Denyo DCA-600P User manual

No.C48431 00604A
INSTRUCTION MANUAL
ENGINE-DRIVEN AC GENERATOR
DCA-600P
IMPORTANT: READ AND UNDERSTAND THIS MANUAL
CAREFULLY BEFORE USE OF THIS MACHINE.
KEEP THIS MANUAL FOR YOUR FUTURE REFERENCE.
2-8-5 Nihonbashi-horidomecho, Chuo-ku, Tokyo, 103-8566 Japan

CONTENTS
SAFETY PRECAUTIONS FOR GENER
A
TORS .................................................................... 2
1. DCA series ........................................................................................................................ 8
1-1 General ................................................................................................................... 8
1-2 Machine structure ................................................................................................... 8
1-3 Machine a
pp
earance and internal com
p
onent devices ........................................... 8
1-4 Control switches and meters ................................................................................... 10
1-4-1 En
g
ine start/sto
p
controls ....................................................................................... 10
1-4-2 En
g
ine indicators .................................................................................................... 12
1-4-3 Generator controls and indicators ........................................................................... 19
2. Trans
p
ortation, stora
g
e and installation ............................................................................ 20
2-1 Safet
y
p
recautions for trans
p
ortation, stora
g
e and installation ............................... 20
2-2 Transportation ......................................................................................................... 21
2-3 Stora
g
e ................................................................................................................... 21
2-3-1 Stora
g
e method ...................................................................................................... 21
2-3-2 Preparin
g
for operation ........................................................................................... 22
2-4 Installation ............................................................................................................... 23
2-4-1 Installation ............................................................................................................... 23
2-4-2 Checkin
g
after installation ....................................................................................... 26
3. O
p
eration .......................................................................................................................... 29
3-1 Safet
y
p
recautions for o
p
eration ............................................................................. 29
3-2 Connectin
g
the load ................................................................................................ 31
3-2-1 Precautions in connectin
g
the load ......................................................................... 31
3-2-2 Non-liner and sensitive loads .................................................................................. 31
3-2-3 Selection of cables .................................................................................................. 32
3-2-4 connectin
g
the load ................................................................................................ 33
3-3 Groundin
g
............................................................................................................... 34
3-4 Before startin
g
......................................................................................................... 34
3-4-1 Checku
p
before start-u
p
......................................................................................... 34
3-4-2 Instruction for Fuel Device ...................................................................................... 36
3-5 Startin
g
.................................................................................................................... 37
3-6 Durin
g
o
p
eration ..................................................................................................... 38
3-7 Sto
pp
in
g
.................................................................................................................. 38
3-7-1 Stoppin
g
method ..................................................................................................... 38
3-7-2 Emer
g
enc
y
sto
p
...................................................................................................... 38
3-7-3 Protection device .................................................................................................... 38
4. Fuel, coolant and lubricants ..............................................................................................40
5. Periodic checkup and maintenance .................................................................................. 43
5-1 Safety precautions for periodic checkup and maintenance ..................................... 43
5-2 Periodic chechup ..................................................................................................... 44
5-2-1 Maintenance schedule ............................................................................................ 44
5-2-2 Checking/every 250 hours ...................................................................................... 45
5-2-3 Checking/every 500 hours ...................................................................................... 46
5-2-4 Checking/every 1000 hours .................................................................................... 51
5-2-5 Table of periodical maintenance and checking ....................................................... 52
6. Troubleshooting .................................................................................................................. 53
7. Principal data ...................................................................................................................... 54
7-1 Readings on gauges ...............................................................................................54
7-2 Setting of switches .................................................................................................. 54
7-3 Reference conditions .............................................................................................. 54
7-4 Limitations ............................................................................................................... 54
7-5 General specifications ............................................................................................. 55
7-6 Conversion list of SI units into UK/US units ............................................................ 56

- 1 -
FOREWORD
• We are very thankful for your special choice of our MACHINE in the market.
• Please read this manual carefully and understand for proper use this machine.
• Please keep this manual at your prescribed location where operator can always take this manual.
• If you have any question or problem on this operation, please contact your nearest Distributors.
• Pay special attention to statements preceded by the following word.
DANGER: indicates an imminently hazardous situation which, if not heeded, will result in
death or serious injury.
WARNING: indicates a potentially hazardous situation which, if not heeded, could result in
death or serious injury.
CAUTION: indicates a hazardous situation which, if not heeded, may result in minor or
moderate injury or damage to the machine.
[ NOTE ]: indicates useful information for the machine operations.

