Denyo DCA-25USI User manual

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 "Z[\ WA NING"
and "A CAUTION" for the sake of safety.
Always keep this manual at your machine for the sake of safety.
DCA-2 5 U S I
DCA-25 U S I 2
DCA-45 U S I
DCA-4 5 U S I 2
DCA-60USH
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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.
A ARNING: This symbol refers to a hazard or unsafe practice which can result
in severe personal injury or death.
A 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.

Safety label
Safety labels are attached to the following positions of the machine.
* Keep these safety labels clean at all times.
* hen 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 Safety instruction B9221 0100 5arning : hot surfaces B9052 0020
2 arning : moving parts Б9050 0050 6arning : diesel fuel B9055 0070A
3arning : hot coolant Б9051 0030 7arning : electric shock B9221 0110
4 Caution ; exhaust gas B9052 0000
- 2 -

A WARNING
ENGINE EXHAUST can kill.
I 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.
- 3 -

ELECTRIC SHOCK can kill.
V 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.
* hen 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.
* hen opening the control panel for voltage selection, etc., turn OFF the circuit breaker
and stop the machine.
A WARNING
- 4 -

A 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.
A ARNING
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.
■* hen 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.
* hen making check or maintenance of the machine,
be sure to stop the machine in advance.
* The motor fan for cooling radiator will keep on
running for a while even after engine stops.
Before beginning a repair/maintenance work,
moake sure that the motor fan has stopped
completely.
- 5 -

A WARNING
DIESEL FUEL can cause fire or explosion.
I Fuel and oil are flammable. Incorrect handling
results in danger of ignition or fire.
* hen 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.
* ipe off spilt fuel and oil.
A ARNING
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.
* hen cooling water needs to be checked or supplied, ^
wait until the engine is cooled (50 ‘C or less as
measured with the water temperature gauge).
- G -

A CAUTION
Stacking
■ Improper stacking of machines may cause falling or dropping accidents.
hen 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 stack
ed 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.
1
C l
1
09
1 ___ 1
.■ ■!
D
1 '
I i □ =
У7777777777777777'/77?7777777
Do not operate the machines in the state of
stacking to prevent falling or dropping accidents.
A 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 bums.
* hen 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.

A 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,
* hen 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.
HI The battery acid is dilute sulfuric acid. Improper
handling will cause unexpected bums.
* hen 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.
- 8 -

A 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.
A 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.
A 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.
- 9 -

Transportation
U 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.
* hen 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.
* hen loading the machine on the truck or the like,
fix the machine firmly by support hooks on the both
side.
A CAUTION
- 10 -

2. Construction
2 -1 Outline and part names
1. control panel
2. output terminal
3. fuel in
A. fuel drain plug
5. oil drain plug
6. hanger rod
7. support hook
8. coolant in
9. exhaust gas outlet
10. coolant drain pulg
- 1 1 -

11. diesel engine
12. AC generator
13. battery
14. radiator
15. electric fan
16. reserve tank
[DCA-4 5 US IJ
17. engine oil in
18. dipstick
19. fuel filter
20. control box
21. air cleaner
22. oil filter
- 12 -

2 - 2 Operating panel, control panel and part names
1. frequency meter
2. AC ammeter
3. AC voltmeter
4. voltage regulator
5. circuit breaker (3-phase)
6. circuit breaker (1-phase)
7. pilot lamp
8. panel light
9. panel light switch
10. engine indicator
11. starter switch
12. preheat lamp
13. emergency stop button
14. throttle lever
15. frequency adjust screw
16. fuel priming pump button
(45USI-USI2, 60USH)
- 13 -

2- 3 Meters
Engine indicators
N u m b er I n d i c a t o r
(1) Number Indicator
That indicates the numerical values of engine speed, engine oil pressure,
run hours, battery charging voltage, or engine coolant temperature,
Each indication is selectable by pushing the " SELECT " button.
Unit Indicated Items
min'1 engine speed
X ЮОкРа engine oil pressure
hour run hours
Vbattery charging voltage
*C engine coolant temperature
AUTO automatic indication change
Unless " SELECT 11 switch is pushed, " Engine Speed " is always
indicated immediately after engine starts
- 14 -

