Denyo DCA-13ESK User manual

No. B18443 01404A
ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ
ＤＩＥＳＥＬ ＧＥＮＥＲＡＴＯＲ
Before using, be sure to read this manual for the sake of safety.
Be sure to observe the items under symbol marks " WARNING"
and "CAUTION" for the sake of safety.
Always keep this manual at your machine for the sake of safety.
ＤＣＡ－１３ＥＳＫ
ＤＣＡ－１５ＥＳＫ
ＤＣＡ－２０ＥＳＫ
ＤＣＡ－２５ＥＳＫ
HEAD OFFICE
4-2-2,KAMITAKADA,NAKANO-KU
TOKYO 164-8510, JAPAN
TEL. [phone]
FAX. [phone] Printed in Japan

FOREWORD
* Your machine is a portable type diesel generating set.
* Do not install, operate or repair this machine without reading this operating manual.
* This generator set (machine) must be operated by a person having sufficient knowledge
and skill for the sake of safety.
Notes on instruction manual
* This instruction manual explains correct operation and maintenance of the machine to
ensure its performance.
Incorrect handling of the machine may lead to a serious injury or decease.
Before using, be sure to read this manual carefully.
Particularly, the items under " Safety precautions",
" WARNING" and " CAUTION" must be read thoroughly.
* Keep this manual in the case behind the rear or side door for future reference.
* Read the contents of the warranty card attached to the machine.
・If this manual becomes illegible by spot or damage, contact distributor or our office to get
new manual.

- Contents -
1. Safety Precautions
2. Construction
2-1 Outline and parts names
2-2 Operating panel, control panel and parts names
2-3 Meters
2-4 Use switches and controllers
3. Transportation and installation
3-1 Transportation of machine
3-2 Installation of machine
4. Connecting the load
4-1 Cables to be used
4-2 Connecting the load
4-3 Grounding
5. Operation
5-1 Checking prior to operation
5-2 Startup
5-3 Handling during operation
5-4 Shutdown
5-5 Protection device
6. Lubrication, cooling water and fuel
6-1 Engine oil
6-2 Cooling water
6-3 Fuel
7. Handling of battery
7-1 Caution on battery charge
7-2 Connection of booster cable, and installation
8. Periodical checking and maintenance
8-1 Maintenance schedule
8-2 Checking/first 50 hours
8-3 Checking/every 100 hours
8-4 Checking/every 200 hours
8-5 Checking/every 400 hours
8-6 Checking/every 500 hours
8-7 Checking/every 1000 hours
8-8 Checking/every 2000 hours
8-9 Other checks and Maintenance
8-10 Table of periodical maintenance and checking
9. Troubleshooting
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10. Long-term storage
11. Service data
11-1 Specifications
11-2 AC generator specifications (for custom voltage)
11-3 Outline drawing
11-4 Generator connection diagram
11-5 Engine wiring diagram
12. Options instruction Manual
12-1 Earth leakage relay
12-2 Instruction for Fuel source changeover Device
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1
1. Safety Precautions
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.

2
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.
No. Parts name Parts number No. Parts name Parts number
1 Warning:exhaust gas B9042 0000 5 Caution:high temp B9052 0020
2 Warning:output voltage B9211 0250 6 Support hook B9121 0020A
3 Warning:fire accident B9055 0070A 7 Warning:radiator cap B9051 0030
4 Warning:moving part B9050 0050

3
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.
WARNING
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.
WARNING
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.

4
WARNING
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.
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.
WARNING
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.

5
CAUTION
Stacking
■Improper stacking of machines may cause falling or
dropping accidents. When stacking other machines on this
machine, be sure to observe the following points.
* Check that the bonnet of the machine is free from damage and that
the fixing bolts are not loosened and missing.
* Put the machine horizontally on a solid foundation which
withstands the weight of stacked machines.
* Machines can be stacked up to 2 stages. The weight and size of
stacked machines should be less than those of this machine.
* Using square timbers as shown right, put each machine making
sure that the weight is even.
■Do not operate the machines in the state of stacking to prevent
falling or dropping accidents.
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.

6
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.
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.

7
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.
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.

