Denyo DCA-30ESX User manual

I NSTRUCT I ON MANUAL
DEN YO
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 ■A WARNIN '
and "A CAUTION" for the sake of safety.
Always keep this manual at your machine for the sake of safety.
D C A - 3 O E S X
D C A “ 4O E S X
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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, ser ice personnel, or the equipment.
A WARNIN : This symbol refers to a hazard or unsafe practice which can result
in se ere 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 effecti e
operation and many years of satisfactory operation.
Some of the items shown by "Zf\ CAUTION" may also cause death or serious injury.
Be sure to obser e 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 ad ise him to read this instruction manual carefully.
* Do not modify the machine at your discretion, as it affects the safety, performance
or the Ufe 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 in alid.
- 1 -

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 Б9211 0140
2Warning : mo ing parts В9050 0050
3 Warning : hot coolant B9051 0030
4Caution : exhaust gas B9052 0000
5Warning : hot surfaces B9052 0020
6 Warning : diesel fuel B9055 0070A
7Warning : electric shock B9311 0050
© I S
A VIEW
CONTROL PANEL
(DCA-40ESX)
2 -

A WARNIN
ENGINE EXHAUST can kill.
Ё Insufficient entilation may lead to death due to
lack of oxygen or poisoning by exhaust gases.
* Do not use the machine in a place of poor entilation
or in a place where exhaust gases stays.
* Do not use the machine indoors or in storehouse, tunnel,
ship hold, tank, etc. of poor entilation.
* If it becomes necessary to use the machine in the
abo e places, the exhaust pipe should be extended
to a well entilated place. In this case, use a entilator
to ensure proper entilation.
* Do not direct the exhaust outlet to nearby pedestrians
and houses.
- 3 -

A WARNIN
ELECTRIC SHOCK can kill.
Ш Do not touch the output terminals during operation
to pre ent decease due to electric shock.
* Ne er 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 co er closed and the terminal
bolts tightened while the machine is running.
* A low oltage is generated e en when the machine is
in low speed idle operation.
Be sure to stop the machine completely.
S 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 oltage selection, etc., turn OFF the circuit
breaker and stop the machine.

A WARNIN
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 WARNIN
MOVIN PARTS can cause severe injury.
I Rotary unit which runs at a high speed is located
in the machine,
(Note that it i? ery 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
pre ent 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 ad ance.
- 5 -

Ж WARNIN
DIESEL FU EL can cause fire or explosion.
I 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 lea e flammable objects (paper, wood
chips, etc.) and hazardous objects (oil, powder, etc.)
near the machine.
* Wipe off spilt fuel and oil.
Ж WARNIN
HOT COOLANT can cause se ere scalds.
9 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°C or
less as measured with the water temperature gauge).
- 6 -

Ж CAUTION
Sta citing
I Improper stacking of machines may cause falling or dropping accidents.
When stacking other machines on .this machine, be sure to obser e 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 e en.
Q
□ c
7/7777777У777777Г77777777777
Do not operate the machines in the state of
stacking to pre ent falling or dropping accidents.
Ж CAUTION
HOT PARTS can burn skin.
9 High temperature units are located in the machine,
(Note that these units are ery 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
pre ent unexpected bums.
* When making check or maintenance of the machine,
be sure to stop the machine.
* The bonnet is still hot e en after the machine is
stopped.
Be careful until the engine is completely cooled.
- 7 -

A CAUTION
BATTERY
Щ Battery generates flammable gases.
Improper handling may lead to explosion
or serious injury,
* Battery should be charged in a well entilated
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.
9 The battery acid is dilute sulfuric acid. Improper
handling will cause unexpected bums.
* When the battery acid gets on your clothes or skin, wash it out with a large
olume of water immediately. If it gets in your eyes, wash with a large olume of
water immediately and consult your doctor.
- In the worst case, it will put out your eyes.
Ш For checking or handling of the battery, be sure to stop the engine in ad ance.
- 8 -

Ж CAUTION
Operator
Щ 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.
M 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
Ш 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
Щ Before connecting this machine t o a n y building's electrical system , a licensed
electrician must install an isolation(transfer) switch.
* Serious injury or death may result without this transfer switch.
- 9 -

А CAUTION
Transportation
Ш 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.
3 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.
- 10 -

2. Construction
2-1 Outline and part names
(DCA-40ESX)
1. oil drain plug
2. exhaust gas outlet
3. hanger rod
4. support hook
5. coolant in
6. output terminal
7. fuel in
8. fuel drain plug
9. coolant drain plug
10. engine indicator
11. operating panel
12. control panel
- 11 -

1. air cleaner
2. oil filter
3. fuel filter
4. reser e tank
5. AC generator
6. diesel engine
7. radiator
8. oil le el gauge
9. control box
10. fuel tank
11. battery
- 12 -

