Denyo DCA-150LSKE User manual

NO. C08443 04204
ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ
ＤＥＮＹＯ
ＤＩＥＳＥＬ ＧＥＮＥＲＡＴＩＮＧ ＳＥＴＳ
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－１５０ＬＳＫＥ
2-8-5 Nihonbashi-horidomecho, Chuo-ku, Tokyo, 103-8566

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 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 ---------------------------------------------- 1
2. Construction ---------------------------------------------------- 11
2-1 Outline and part names ------------------------------------ 11
2-2 Operating panel, control panel and part names ------------- 13
2-3 Meters ---------------------------------------------------- 14
2-4 Use of switches and controllers --------------------------- 21
3. Transportation and installation --------------------------------- 27
3-1 Transportation of machine --------------------------------- 27
3-2 Installation of machine ----------------------------------- 28
4. Connecting the load --------------------------------------------- 30
4-1 Voltage selector switch ------------------------------------- 30
4-2 Cables to be used ---------------------------------------- 31
4-3 Connecting the load --------------------------------------- 32
4-4 Grounding --------------------------------------------------- 35
5. Operation ------------------------------------------------------- 37
5-1 Checking prior to operation ------------------------------- 39
5-2 Startup --------------------------------------------------- 44
5-3 Handling during operation --------------------------------- 47
5-4 Shut down -------------------------------------------------- 48
5-5 Protection device ----------------------------------------- 49
6. Parallel operation ---------------------------------------------- 50
6-1 Preparation for parallel operation ------------------------ 50
6-2 Parallel operation ---------------------------------------- 51
6-3 Precautions ----------------------------------------------- 53
6-4 Shut down ------------------------------------------------- 53
7. Lubrication, cooling water and fuel ----------------------------- 54
7-1 Engine oil ------------------------------------------------ 54
7-2 Cooling water --------------------------------------------- 56
7-3 Fuel ------------------------------------------------------ 56
8. Handling of battery --------------------------------------------- 57
8-1 Caution on battery charge --------------------------------- 58
8-2 Connection of booster cable, and installation ------------- 59
9. Periodical checking and maintenance ----------------------------- 60
9-1 Maintenance schedule -------------------------------------- 63
9-2 Checking/first 125 hours ---------------------------------- 64
9-3 Checking/every 250 hours ---------------------------------- 65
9-4 Checking/every 500 hours ---------------------------------- 67
9-5 Checking/every 1000 hours ---------------------------------- 70
9-6 Table of periodical maintenance and checking -------------- 72
10. Troubleshooting ------------------------------------------------- 74
11. Long-term storage ----------------------------------------------- 82
12. Service data ---------------------------------------------------- 83
12-1 Specifications ------------------------------------------- 83
12-2 Outline drawing ------------------------------------------ 84
12-3 Generator connection diagram ----------------------------- 85
12-4 Engine wiring diagram ------------------------------------ 86
12-5 Controller wiring diagram -------------------------------- 87
13. Options instruction manual -------------------------------------- 88
13-1 Earth leakage relay -------------------------------------- 88
13-2 Instruction for fuel source changeover device
（Three-way value) ---------------------------------------- 93
13-3 Single-phase output receptacles ---------------------------- 95

- 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
１ Safety instruction B9211 0140
２ Warning：moving parts B9040 0100
３ Warning：hot coolant B9041 0030
４ Warning：exhaust gas B9052 0000A
５ Warning：hot surfaces B9042 0040
６ Warning：diesel fuel B9045 0220
７ Warning：electric shock B9211 1160
Caution：support hook B9121 0020B
B9052 0000A
C9045 0030A
C9211 0200A

- 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.

- 4 -
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.

- 5 -
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.
WARNING
MOVING PARTS can cause severe injury.
■ Rotary uni t which runs at a high speed is located
in the machine.
(Note that it is very dangerous if you touch it.)
* Be sure to close the door and lock it during operation.
* When the door needs to be opened during operation,
do not get your hands and head in the machine to
prevent them from being caught in the machine which
may lead to injury.
* When making check or maintenance of the machine,
be sure to stop the machine in advance.

