressure Shut-down 0.49 ×100kPa

Engine coolant temperature Shut-down 115 ℃

7-3 Reference conditions Absolute inlet pressure……………………………………………………….100kPa Relative air humidity…………………………………………………………60% Air inlet temperature…………………………………………………………27℃ Generator load………………………………………………………………..continuous 7-4 Limitations Maximum ambient temperature………………………………………………40℃ Maximum altitude……………………………………………………………1000m Maximum relative air humidity………………………………………………85%

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7-5 General specifications DCA type 15 25 35

1. Engine

Kubota, type…………………………………… D1703 V2203 V3300

No-load speed (50Hz), approx……………......….min-1 1575 ← ←

Load speed (50Hz), approx…….…………….…. min-1 1500 ← ←

Electrical system…………………………………....V 12 ← ←

Batteries:

・ Number……………………………………. 1 ← ←

・ Voltage……………………………………..V 12 ← ←

・ Capacity……………………………………Ah 65 ← 70

Oil circuit capacity…………………………….ℓ 5.6 7.6 13.2

Cooling circuit capacity……………………….ℓ 6.4 7.9 10.5

Fuel tank capacity, approx…...………………...ℓ 62 ← 82

2. Generator

Ty p e … … … … … … … … … … … … … … … … … DF- 0170K

DF- 0270K

DB- 0391KU

Rated output 50Hz…………………………….kVA 12.5 20 30

V o l t a g e ( r a n g e ) , l i n e - t o - n e u t r a l

50Hz…………………………………………..V 220 / 231 / 240

V o l t a g e ( r a n g e ) , l i n e - t o - l i n e

50Hz…………………………………………...V 380 / 400 / 415

Frequency……………………………………...Hz 50 ← ←

Speed (50/60Hz)…………………………………min-1 1500 ← ←

Power factor…………………………………... 0.8 ← ←

Number of phases…………………………….. 3 phases + neutral

Winding connection………………………….. star ← ←

Temperature specification…………………….℃ -5°~40° ← ←

I n s u l a t i o n … … … … … … … … … … . . . C l a s s F ← ←

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DCA type 15 25 35

Insulation armature winding class……………... F ← ←

Insulation field winding, class…………………. F ← ←

Sensitivity of residual current relay…………….mA 30 ← ←

Maximum diffusion resistance of earthing rod……………………………..…….Ω 500 ← ←

Setting of main circuit breaker…………………A 20 30 50

Setting of 1 phase circuit breaker………………A 20 30 32

3. Unit

Length, approx…………………………………mm 1390 1540 1900

Width, approx………………………………….mm 650 ← 860

Height, approx…………………………………mm 1050 ← 1130

Net mass (dry), approx………………………...kg 565 640 950

1) On later production units only 7-6 Conversion list of S1 units into UK/US units

1bar = 14.504 psi 1kW = 1.341 hp (UK and US) 1m = 3.281 ft 1N = 0.225 lbf

1g = 0.035 oz 1ℓ = 0.264 US gal 1mm = 0.039 in 1Nm = 0.738 lbf.ft

1kg = 2.205 lb 1ℓ = 0.220 lmp gal (UK) 1m3/min = 35.315cfm x℃ =(32+1.8x)°F

1km/h = 0.621 mile/h 1ℓ = 0.035 cu.ft 1mbar = 0.401 in wc △tl℃ = 1.8°F

1bar = 100kPa