AlphaGen DCX3000 User manual

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Keep this owner’s manual handy, so you can refer to it at any time.
This owner’s manual is considered a permanent part of the generator
and should remain with the generator if resold.
The information and specifications included in this publication were in
effect at the time of approval for printing. Honda Motor Co., Ltd.
reserves the right, however, to discontinue or change specifications or
design at any time without notice and without incurring any obligation
whatever.
2004 Honda Motor Co., Ltd. All Rights Reserve
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
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INTRODUCTION
We want to help you get the best results from your new generator and
to operate it safely. This manual contains all the information on how to
do that; please read it carefully.
As you read this manual, you will find information preceded by a
symbol. That information is intended to help you avoid
damage to your generator, other property, or the environment.
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty policy
is a separate document that should have been given to you by your
dealer.
Congratulations on your selection of this generator. We are certain
you will be pleased with your purchase of one of the finest generators
on the market.
When your generator needs scheduled maintenance, keep in mind
that your Alphagen servicing dealer is specially trained in servicing
this generator. Please contact your Alphagen dealer to have your
generator serviced. Your servicing dealer is dedicated to your
satisfaction and will be pleased to answer your questions and
concerns.
Best Wishes,
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2
A FEW WORDS ABOUT SAFETY
Safety Labels
Safety Messages
Safety Headings
Safety Section
Instructions
Your safety and the safety of others are very important. And using this
generator safely is an important responsibility.
To help you make informed decisions about safety, we have provided
operating procedures and other information on labels and in this
manual. This information alerts you to potential hazards that could
hurt you or others.
Of course, it is not practical or possible to warn you about all the
hazards associated with operating or maintaining a generator. You
must use your own good judgement.
You will find important safety information in a variety of forms,
including:
on the generator.
preceded by a safety alert symbol and one
of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
be or if
you don’t follow instructions.
be or if
you don’t follow instructions.
be if you don’t follow
instructions.
such as
IMPORTANT SAFETY INFORMATION .
such as
how to use this generator correctly and safely.
This entire book is filled with important safety information please
read it carefully.
You WILL KILLED SERIOUSLY HURT
You CAN KILLED SERIOUSLY HURT
You CAN HURT
GENERAT OR SAFET Y .
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CONTENTS
................................................................................GENERATOR SAFETY .6
........................................................................CONTROLS & FEATURES .12
...............................................................................BEFORE OPERATION .20
..................................................IMPORTANT SAFETY INFORMATION .6
......................................................................Operator Responsibility .6
.................................................................Carbon Monoxide Hazards .6
.......................................................................Electric Shock Hazards .7
........................................................................Fire and Burn Hazards .7
.................................................................................Refuel With Care .8
.................................................................SAFETY LABEL LOCATIONS .9
...........................................COMPONENT & CONTROL LOCATIONS .12
............................................................................................CONTROLS .14
.............................................................DC Voltage Selector Switch .14
................................................................................Fuel Valve Lever .14
.......................................................................................Choke Knob .15
....................................................................................Engine Switch .15
.....................................................................................Recoil Starter .16
....................................................................................Output Switch .16
.............................................................................................FEATURES .17
...............................................................................Ground Terminal .17
............................................................................DC Output Coupler .17
...........................................................................................Voltmeter .17
........................................................................EcoThrottle System .17
................................................................................Output Indicator .18
............................................................................Overload Indicator .18
............................................................................Oil Alert Indicator .19
.........................................................................................Fuel Gauge .19
................................................ARE YOU READY TO GET STARTED ? .20
.........................................................................................Knowledge .20
.............................................IS YOUR GENERATOR READY TO GO ? .20
...............................................................................Check the Engine .21
TM
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CONTENTS
..............................................................................................OPERATION .22
.............................................................SERVICING YOUR GENERATOR .30
.....................................................SAFE OPERATING PRECAUTIONS .22
..........................................STARTING THE ENGINE/DC OPERATION .23
....................................................................................Forced Output .26
......................................................................STOPPING THE ENGINE .28
.............................................THE IMPORTANCE OF MAINTENANCE .30
......................................................................MAINTENANCE SAFETY .31