ith " AUTO " selected, indication is automatically changed every
three (3) seconds,
- 1 - Engine Speed
Revolutions per minute is indicated.
1500min ~ 1 is indicated at 50Hz and 1800 m in " 1 is indicated at 60Hz.
- 2 - Engine Oil Pressure
2 to 5 X 100 kPa ( 2 to 5 kg / cm! ) should be indicated at normal
engine operation. Higher value would be indicated in cold condition
immediately after engine starts. Conduct a warming - up operation
until it indicates normal value.
- 3 - Hun Hours
That indicated total running hours.
- 4 - Battery Charging Voltage
That should indicate more than 26V (25USI‘USI2, 45USTUSl2:more than
12. 5V) at engine running.
- 5 - Engine Coolant Temperature
That should indicate a temperature between 75 to 90 tC 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.
- 6 - Automatic Indication Change
Each of the above - started indications from the - I - to - 5 - changes by turns
every 3 seconds.
(2) 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
sametime 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 feul level.
- 15 -

Numbers of
lamps turned - on
Color of lamps
DCA-25USI DCA-25USI2 DCA-45USI
DCA-60USH
DCA-4 5USI2
Fuel level
(L) Fuel level
CL) Fuel level
(L) Fuel level
(L)
6all green 80 to full 70 to full 140 to full 125 to full
5all green 70 to 75 60 to 70 120 to 140 100 to 125
4all green 60 to 70 50 to 60 100 to 120 75 to 100
3red on 1st lamp from
bottomgreen on
2nd & 3rd lamps
45 to 60 35 to 50 75 to 100 45 to 75
2all red 30 to 45 25 to 35 50 to 75 25 to 45
1red 0 to 30 0 to 25 0 to 50 0 to 25
(3) Alarm and Memory at Abnomal Condition
hen any abnormal condition occurs in engine oil pressure, battery charging voltage,
or engine coolant temperature, the indication will change as the followings ;
- 1 - The indication changes to " AUTO " , and the abnormal value and unit will
be indicated lighting on and off.
- 2 - hen the abnormal condition is corrected, the on - and - off indication will
stop.
- 3 - If engine would stop urgently and automatically or stop manuslly with
the abnormal condition, the abnormal value will be memorized, and then
indicated even after engine is started again.
In this case, keep on pushing the button " AUTO " for more than 5 seconds,
and the abnormal indication will be reset to normal.
I
Generator indicators
(1) Frequency meter
This meter indicates frequency of the output
voltage.
Make sure that it indicates 50Hz or 60Hz during
operation.
ф ® S p ф 5s
'X \ ' Л К / A
V7
A-
e ® Ф 0
0 0
... _i
50Hz 60Hz
- 16 -

(2) AC ammeter
This meter indicates AC current flowing into the
connected load. Make sure that it is always
pointing below the rated current.
hen running the three phase and single phase
loads together, this meter indicates total current of
them.
hen running either the three phase or single
phase load, this meter indicates the current flowing
into the load.
The current of each phase can be checked using
the ammeter change over switch.
(Only for 45USI-USI2, 60USH)
(3) AC voltmeter
50H2 6OH2
\ ij ' л , %x>
Ф &
00
This meter indicates AC output voltage. Make
sure that it indicates rated voltage.
- 17 -

Indication/alarm lamp
(1) Preheat lamp
hen the starter switch is set in the preheat position,
this lamp becomes red heated in about 30 seconds,
indicating that the machine has been preheated to be ready
for startup.
In the case of 25USI-USI2 and 45USI-USI2 it will
automatically preheating device.If turn the.starter switch to "R
un" position, it will according to cooling water (coolant)
temperature with the preheat lamp goes on. hen the prehe
at lamp goes off, it indicates that preheating is completed.
(2) arning Lamps
This monitor indicates the following failures, if any one of them occurs.
ф High jacket water temperature ( ATER TEMP)
WATER TEMP lamP Soes on when the water temperature rises abnormally. If
the lamp goes on during operation, the emergency stop
device immediately operates to shut down the engine automatically.
© Oil pressure failure (OIL PRESS)
OIL PRESS ^ this lamp goes on during operation, the emergency stop device
immediately operates to shutdown the engine automatically.
® Air filter blinding (AIR FILTER)
AIR FILTER hen the air element is blinded, this lamp goes on. Indicating that
the element should be immediately cleaned or replaced.
- 18 -

<D High fuel filter water level {FUEL FILTER ATER LEVEL)
FUEL FILTER This lamp turns on when the water level in the fuel filter would rise.
WATER м
LEVEL Е Я З Drain the water in the strainer soon after the lamp would turn on.
(Only for 25USI-USI2 & 45USLUSI2)
Method of Draining
1) Loosen the drain plug.
2) Push the priming pump to drain water.
- 19 -