Denyo DCA-600SPK User manual

INSTRUCTION MANUAL
D E N 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 WARNING
and Д CAUTION for the sake of safety.
Always keep this manual at your machine for the sake of safety.
MODEL : DCA—600SPK
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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 WARNING: 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 Д CAUTION1' 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.
* 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
1Safety instruction B9211 0040 6 Warning: moving part B9040 0040
2 Warning: exhaust gas B9042 0000 7 Warning: fire accident B9045 0000
3Warning: output voltage B9311 0050 8 Caution: high temp B9040 0030
4Warning: electric leakage B91110040 9 Warning: radiator cap B9041 0010
5 Warning: electrical shock B9311 0060 10 Warning: house wiring B911J 0030
11 Caution: muffler B9111 0020
- 2 -

Д WARNING
ENGINE EXHAUST can kill.
I Insufficient ventilation ma lead to death due to
lack of ox gen or poisoning b 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 -

A 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.
(In the parallel operation, be sure to shut down the other
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 ma
lead to death due to electric shock.
* Always close the control panel and tighten the fixing bolts before operating the machine.
* Always dose 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.
(In the parallel operation, be sure to shut down the other machine.)
- 4 -

Д WARNING
ELECTRIC SHOCK b leak can kill.
I Improper grounding ma lead to death due
to electric shock.
r 4-4. Grounding See p.32j
* Be sure to execute the grounding of the machine and
the load according to the local rule.
Д WARNING
MOVING PARTS can cause severe injur .
I Rotar unit which runs at a high speed is located
in the machine.
(Note that it is ver dangerous if ou 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 ■
be sure to stop the machine in advance.
- 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.
* 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.
A WARNING
HOT COOLANT can cause severe scalds.
I 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). c~~-

A CAUTION
Stacking
Improper stacking of machines ma 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 np 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.
В
/ У V 7
Do not operate the machines in the state of
stacking to prevent felling or dropping accidents.
A CAUTION
HOT PARTS can burn skin.
■ High temperature units are located in the machine.
(Note that these units are ver dangerous if the are
used incorrectl .)
* 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.
* 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.
- 7 -

A CAUTION
BATTERY
■ Batter generates flammable gases.
Improper handling ma lead to explosion
or serious injur .
* 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.
U The battery acid is dilute sulfuric acid. Improper
handling will cause unexpected bums.
* When the battery add 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.
- 8 -

Д CAUTION
Muffler
■ During operation or immediatel after stop of
the machine, touching to muffler ma bum skin.
* Muffler is on the roof of the machine. After stop of the
machine, do not go up the roof until the muffler
is completely cooled.
Д 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.
Д 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.
й \
- ______
- 9 -

АCAUTION
Connection to house wiring
■ Before connecting this machine to any building’s electrical system, a licensed
electrician must install an isolationftransfer) switch.
* Serious injury or death may result without this transfer switch.
A 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 two hangers located at
the roof center.
* Keep out under the lifted machine.
I 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
Г 12— 1. Specifications See p. 79 j and
Г 12—2. Outline drawing See p.80 j .
-10-

2. Construction
2-1 Outline and part names
IAC generator 10 fuel filter 19 voltage change over board
2 diesel engine 11 ofl filter 20 breather pipe
3output terminal 12 air cleaner 21 fuel tank
4 battery 13 coolant reserve tank 22 corrosion resistor
5 fuel in 14 oil drain pump 23 hanger rod
6engine oil in 15 fuel drain plug 24 support hook
7 coolant in 16 radiator 25 fuel inlet
8fuel level gauge 17 control box 26 fuel outlet
9 dipstick 18 muffler
-1 1 -

2-2 Operating panel, control panel and part names
:^ Т х з з ) (з 5;
OPERATING PANEL
control panel
frequency meter
AC ammeter
ammeter change-over switch
AC voltmeter
voltmeter change-over switch
pilot lamp
circuit breaker
8 voltage regulator
9 panel light
10 panel light switch
11 synchronizing lamp
12 single-parallel change-over switch
13 frequency change-over switch
1
2
3
4
5
6
7
operating panel
21 tachometer
22 throttle lever
23 oil pressure gauge
24 oil temperature gauge
25 water temperature gauge
26 charging ammeter
27 fuel gauge
28 warning lamp unit
29 battery switch
30 starter switch
31 healer switch
32 preheat lamp
33 emergency slop button
34 running caution lamp
35 speed chang- over switch
-12-

