Denyo DCA-6LSX User manual

I N S T R U С T I О N MANUAL
DIESEL G E N E R A T O R
Before using, be sure to read this manual for the sake of safety.
Be sure to observe the items under symbol marks "A WARNING
and "A CAUTION'' for the sake of safety.
Always keep this manual at your machine for the sake of safety.
D С A - 6 L S X
D С A - 1 0 L S X
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FOREWORD
* Your machine is a portable t pe diesel generating set.
* Do not install, operate or repair this machine without reading this operating manual.
* This generator set (machine) must be operated b a person having sufficient knowledge
and skill for the sake of safet .
Notes on instruction manual
* This instruction manual explains correct operation and maintenance of the machine to
ensure its performance.
Incorrect handling of the machine ma lead to a serious injur or decease.
Before using, be sure to read this manual carefull .
Particularl , the items under11 Safet precautions",
"A WARNING" and "A CAUTION" must be read thoroughl .
* Keep this manual in the case behind the rear or side door for future reference.
* Read the contents of the warrant card attached to the machine.
* If this manual becomes illegible b spot or damage, contact distributor or our office to
new manual.

1. Safet Precautions - Contents - 1
2. Construction. 8
2-1 Outline and parts names 8
2-2 Operating panel, control panel and pads names 10
2-3 Meters 11
2-4 Use switches and controllers 14
3. Transportation and installation 16
3-1 Transportation of machine 16
3-2 Installation of machine 16
4. Connecting the load ............... 18
4-1 Cables to be used ----------- 18
4-2 Connecting tire load 19
4-3 Grounding 21
5. Operation 22
5-1 Checking prior to operation 22
5-2 Startup 26
5-3 Handling during operation 28
5-4 Shutdown 29
5-5 Protection device 30
6. Lubrication, cooling water and fuel ----------- 31
6-1 Engine oil 31
6-2 Cooling water 32
6-3 Fuel 32
7. Handling of batter 33
7-1 Caution on batter charge 34
7-2 Connection of booster cable, and installation 35
8. Periodical checking and maintenance 36
8-1 Maintenance schedule — ............ 38
8-2 Checking/first 50 hours — ............... 39
8-3 Checking/ever 100 hours - ................ 40
8-4 Checking/ever 200 hours 41
8-5 Cheeking/ever 400 hours — 41
8-6 Checking/ever 500 horn-s 42
8-7 Checking/ever 1000 hours 42
8-8 Checking/ever 2000 hours 42
8-9 Other checks and Maintenance 42
8-10 Table of periodical maintenance and checking 43
9. Troubleshooting 44

10. Long-term storage 46
11. Service data — 47
11-1 Specifications 47
11-2 AC generator specifications (for custom voltage) ................. 49
11-3 Outline drawing 50
11-4 Generator connection diagram 52
11-5 Engine wiring diagram 58
12. Options instruction Manual - 60
12-1 Instruction for Fuel source changeover Device 60

1. Safety Precautions
In order to ensure safe operation, the following s mbols are used for explanation of the
machine operation.
The following s mbols, found throughout this manual, alert ou to potentiall dangerous
conditions to the operator, service personnel, or the equipment.
A WARNING:
This s mbol refers to a hazard or unsafe practice which can result in severe personal injur
or death.
A CAUTION:
This s mbol refers to a hazard or unsafe practice which can result in personal injur or
product or propert damage,
[Note]:
This s mbols show handling precautions for effective operation and man ears of
satisfactor operation.
Some of the items shown b "A CAUTION" ma also cause death or serious injur .
Be sure to observe all the items, as the are important for safe operation.
* If the machine is used b an outsider, ou are requested to explain him correct handling
and advise him to read this instruction manual carefull .
* Do not modif the machine at our discretion, as it affects the safet , performance or the
life of the machine.
* If the machine is modified or it is used incorrectl against this manual or unauthorized
parts are used, the warrant of manufacturer will become invalid.

Safety label
Safet labels are attached to the following positions of the machine.
* Keep these safet labels clean at all times.
* When safet labels are spoiled or lost, contact distributor or onr office specif ing the
nameplate No. shown below and ask for new ones.
No. Parts name Parts number No. Parts name Parts number
1Warning:exhaust gas B9052 0000 5 Cantion:hightemp B9042 0040
2 Warning:output voltage D9211 0050 6Support hook B912I 0020A
3Warning:fire accident В9045 0220 7Warning:radiator cap B90410030
4Warnmgimoving part B90400100