............................................................................Safety Precautions .31
................................................................MAINTENANCE SCHEDULE .32
...........................................................................................REFUELING .33
...............................................................FUEL RECOMMENDATIONS .34
..................................................................ENGINE OIL LEVEL CHECK .35
...........................................................................ENGINE OIL CHANGE .36
....................................................ENGINE OIL RECOMMENDATIONS .37
........................................................................AIR CLEANER SERVICE .38
.............................................................FOAM AIR FILTER CLEANING .40
.................................................................SEDIMENT CUP CLEANING .41
.........................................................................SPARK PLUG SERVICE .43
................................................................SPARK ARRESTER SERVICE .45
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CONTENTS
..................................................................................................STORAGE .48
......................................................................................TRANSPORTING .53
.......................................TAKING CARE OF UNEXPECTED PROBLEMS .54
..........................................TECHNICAL & CONSUMER INFORMATION .58
........................................................................................................INDEX .68
.............................QUICK REFERENCE INFORMATION .Inside back cover
....................................................................STORAGE PREPARATION .48
.............................................................................................Cleaning .48
.....................................................................................................Fuel .48
...........................................................................Engine Preparation .51
...................................................................STORAGE PRECAUTIONS .52
................................................................REMOVAL FROM STORAGE .52
.............................................................................ENGINE PROBLEMS .54
....................................................................GENERATOR PROBLEMS .56
................................................................TECHNICAL INFORMATION .58
...................................................................Serial Number Location .58
....................Carburetor Modification for High Altitude Operation .59
.............................................................................Oxygenated Fuels .60
............................................Emission Control System Information .61
.............................................................................................Air Index .63
....................................................................................Specifications .64
.................................................................................Wiring Diagram .65
...............................................................CONSUMER INFORMATION .66
.......................................................................................Publications .66
.........................................................Customer Service Information .67
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GENERATOR SAFETY
IMPORTANT SAFETY INFORMATION
Carbon Monoxide Hazards
Operator Responsibility
This generator is designed for use with CATV/Telecommunications
equipment that has suitable power requirements. Other uses can
result in injury to the operator or damage to the generator and other
property.
Most accidents can be prevented if you follow all instructions in this
manual and on the generator. The most common hazards are
discussed below, along with the best way to protect yourself and
others.
If you run the generator in a confined or even partially enclosed area,
the air you breathe could contain dangerous amounts of exhaust
gas. To keep exhaust gas from building up, provide adequate
ventilation.
Exhaust contains poisonous carbon monoxide, a colorless, odorless
gas. Breathing exhaust can cause loss of consciousness and may
lead to death.
Be sure that anyone who operates the generator receives proper
instruction. Do not let children operate the generator without
parental supervision.
Know how to stop the generator quickly in case of emergency.
Understand the use of all generator controls, output receptacles,
and connections.
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7
GENERATOR SAFETY
Electric Shock Hazards
Fire and Burn Hazards
The generator produces enough electric power to cause a serious
shock or electrocution if misused.
If the generator is stored outdoors, unprotected from the weather,
check all of the electrical components on the control panel, before
each use. Moisture or ice can cause a malfunction or short circuit in
electrical components which could result in electrocution.
Using a generator or electrical appliance in wet conditions, such as
rain or snow, or near a pool or sprinkler system, or when your hands
are wet, could result in electrocution. Keep the generator dry.
Do not touch uninsulated portion of output coupler.
Risk of electrical shock.
The exhaust system gets hot enough to ignite some materials.
Keep the generator at least 3 feet (1 meter) away from buildings
and other equipment during operation.
Do not enclose the generator in any structure.
Keep flammable materials away from the generator.
The muffler becomes very hot during operation and remains hot for
a while after stopping the engine. Be careful not to touch the muffler
while it is hot. Let the engine cool before storing the generator
indoors.
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GENERATOR SAFETY
Refuel With Care
Gasoline is extremely flammable, and gasoline vapor can explode.
Allow the engine to cool if the generator has been in operation. Refuel
only outdoors in a well-ventilated area with the engine OFF. Do not
overfill the fuel tank. Never smoke near gasoline, and keep other
flames and sparks away. Always store gasoline in an approved
container. Make sure that any spilled fuel has been wiped up before
starting the engine.
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GENERATOR SAFETY
SAFETY LABEL LOCATIONS
These labels warn you of potential hazards that can cause serious
injury. Read them carefully. If a label comes off or becomes hard to
read, contact your Alphagen servicing dealer for a replacement.