2- 3 Meters
Engine indicators
(1) Tachometer (0-3000rpm)
(2) Hour meter
(COI ОЮКЙ)
(3) Water temperature
(4) Oil pressure gauge
This meter indicates the number of revolutions
(per minute) of the engine.
It indicates 1500rpm at 50Hz or ISOOrpm at 60Hz.
This meter indicates the total running time of the
engine. This meter is built in the tachometer.
The hour meter has been set for use at ISOOrpm.
Accordingly, when the machine is used at 180Grpm,
it indicates the total time approximately 20% more
than the actual operation time.
gauge
This is normal when it indicates 75 to 95 °C'during
operation.
[Note] If it indicates higher values, turn OFF the
load and set the machine in cooling
operation by setting the speed change-over
switch to LOW position, and until the
temperature lowers.
This is normal when it indicates 3 to x lOOkPa
during operation.
If the engine is cool, it may indicate higher values
at the time of startup. Put the engine in warming up
operation and wait until oil pressure becomes normal.
-13-

(5) Charging ammeter
(6) Fuel level gauge
(7) Oil temperature gauge
Generator indicators
(1) Frequenc meter
This meter indicates the current supplied by the
alternator to batteries.
It is normal when it indicates the range of 0 or +.
This meter indicates the fuel level in the fuel tank.
This meter indicates the oil temperature of the
engine oil.
It is normal when it indicates 70 to 120 °C during
the operation.
This meter indicates frequency of the output
voltage.
Make sure that it indicates 50Hz or 60Hz during
operation.
-14-

(2) AC ammeter
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-over switch.
(3) AC voltmeter
AC Voltmeter
This meter indicates AC output voltage. Make
sure that it indicates rated voltage.
Line-to-line voltages can be checked using the
voltmeter change-over switch.
-15-

Indication/alarm lamp
(1) Preheat lamp
This lamp is for starting in the cold weather. Pull the
heater switch, and about 80 seconds later the lamp will
turn off to indicate a completion of preheating.
(2) Running caution lamp This lamp goes on during low speed operation.
(3) Warning lamp nit
This monitor indicates the following failures, if any one of them occurs.
ф 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
device immediately operates to shut down the engine automatically.
Г 5—1.(2) Check on engine cooling water See p.36j
-16-

ф Oil pressure failure (OIL PRESS)
If the 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.
After stop of the engine, the lamp stays on unless the starter switch
is turned to STOP position.
Г 5—1.(1) Checking on engine oil See p.35 j
ф Fuel level failure (FUEL LEVEL)
When fuel is running low, this lamp goes on, and it should be supplied
at the tank.
Г 5—1.(4) Check on fuel See p.37 j
(D Battery acid level failure (ВАТТ LOW LEVEL)
When battery acid is running low, this lamp goes on, and distilled
water should be supplied to the battery.
Г 5—1.(5) Check on battery acid See p.38 j
© Oil filter blinding (OIL FILTER)
When the oil filter is blinded, this lamp goes on. Indicating that the
oil filter should be immediately replaced and also replace the engine oil
concurrently.
r 9— 2.(1) Replacement of engine oil See p.64 j
r 9—2.(2) Replacement of engine oil filter element See p.65 j
© 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.
r 9- 2.(3) Cleaning of air cleaner element See p.66 J
r 9-4.(2) Replacement of air cleaner element See p.71 j
-17 -

2-4 Use of switches and controllers
Switches
(1) Battery switch
(2) Starter switch
STOP
; RUN
t /
I /
This switch should be set in the ON position during
operation. And after stop the engine, this switch should
be set in the OFF position.
[Note] Do not turn tin’s switch to OFF position
during operation. Otherwise, the engine may
not be able to be stopped by normal operation, or
it may cause damage to the electric equipment.
Functions:
Ф 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.
Ф RUN
This switch should be set in this position when the
machine is in operation,
© START
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 .
-18-

(3) Speed change-over switch
START
Automatic idling
i
■LOW HIGH
Functions:
Ф START / AUTOMATIC IDLING
When the engine is started with the speed change— over
switch set at this position, the engine idles for about 20
seconds and then automatically changes over to high speed
operation.
When starting the engine, set the switch in this position.
© LOW
When the switch is turned to this position, the engine
continues to idle. When stop of the engine, turn the speed
change-over switch to this position and put the machine in
cooling operation for a few minutes before turn the starter
switch to OFF position.
© HIGH
Setting the switch to this position releases the automatic •
idling function, allowing the engine to be run at the speed
set by the throttle lever.
(4) Heater switch
When start up the engine at cold weather, this switch is
used.
r 5-3. Starting in the cold weather See p.43 j
(5) Emergency stop button
О
This is a push button to stop the engine urgently on
emergency case.
[N ote]
Do not push the button without emergency case.
-19-