A WARNING
ENGINE EXHAUST can kill.
0 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 sta s.
* Do not use the machine indoors or in storehouse, tunnel, ship hold,
tank, etc, of poor ventilation.
* If it becomes necessar 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 nearb pedestrians and houses.
A WARNING
ELECTRIC SHOCK can kill,
0 Do not touch the output terminals during operation to
prevent decease due to electric shock.
* Never touch the output terminals during operation. If our hands or
the machine are wet, it will result in a death or serious injur .
* 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 completel ,
S3 Do not touch the electrical parts in the machine during
operation, as it ma lead to death due to electric shock.
* Alwa s close the- control panel and tighten the fixing bolts before .
operating the machine.
* Alwa s 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. ___________________
A WARNING
ELECTRIC SHOCK by leak can kill.
S Improper grounding ma 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 WARNING
MOVING PARTS can cause severe injur .
H 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
our hands and head in the machine to prevent them from being
caught in the machine which ma lead to injur .
* When making check or maintenance of the machine, be sure to
stop the machine in advance.
BSA
A WARNING
DIESEL FUEL can cause fire or explosion.
H 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 awa 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.
Ml
's
A WARNING
HOT COOLANT can cause severe scalds.
Bi If the radiator cap is opened while the water temperature is
high, steam or hot water wifi spout out.
* During operation or immediatel 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.
Ш

A CAUTION
Stacking
Ш 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 horizontall 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.
151 Using square timbers as shown right, put each machine making
sure that the weight is even.
S Do not operate the machines in the state of stacking to prevent
falling or dropping accidents. _______________ _ ______
A CAUTION
HOT PARTS can bum skin.
H 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 our
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 j,
until the engine is completel cooled. _____________ _________
5

A CAUTION
Battery
H Batter generates flammable gases. Improper handling ma
lead to explosion or serious injur .
* Batter should be charged in a well ventilated location. Otherwise,
flammable gases are accumulated which ma be ignited and
exploded.
* When connecting a booster cable, do not jumper the terminals (+
and —). Otherwise, the flammable gases generated from the
batter ma be ignited and exploded b sparks.
* For maintenance of the machine, disconnect the ground cable on
the ground side.
Ш The batter acid is dilute sulfuric acid. Improper handling will
cause unexpected bums.
* When the batter acid gets on our clothes or skin, wash it out with
a large volume of water immediatel . If it gets in our e es, wash
with a large volume of water immediatel and consult our doctor.
- In the worst case, it will put out our e es.
H For checking or handling of the batter , be sure to stop the
engine and turn OFF the batter switch in advance. ________________
A CAUTION
Operator
S Do not operate the machine if operator is tired too much or
drinks some alcohol or take some drugs.
* Otherwise, it ma cause unexpected, accidents or injur .
Ш During checking or maintenance, be sure to put on suitable
clothes and protectors.
* Do not put on bagg clothes, necklace, etc., because the are easil
caught b projections which ma cause injuries. _________________
6

A CAUTION
Noise
S This machine generates large noise if the door is open.
Surrounding to large noise ma cause hearing trouble,
* Close and lock the door during operation.
* If opening the door is necessar during operation, be sure to put on
the ear protector. ___________________________________________
A CAUTION
Connection to house wiring
И Before connecting this machine to an building's electrical
s stem, a licensed electrician must install an isolation(transfer)
switch.
* Serious injur or death ma result without this transfer switch.
A CAUTION
Transportation
И Do not lift the machine at the support hook or the ladder because
it is not strong enough for lifting and ma cause a falling accident.
* When lifting the machine, use the hanger located at the roof center.
* Keep out under the lifted machine.
Si Do not lift or do not transport the machine during operation, as it
ma cause damage to the fan or serious trouble.
* When loading the machine on the truck or the like, fix the machine
firml b support hooks on the both side. __________ i ______
7

. Construction
2-1 Outline and parts names
1. CONTROL PANEL
2. FUEL IN
3. HANGER ROD
4. DOOR LATCH
5. SUPPORT HOOK (FOR ROPE)
6. AIR INTAKE
7. EXHAUST GAS OUTLET
8. COOLANT IN
9. FUEL DRAIN PLUG
10. OIL DRAIN PLUG
11. COOLANT DRAIN PLUG
12. VENTILATION
13. KEY
(DCA-10LSX)
8

1. AC GENERATOR 7. OIL FILTER
2. DIESEL ENGINE 8. OIL LEVEL GAUGE
3. ADR CLEANER 9. RADIATOR
4. FUEL TANK 10. COOLANT RESERVE TANK
5. FUEL FILTER 11. BATTERY
6. OIL INLET 12. THREE-WAY VALVE
(OPTION)
(DCA-10LSX)
9

2-2 Operating panel, control panel and parts names
1. FREQUENCY METER
2. AC AMMETER
3. AC VOLTMETER
4. VOLTAGE REGULATOR
5. AC CIRCUIT BREAKER
6. AC CIRCUIT BREAKER - for RECEPTACLE (OPTION)
7. STARTER SWITCH
8. ENGINE MONITOR
NUMBER INDICATION: RUN HOURS
LAMP INDICATION : FUEL LEVEL, PREHEAT
WARNING LAMPS : WATER TEMP., OIL PRESS., CHARGING
9. THROTTLE LEVER
10. FREQUENCY ADJUST SCREW
11.1 -PHASE OUTPUT TERMINAL
12, 1-PHASE OUTPUT RECEPTACLE (OPTION)
(DCA-10LSX)
10