2-2 Operating panel, control panel and part names
(DCA-40ESJQ
No. CONTROL PANEL No. OPERATING PANEL
1frequency meter 31 engine indicator
2AC ammeter indicator:
3AC oltmeter engine speed, oil press, water temp,
4oltage regulator battery charging oltage
5circuit breaker (1-phase) integrating time
6pilot lamp
7 panel light luel le el indicator
8 earth leakage relay warning lamps
32 starter switch
33 preheat lamp
34 emergency stop button
35 throttle le er
36 frequency adjust screw
37 fuel priming pump button
38 panel light switch
- 13 -

2-3 Meters
Engine indicators
Fig.4
(1) Engine indicator
That indicates the numerical alues of engine speed, engine oil pressure, run hours,
battery charging oltage, or engine coolant temperature.
Indicated Items Unit
engine speed min*1
engine oil pressure XlOOkPa
battery charging oltage V
engine coolant temperature °C
- 14 -

- 1 - Engine Speed
Re olutions per minute is indicated. 1500mm1 is indicated at 50Hz and 1800 min'1 is
indicated at 60Hz.
-2- Engine Oil Pressure
2 to 5 x 100 kPa should be indicated at normal engine operation.
Higher alue would be indicated in cold condition immediately after engine starts.
Conduct a warning - up operation until it indicates normal alue,
- 3 - Battery Charging Voltage
That should indicate more than 12.5V at engine running.
- 4 - Engine Coolant Temperature
That should indicate a temperature between 75 to 95 °C 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 alue.
(2) Fuel Level Indicator
That Indicates a fuel le el 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 le el 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 le el.
DCA-30ESX DCA-40ESX
Numbers of
lumps tumed-on Fuel le el (L)
985 to full 105 to full
880 to 85 90 to 105
770 to 80 80 to 90
6 60 to 70 65 to 80
5 50 to 60 55 to 65
4 40 to 50 45 to 55
3 35 to 40 35 to 45
2 25 to 35 25 to 35
1 0 to 25 0 to 25
- 15 -

(3) Alarm and Memory at Abnormal Condition
When any abnormal condition occurs in engine oil pressure, battery charging oltage,
or engine coolant temperature, the indication will change as the following;
-1 - The Indicator shows its defect with blinking numbers.
- 2 - When the abnormal condition is corrected, the on - and - off indication will stop.
- 3 - If engine would stop urgently and automatically or stop manually with the abnormal
condition, the abnormal alue will be memorized, and then indicated e en after engine
is started again.
In this case, keep on pushing the button “RESET31 for more than 5 seconds, and the
abnormal indication will be reset to normal.
(4) Hour Meter
® When you turn the starter switch to “RUN” position, and push the selector button
located on the right side of the Hour Meter, you can see the numbers mentioned
below;
* “ODD” Total running hour
• “TRIP Running hours “A” on a certain period
■ “TRIP^]” Running hours “B” on a certain period
Ф If you want to reset the Trip Meters, push the selector button for more than 1 second,
after selecting each meters.
- 16 -

(5) The hour meter has an internal battery
The engine monitor incorporates both a rechargeable internal battery as well as a
charging circuit.
While the generator is not in operation, the engine monitor will still indicate the
hours operated ia its internal battery. While the generator is in operation, the internal
battery recharges.
When the generator remains unused for a long period of time, the battery will
continue to lose its charge. Once the charge is exhausted, the hour meter will not
indicate hours, and the battery will need to be recharged. From a completely
exhausted state, recharging the battery for 30 minutes will only result in a 30
minute charge to the battery. Howe er, if charged for 3 hours, the hour meter will in
dicate hours for more than 10 days without another charge.
Please refer to the table below to see the relationship between battery time
charging ersus length of indication by the hour meter.
- 17 -

enerator indicators
(X) Frequency meter
Ф ¥ e,
' V *
IL
# ¥ Jo
Г
® ©
0
». A
Q a
0
50Hz 60Hz
This meter indicates frequency of the output
oltage.
Make sure that it indicates 50Hz or 60Hz 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.
The current of each phase can be checked using
the ammeter change o er switch.
(3) AC oltmeter
This meter indicates AC output oltage. Make
50Hz 60Hz sure that it indicates rated oltage.
- 18 -

Indication/alarm lamp
(1) Preheat lamp
This machine has automatically preheating de ice.
If turn the starter switch to “RUN” position, it will according to
cooling water (coolant) temperature with the preheat lamp goes on.
When the preheat lamp goes off, it indicates that preheating is
completed.
(2) Warning Lamps
This monitor indicates the following failures, if any one of them occurs.
© High jacket water temperature (WATER TEMP)
This lamp goes on when the water temperature rises abnormally. If
the lamp goes on during operation, the emergency stop
de ice immediately operates to shut down the engine automatically.
Oil pressure failure (OIL PRESS)
If this lamp goes on during operation, the emergency stop de ice
immediately operates to shutdown the engine automatically.
Air Filter blinding (AIR FILTER)
When the air element is blinded, this lamp goes on. Indicating that
the element should be immediately cleaned or replaced.
- 19 -