8
2. Construction
2-1 Outline and parts names
1. CONTROL PANEL
2. FUEL IN
3. HANGER ROD
4. DOOR LATCH
5. SUPPORT HOOK (FOR ROPE)
6. AIR INTAKE
7. EXHAUST GAS OUTLET
8. COOLANT IN
9. FUEL DRAIN PLUG
10. OIL DRAIN PLUG
11. COOLANT DRAIN PLUG
12. VENTILATION
13. KEY

9
1. AC GENERATOR
2. DIESEL ENGINE
3. AIR CLEANER
4. FUEL TANK
5. FUEL FILTER
6. OIL INLET
7. OIL FILTER
8. OIL LEVEL GAUGE
9. RADIATOR
10. COOLANT RESERVE TANK
11. BATTERY
12. THREE – WAY VALVE
(OPTION)

10
2-2 Operating panel, control panel and parts names
1. FREQUENCY METER
2. AC AMMETER
3. AC VOLTMETER
4. VOLTAGE REGULATOR
5. AC CIRCUIT BREAKER
6. AC CIRCUIT BREAKER – for RECEPTACLE (OPTION)
7. EARTH LEAKAGE RELAY (OPTION)
8. STARTER SWITCH
9. THROTTLE LEVER
10. FREQUENCYADJUST SCREW
11. ENGINE MONITOR
NUMBER INDICATION : RUN HOURS
LAMP INDICATION : FUEL LEVEL, PREHEAT
WARNING LAMPS : WATER TEMP., OIL PRESS., CHARGING

11
2-3 Meters
Engine monitor
(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.
Numbers of
lamps turned-on Color of lamps Fuel level (L)
6 all green 55 to full
5 all green 45 to 54
4 all green 35 to 44
3 all green 27 to 34
2 all red 19 to 26
1 all red 0 to 18
(2) Hour meter
This meter indicates the total running time of the engine.

12
Generator indicators
(1) Frequency meter
This meter indicates frequency of the output voltage.
Make sure that it indicates 50Hz during operation.
(2) AC ammeter
This meter indicates AC current flowing into the connected
load. Make sure that it is always pointing below the rated
current.
When running the three phase and single phase loads
together, this meter indicates total current of them.
When running either the three phases or single-phase load,
this meter indicates the current flowing into the load.
(3) AC voltmeter
This meter indicates AC output voltage. Make sure that it
indicates rated voltage.

13
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.
①High 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.
②Oil 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 shutdown the engine
automatically.
③Insufficient 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 shutdown the engine
automatically.

14
2-4 Use of switches and controllers
Switches
(1)Starter switch
Functions:
①Stop
This switch should be set in this position unless the machine
is in operation. The key can be inserted or pulled out in this
position.
②Run
This switch should be set in this position when the machine
is in operation.
③Start
This is the position to start the engine. When your hand is
released from the key after starting, it is automatically set in
the position of “RUN”.
④Preheat
This is the position to start the engine when the air
temperature is low. Set the switch in this position until the
preheat lamp goes off, and then set it in the start position.
(2) Speed control device
・Throttle lever
This lever is used to control the engine speed. Set the
lever at the "START/IDLING" position for startup or
warm up/cooling operation of the engine and at the
"RUN" position for constant speed operation of the
machine (at 50Hz or 60Hz).
・Frequency adjusting screw
This screw is used to adjust the frequency. With the
throttle lever set at the "RUN" position, turn the screw
to the "HIGH" side to increase the frequency and to the
"LOW" side to decrease it.

15
(3) Circuit breaker
This is a main switch to supply power to a load. When the
load is shorted or in the state of overload, it trips to protect
the generator against trouble.
[Note] :
Do not use this circuit breaker to turn ON/OFF the load, to
prevent damage to the circuit breaker.
When it trips with over-current, the handle of the breaker
stops between ON and OFF positions. This is what is called
the trip condition.
In this case, push the handle down to the OFF position to
reset it, or else, it cannot be set in ON position.
Voltage regulator
(1) Voltage regulator
This regulator is used to control the output voltage. Turn the
regulator to clockwise to increase the voltage and counter-
clockwise to decrease it. Adjust the voltage to the rated
voltage with this regulator.

16
3. Transportation and installation
3-1 Transportation of machine
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. The
detail as machine size is referred to
「11-1. Specifications See p.47, 48」
3-2 Installation of machine
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.