- 2 -
SAFETY PRECAUTIONS FOR GENERATORS
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.

- 3 -
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.
Parts name Parts number
CAUTION : Instruction manual B9111 0220
DANGER : Electric shock B4510 0250
WARNING : Fire/explosion B9045 0100
CAUTION : Burn B9111 0240
CAUTION : Moving parts B9040 0050
CAUTION : Hot coolant B9041 0020
CAUTION : Engine fan B9040 0060
WARNING : Engine exhaust B9042 0020
CAUTION:
Instruction manual
• Do not use machine before reading the instruction manual.
• Do access to machine in accordance with the instruction manual when machine is in fault.
• Do consult to authorized person for repair or maintenance to avoid incidents.

- 4 -
DANGER: 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.
DANGER:
ELECTRIC SHOCK
by leak can kill.
CAUTION:
MOVING PARTS can
cause severe injury.
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.
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 op-
eration, 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 ma-
chine, be sure to stop the machine in advance.

- 5 -
WARNING: DIESEL
FUEL can cause fire
or explosion.
CAUTION:
HOT COOLANT can
cause severe scalds.
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.
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 sup-
plied, wait until the engine is cooled (50°C or less
as measured with the water temperature gauge).
CAUTION:
HOT PARTS can burn
skin.
CAUTION: Battery.
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.
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 accu-
mulated 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 immediate-
ly. 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: 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 ventila-
tion 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.

- 6 -
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.
CAUTION: Transportation.
Do not lift the machine except hanger of base
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 hanger on the
both side.

- 7 -
SAFETY LABEL
Model DCA-600P
This instruction manual
describes how to handle the
machine with a view to
promising safety run, maximum
efficiency and long durability.
Read the manual attentively
before starting the machine
operation for correct handling,
operation and appropriate
maintenance from the beginning.
The maintenance schedule
consists of a procedure of
keeping the machine in good
condition.
For the user, keep the manual
carefully for machine operation
and maintenance according to
the instructions. Observe all the
safety precautions including
ones stated in the manual.
Entrust the repair to trained
personnel of Denyo or its
distributor who are capable of
contacting us as required.
When consulting us, specify
the model and serial number
indicated on the nameplate.
For data not specified in the
manual, see “Principal data”.
The company reserves the right
to make changes without prior
notice.
Parts number
1DANGER: Electric shock
2WARNING: Fire/explosion
3CAUTION: Burn
4CAUTION: Moving parts
5CAUTION: Instruction manual
6CAUTION: Hot coolant
7CAUTION: Engine fan
8WARNING: Engine exhaust

- 8 -
SAFETY PRECAUTION:
• The user must carry out all safety precautions stated in the manual.
• If any statement in this book, especially with regard to safety, does not comply
with local legislation, the stricter of the two shall apply.
1. DCA SERIES
1-1 General
• DCA series generator is intended for generating power source where there is no power source.
• For further details, see “7 Principal data”.
1-2 Machine structure
• The generator which is directly driven by Perkins water-cooled diesel engine is mounted on
the common frame along with control equipment, radiator, battery(option), fuel tank(option)
and other auxiliary equipment. See Fig. 1.
1-3 Machine appearance and internal component devices
• There are the hanger at the base on its both sides. When lifting the machine, use the hanger.
Do not resort to winding rope because it is not strong enough. See Fig. 2.
• The engine cooling water refilling port and fuel refilling port(option) are located on the top
surface of the machine.
• The drain plugs for engine oil, cooling water and fuel(option) are located at the base side
under the machine. Tags of their respective names are attached there.
Fig. 1 Model DCA-600P
Parts number
1. AC generator
2. Diesel engine
3. Control box
4. Fuel tank (option)
5. Radiator
6. Battery (option)
7. Muffler (option)
8. Intercooler

- 9 -
Fig. 2 Model DCA-600P
Parts number Parts number
1. Hanger 6. Radiator cooling water drain plug
2. Radiator cooling water refilling port 7. Engine exhaust port (without muffler)
3. Fuel tank refilling port (with fuel tank) 8. Engine exhaust port (with muffler)
4. Fuel drain plug (with fuel tank) 9. Fuel inlet (only without fuel tank)
5. Oil drain plug 10. Fuel outlet (only without fuel tank)