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GENERATOR SAFETY
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GENERATOR SAFETY
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CONTROLS & FEATURES
COMPONENT & CONTROL LOCATIONS
ENGINE SWITCH
CHOKE KNOB
FUEL VALVE LEVER
OUTPUT
INDICATOR
OVERLOAD
INDICATOR
OUTPUT SWITCH
GROUND
TERMINAL
DC OUTPUT
COUPLER
OIL ALERT
INDICATOR
VOLTMETER
Use the two illustrations on these pages to locate and identify the
most frequently used controls.
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CONTROL & FEATURES
AIR CLEANER
SPARK PLUG CAP
MUFFLER
OIL FILLER CAP/
DIPSTICK
OIL DRAIN PLUG
OIL MAINTENANCE COVER
STARTER GRIP
FUEL TANK CAP
FRONT HANDLE
REAR HANDLE
DC VOLTAGE
SELECTOR SWITCH
MAINTENANCE COVER
FUEL GAUGE
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CONTROL & FEATURES
CONTROLS
DC Voltage Selector Switch
Fuel Valve Lever
OOFFFF
OONN
DC VOLTAGE SELECTOR SWITCH
FUEL VALVE LEVER
MAINTENANCE COVER
The DC voltage selector switch is
used to select generator DC
voltage; either 36 V or 48 V.
The fuel valve lever is located on
the control panel.
To operate the DC voltage
selector switch, make sure the
engine is off, then open the
maintenance cover.
After selecting the voltage, close
the maintenance cover.
Select the same voltage as the
battery voltage of the UPS battery
string.
The fuel valve lever must be in the
ON position for the engine to run.
After stopping the engine, turn
the fuel valve lever to the OFF
position.
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15
CONTROL & FEATURES
CONTROLS
Choke Knob
Engine Switch
CHOKE KNOB
OOPPEENN
OOFFFF
OONN
CCLLOOSSEEDD
ENGINE SWITCH
ENGINE SWITCH KEY
The choke knob opens and closes
the choke valve in the carburetor.
The CLOSED position enriches
the fuel mixture for starting a cold
engine.
The OPEN position provides the
correct fuel mixture for operation
after starting, and for restarting a
warm engine.
OFF Stops the engine. The
engine switch key can be
removed/inserted.
The engine switch controls the
ignition system.
ON Running position, and for
starting with the recoil starter.
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CONTROL & FEATURES
Recoil Starter
Output Switch
STARTER GRIP
OUTPUT SWITCH
Pulling the starter grip operates
the recoil starter to crank the
engine for starting.
Do not allow the starter grip to
snap back against the engine.
Return it gently to prevent
damage to the starter.
Do not let the starter rope rub
against the generator body or
the rope will wear out
prematurely.
The output switch has two functions.
Stop Output
During the output operation,
press the output switch to
stop output. To reset, stop
and restart the engine.
Forced Output
Following the forced output
procedure, the generator will
provide output to charge the
battery string when the
battery string charge is too
low to activate automatic
charging.
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CONTROL & FEATURES
FEATURES
Ground Terminal
DC Output Coupler
Voltmeter
EcoThrottle System
DC OUTPUT COUPLER
Positive
side
Negative
side
The ground terminal is connected
to the frame of the generator and
the metal non-current-carrying
parts of the generator.
Before using the ground terminal,
consult a qualified electrician,
electrical inspector or local
agency having jurisdiction for
local codes or ordinances that
apply to the intended use of the
generator.
The DC output coupler may ONLY
be used for charging UPS 36 V or
48 V battery strings.
When connecting the power cord
to the DC output coupler, always
use the correct coupler and power
cord.
The voltmeter indicates the voltage of the UPS batteries when
connected to the DC output coupler.
The EcoThrottle system automatically reduces engine speed when
the UPS battery string is fully charged.
When the UPS battery string becomes discharged, the engine returns
to the proper speed to recharge the batteries.
TM
TM
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CONTROL & FEATURES
Output Indicator
Overload Indicator
OUTPUT INDICATOR
(GREEN)
OVERLOAD INDICATOR
(RED)
The output indicator (green) is illuminated when the generator is
operating normally. It indicates that the generator is producing
electrical power at the DC output coupler.
The overload indicator (red) will go steady ON if the generator is
overloaded, the converter becomes overheated or there is a short
circuit in the connected UPS battery string. The overload indicator
(red) will stay ON, and after about five seconds, current to the
connected UPS and the output indicator (green) will go OFF. When the
UPS battery voltage is too low or too high, the overload indicator (red)
will flash.
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