2-3 Meters
Engine monitor
(X) Fuel level indicator
That indicates a fuel level in the fuel tank. Green lamps
will turn on with foil tank. As the foel level drops, the
numbers of the turn-011 lamps decrease and at the sometime
the color of lamps changes from green to red.
Replenish the tank when there becomes onl one lamp turned
on. The table below shows the relation between numbers of
tum-on lamps and foel level.
Numbers of
lamps turned-on Color of lamps Fuel level (L)
DCA-6LSX Fuel level (L) DCA-10LSX
6 all green 28 to foil 53 to full
5all green 22 to 27 47 to 53
4all green 17 to 21 41 to 47
3all green 12 to 16 33 to 41
2all red 8 to 11 21 to 33
1 all red Oto 7 Oto 21
(2) Hour meter
This meter indicates the total running time of the engine.
ШШЕШШ
ШПШШШ
□ a о tn tm n
11

Generator indicators
(X) Frequency meter
This meter indicates frequenc of the output voltage.
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 alwa s pointing below the rated
current.
When running the three phase and single phase loads
together, this meter Indicates total current of them.
When running either the three phases or single-phase load,
this meter indicates the current flowing into the load.
(3) AC voltmeter
This meter indicates AC output voltage. Make sure that it
indicates rated voltage.
1

Indication/alarm lamp
(1) Preheat lamp
When the starter switch is set in the "PREHEAT" position,
this lamp goes on.
In a little time this lamp goes off, indicating that the machine
has been preheated to be read for startup.
(2) Warning Lamps
This monitor indicates the following failures, if an one of
them occurs.
ф High jacket water temperature
This lamp goes on when the water temperature rises
abnormall .
If this lamp goes on during operation, the emergenc stop
device immediatel operates to shut down the engine
automaticall .
(2) Oil pressure failure
If this machine is in normal operation, this lamp sta s 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 emergenc stop
device immediatel operates to shutdown the engine
automaticall .
© Insufficient charge
This lamp goes on when the output voltage of the alternator
drops unusual value.
If this lamp goes on during operation, the emergenc stop
device immediatel operates to shutdown the engine
automaticall .
13

2-4 Use of switches and controllers
Switches
(l)Starter switch
Functions:
Ф Stop
This switch should be set in this position unless the machine
is in operation. The ke 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.
Ш w
® Start
This is the position to start the engine. When our hand is
released from the ke after starting, it is automaticall set in
the position of “RUN”.
© Preheat
This is the position to start the engine when the air
temperature is low. Set the switch in this position until the
preheat lamp goes off, and then set it in the start position.
(2) Speed control device
■ Throttle lever
This lever is used to control the engine speed. Set the
lever at the "START/IDLING" position for startup or
warm up/cooling operation of the engine and at the
"RUN" position for constant speed operation of the
machine (at 50Hz or 60Hz).
* Frequenc adjusting screw
This screw is used to adjust the frequenc . With the
throttle lever set at the "RUN" position, turn the screw
to the "HIGH" side to increase the frequenc and to the
"LOW" side to decrease it.
'J
REQUEUCY ADJUST SCREW
Ш Ш
HIGH LOW
14

(3) Circuit breaker
This is a main switch to suppl power to a load. When the
load is shorted or in the state of overload, it trips to protect
the generator against trouble.
[Note] :
Do not use this circuit breaker to turn ON/OFF the load, to
prevent damage to the circuit breaker.
When it trips with over-current, the handle of the breaker
stops between ON and OFF positions. This is what is called
the trip condition.
In this case, push the handle down to the OFF position to
reset it, or else, it cannot be set in ON position.
Voltage regulator
(1) Voltage regulator
This regulator is used to control the output voltage. Turn the
regulator to clockwise to increase the voltage and counter
clockwise to decrease it. Adjust the voltage to the rated
voltage with this regulator.
VOLTAGE Щ Ш Ш
15

3. Transportation and installation
3~1 Transportation of machine
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 ma cause a
falling accident.
* When lifting the machine, use the hanger located at the roof
center.
* Keep out under the lifted machine.
Ш Do not lift or do not transport the machine during
operation, as it ma cause damage to the fan or serious
trouble.
* When loading the machine on the truck or the like, fix the
machine firml b support hooks on the both side. The
detail as machine size is referred to
ГЦ-l. Specifications See p.47,48 J _____________________
3-2 Installation of machine
A WARNING
ENGINE EXHAUST can kill.
В 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 sta s.
* Do not use the machine indoors or in storehouse, tunnel,
ship hold, tank, etc. of poor ventilation.
* If it becomes necessar 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 nearb pedestrians and
houses.
16