- 10 -
1-4 Control switches and meters
• The control panel is mounted on the bodywork with hinges and is fastened by screws.
Loosening the screws has access to repairing or replacing electrical parts in the control
box.
1-4-1 Engine start/stop controls
Fig. 3 Model DCA-600P
Parts number Parts number
1. Frequency meter 8. Pilot lamp
2. Ac ammeter (U) 9. Engine indicator
3.
A
Ac ammeter (V) 10. Coolant level warning lamp
4. Ac ammeter (W) 11. Operation switch
5. Ac voltmeter 12. Start button
6. Voltage regulator 13. Speed regulator
7. Circuit breaker (for main) 14. Emergency stop button

- 11 -
1. Operation switch
The switch is 2-position switch which can be operated with its specific key only.
1) OFF/STOP
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.
2) RUN
This switch should be set in this position when the machine is in operation.
In this position, the preheating system is energized.
2. Start button
This button keep on pushing to start the engine.
3. Emergency stop button
The stop button is a push button to stop the engine in case of an emergency.
When the button is pressed, it must be unlocked by turning it anti-clockwise
before the engine can be re-started.
4.Speed regulator
Turn the switch toward the “HIGH” side to increase the speed and toward the
“LOW” side to decrease it.
RUNOFF/STOP
OPERATION SWITCH
RUNOFF/STOP
OPERATION SWITCH
KEEP ON PUSHING
TO START ENGINE .
START BUTTON
EMERGENC Y STOP BUTTO N IS RESET
BEFORE STARTING , CHECK
RESET
EMERGENCY STOP BUTTON
HIGH
LOW
SPEED REGULATOR

- 12 -
1-4-2 Engine indicators
5. Engine monitor
(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 ºC
1 - Engine Speed
• Revolutions per minute is indicated. 1500/1800 min-1 is indicated at 50/60Hz.
2 - Engine Oil Pressure
• 3.0 to 6.0 × 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 26.0V at engine running.
4 - Engine Coolant Temperature
• That should indicate a temperature between 75 to 90°C at engine running.
[ NOTE ]: If that would indicate higher temperature, disconnect all loads, and wait until
the temperature comes down to normal value.

- 13 -
(2) Fuel Level Indicator (Only with Fuel Tank)
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 DCA-600P
Fuel level (L)
9450 to full
8405 to 450
7345 to 405
6295 to 345
5245 to 295
4195 to 245
3165 to 195
2120 to 165
10 to 120
(3) Alarm and Memory at Abnormal Condition
When any abnormal condition occurs in engine oil pressure, battery charging voltage,
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 value will be memorized, and then indicated even after engine
is started again.
In this case, keep on pushing the button “RESET” for more than 5 seconds, and the
abnormal indication will be reset to normal.

- 14 -
(4) Warning Lamps
This monitor indicates the following failures, if any one of them occurs.
①High 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 device
immediately operates to shut down the engine automatically.
②Low lubricating oil pressure (OIL PRESS)
If this lamp goes on during operation, the emergency stop device
immediately operates to shut down the engine automatically.
(5) Hour Meter
  ①When 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;
• “ODO” Total running hour
• “TRIP A” Running hours “A” on a certain period
• “TRIP B” Running hours “B” on a certain period
  ②If you want to reset the Trip Meters, push the selector button for more than 1 second,
after selecting each meters.

- 15 -


(6) 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 via 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.
However, if charged for 3 hours, the hour meter will indicate hours for more than 10 days
without another charge.
Please refer to the table below to see the relationship between battery time charging
versus length of indication by the hour meter.
6. Coolant level warning lamp
This lamp goes on when the coolant amount become
lower than the fixed amount.
If the lamp goes on during operation, the emergency stop device
Immediately operates to shut down the engine automatically.
7. Controller breaker
This breaker protects engine hardware.
Before insert the key in the operation switch, switch this breaker to ON.
COOLANT LEVEL WARNING LAMP
CONTROLLER
BREAKER