- 6 -
WARNING
DIESEL FUEL can cause fire or explosion.
■ Fuel and oil are flammable. Incorrect handling
results in danger of ignition or fire.
* When fuel needs to be supplied to the machine,
be sure to stop the engine. Refrain from smoking.
Keep the machine away from fire.
* Do not leave flammable objects (paper, wood
chips, etc.) and hazardous objects (oil, powder, etc.)
near the machine.
* Wipe off spilt fuel and oil.
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 (50℃ or
less as measured with the water temperature gauge).

- 7 -
WARNING
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.
WARNING
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.

- -
WARNING
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 in advance.

- 9 -
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.
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.

- 10 -
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.

- 11 -
2. Construction
2-1 Outline and part names
1. oil drain plug
2. exhaust gas outlet
3. hanger rod
4. support hook
5. coolant in
6. output terminal
7. fuel in
. fuel drain plug
9. control and operating panel
10. fuel level gauge
11. environmental base drain

- 12 -
1. air cleaner
2. oil filter
3. fuel filter
4. reserve tank
5. AC generator
6. diesel engine
7. radiator・inter-cooler
. oil level gauge
9. control box
10. fuel tank
11. battery
12. muffler
13. fuel pre filter
14. engine oil in
15. blowby drain
16. environmental base
17. voltage selector switch

- 13 -
2-2 Operating panel, control panel and part names
No. NAME No. NAME
1 frequency meter 31 engine indicator
2 AC ammeter indicator:
engine speed, oil pressure, water
temp, battery charging voltage,
integrating time
warning lamps
high water temp, low lubricating
oil
pressure, air element blinding,
fuel filter water level, over speed,
fuel level failure
fuel level indicator
3 AC voltmeter
4 output voltage indication lam
p
5 frequency change-over switch
6 speed regulator
7 voltage regulator
circuit breaker (3-phase)
9 circuit breaker (1-phase) (opti
on)
10 earth leakage relay (option) 32 starter switch
11 pilot lamp 33 emergency stop button
12 panel light 34 preheat lamp
13 panel light switch 35 speed change-over switch
14
single-parallel change-over sw
itch
15 synchronizing lamp

- 14 -
16
environmental base fluid level
warning lamp

- 15 -
2-3 Meters
Engine indicators
(1) Engine indicator
That indicates the numerical values of engine speed, engine oil pressure, run hours,
battery charging voltage, or engine coolant temperature.
Indicated Items Unit
engine speed min-1
engine oil pressure ×100kPa
battery charging voltage V
engine coolant temperature ℃

- 16 -
- 1 - Engine Speed
Revolutions per minute is indicated. 1500min-1 is indicated at 50Hz and 1800 min-1 is
indicated at 60Hz.
- 2 - Engine Oil Pressure
2 to 6 × 100 kPa should be indicated at normal engine operation.
Higher value would be indicated in cold condition immediately after engine starts.
Conduct a warning - up operation until it indicates normal value.
- 3 - Battery Charging Voltage
That should indicate more than 26V at engine running.
- 4 - Engine Coolant Temperature
That should indicate a temperature between 75 to 95 ℃at engine running.
Note ; If that would indicate higher temperature, disconnect all loads, decrease
the speed for cool - down operation, and wait until the temperature comes down
to normal value.
(2) Fuel Level Indicator
That Indicates a fuel level in the fuel tank. All the lights are indicated green when the fuel
is full.
The green lights stop indicating one by one as the fuel level decrease, finally the red light
will be indicated when it is only one green light is left.
Replenish the tank when there becomes only one lamp turned on.
The table below shows the relation between numbers of turn - on lamps and fuel level.
Numbers of
lamps turned-on
Fuel level (L)
9 215 to full
8 190 to 215
7 160 to 190
6 135 to 160
5 105 to 135
4 80 to 105
3 65 to 80
2 40 to 65
1 0 to 40