- 16 -
8. Switch and Lamp for Electronic Governor Controller (in the control box)
(1) Isochronous-Droop Change-over switch
The generating set can change the governor control between
”Isochronous Governor Control and Droop Governor Control”
by “Isochronous-Droop Change-over switch” where is equippped
with the control box.
The original position at factory shall be set in “Droop Governor
Control”. Operate the unit in condition of “Droop Control”
in common.
In case of starting with a heavy load, operate the unit in condition
of ” Droop Governor Control” because it is better for starting
efficiency than “Isochronous Governor Control “.
Explanation for the control
①“Isochronous Governor Control “----- Frequency is constant regardless of load.
When the generator is set in a frequency thet will be pointed in condition of NO-LOAD,
the governor controls the frequency constantly regardless of load.
②“Droop Governor Control “----- Frequency will be alternative depending on load.
” Droop Governor Control” means that frequency can be alternative depending on load.
When the rated frequency will be reduced at about 2.0 Hz against NO-LOAD.
Therefore, NO-LOAD frequency should be set at 52.0 to 52.5Hz.
(2) Frequency change – over switch
This is for switching the frequency from 50Hz to 60Hz or 60Hz to
50Hz.
ISOCHRONOUS
DROOP
ISOCHRONOUS-DROOP
CHANGE-OVER SWITCH
FREQUENCY
CHANGE-OVER SWITCH
60Hz
50Hz
FREQUENCY
CHANG E - O VE R S WI TCH
60Hz
50Hz ISOCHRONOUS
DROOP
ISOCHRONOUS-DROOP
CHANGE -O VER SWITCH
SHUTDO WN L AMP ACT IO N ALE R T LAMP FAULT R ES ET
WARNING L AMP DIAG NOSTICS L AMP

- 17 -
(3) Diagnostic Lamp
This lamp is sometimes called the check engine light.
The diagnostic lamp is used to warn the operator of the presence
of an active diagnostic code. The lamp may not be included in all
applications.
(4) Fault Reset
In case turn off the Diagnostic Lamp, push this button.
(5) Engine Monitoring
This engine monitoring system monitors the following parameters.
･Engine oil pressure
･Coolant temperature
･Intake manifold air temperature
･Engine speed
･Boost pressure
･Fuel temperature
The monitoring system has three levels of operation.
The levels are described below.
Warning Operation (level 1)
In the Warning condition, the ECM causes the warning lamp to
come ON. The warning lamp indicates that a fault has been
detected by the engine monitoring system. No further action by
the ECM or the engine occurs.
Action Alert Operation (level 2)
In the Action Alert condition, the ECM causes the action alert
lamp to come on. The Action Alert lamp indicates that a fault has
been detected by the engine monitoring system. This condition is
normally wired in order to cause a shutdown and the shutdown is
controlled by the control panel on the machine.
Shutdown Operation (level 3)
If the fault reaches the Shutdown condition, the ECM causes the
shutdown lamp to come on. Unless the engine is in a Critical
Override condition, the engine will shut down.
DIAGNOSTICS LAMP
WARNING LAMP
ACTION ALERT LAMP
SHUTDOWN LAMP
FAULT RESET

- 18 -
Settings for the Monitoring System
Parameter State Trip Point Delay Time
Low Engine Oil Pressure
Warn Operator On 300 kPa
(43.5 psi) 60 seconds
Action Alert Always On 250 kPa
(36.3 psi) 2 seconds
Engine Shutdown Always On 200 kPa
(29.0 psi) 2 seconds
High Engine Coolant Temperature
Warn Operator On 104°C (219°F) 60 seconds
Action Alert Always On 105°C(221°F) 10 seconds
Engine Shutdown Always On 108°C(226°F) 10 seconds
Engine Overspeed
Warn Operator On 2000 RPM 1 second
Action Alert Always On 2050 RPM 0 second
Engine Shutdown Always On 2140 RPM 0 second
High Intake Manifold Air Temperature
Warn Operator On 75°C (167°F) 60 seconds
Action Alert Always On 78°C (172°F) 10 seconds
High Fuel Supply Temperature
Warn Operator On 60°C (140°F) 60 seconds
Action Alert Always On 68°C (154°F) 60 seconds
High Boost Pressure
Warn Operator On 300 kPa
(43.5 psi) 60 seconds
Action Alert Always On Map 5 seconds