Dynamo Power DP7100 User manual

Diesel Generator
Owner’s Manual
DP7100
This manual provides information regarding the operation and maintenance of these products.
We have made every effort to ensure the accuracy of the information in this manual.
We reserve the right to change this product at any time without prior notice.

PREFACE
PREFACE
Thank you for purchasing products from our company. The following manual is only a guide to assist
you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your
generator. The equipment you have purchased is a complex piece of machinery. We recommend that
you consult with a dealer if you have doubts or concerns as to your experience or ability to properly
maintain or repair your equipment. You will save time and avoid the inconvenience of having to go back
to the store if you choose to write or call us concerning missing parts, service questions, operating advice,
and/or assembly questions. Our air-cooled diesel generators have some of the following features:
Lightweight construction
Air cooled
Four-stroke diesel internal combustion engine
Direct fuel injection system
Electric, remote start
Glow plug(also called preheater or cold starter)
Large fuel tank
Automatic voltage stabilizer
AC circuit breaker protection
AC and DC outputs
Low oil pressure automatic shut down
Dynamo brand air-cooled diesel generators are widely used when electrical power is scarce. Our
generators provide a portable mobile solution in supplying power for field operations during project
construction. Some other known applications include pipeline construction and metal welding when
electrical power is not available.
This manual will explain how to operate and service your generator set.
If you have any questions or suggestions about this manual, please contact your local dealer or us
directly. Consumers should notice that this manual might differ slightly from the actual product as
more improvements are made to our products. Some of the pictures in this manual may differ
slightly from the actual product as well. DYNAMO POWER CORP. reserves the right to make
changes at any time without notice and without incurring any obligation.

TABLE OF CONTENTS
TABLE OF CONTENTS
Chapter 1 Technical Specifications and Data
1
1-1 Overview of the generator
1
1-2 Technical specifications and data
2
1-3 Standard features
3
1-4 Basic operating parameters
3
1-5 General dimensions and overview of the generators
4
Chapter 2 Operating the Diesel Generator
5
2-1 Main points of safety during operation of the generator
5
2-2 Preparation before operation
7
2-3 Checking the operation of the diesel engine
11
2-4 Starting the generator set
12
2-5 How to use glow plug
14
2-6 Proper operation of the generator set
15
2-7 Loading
15
2-8 Stopping the generator
18
Chapter 3 Maintenance
20
3-1 Maintenance schedules
20
3-2 Storing for long periods of time
22
Chapter 4 Troubleshooting
23
4-1 Inspections before operation and maintenance
23
4-2 Malfunction and troubleshooting for diesel engine
23
4-3 Questions and doubts
35
Chapter 5 Generator Parts Diagrams and Listings
36
Chapter 6 Circuit diagram
42

TECHNICAL SPECIFICATIONS AND DATA
CHAPTER 1 TECHNICAL SPECIFICATIONS AND DATA
1-1
Overview of the generator set
Fuel Filler Cap Stationary Rings
_„
..
Air Cleaner
(inside)
Control
Panel
4"Solid Wheel
Lock
Remote Starter
(inside)
Muffler
/(inside)

TECHNICAL SPECIFICATIONS AND DATA
1-2 Technical specifications and data
Table 1 The Single-cylinder diesel generator
Item Model DP7100
Generator data
Generator
technical
data (AC)
Frequency (HZ) 60
60
Rated power (kW)
5.0
Peak power (kW)
6.3
Voltage (VAC)
120/240
Phase type
Single phase
Power factor (cos)
1.0
Speed (rpm)
3600
Excitation
self-excitation , Brushless
Voltage regulator
Capacitor
Continuous operation time (Hr. by half load)
Continuous run for 12 hours
Noise level [dBA/7m] (zero load—full load)
69-74
Connection
Rigid connection driven shaft
Dry weight (kg)1(1b)
Gross weight(ks) /(1b)
160 / 353
180 / 395
Dimensions (LxWxH)(mm)/(inch)
929 x 538 x 724 / 36.6x 21.2 x 28.5
Engine
Engine type
Single cylinder,
4-stroke,air-cooled,vertical,
diesel engine
Fuel type
0# (summer), —10# (winter),
—35#(chill cold) diesel
Lube oil brand
CD or better than CD
Output
I Continuous (kW)
Output
Borex
stroke
(mm)
/(inch)
Max Output(kW)
5.8
86x72 / 3.39x2.83
6,3
Displacement (cc) /(cub inch)
418 / 25.5
Compression ratio
19:1
Lube-oil capacity (L) /(Gal)
1.65 / 0.43
Fuel tank capacity (L) /(Gal)
14.5 / 3.8
Starting system
Electric start/Remote start
Note: Allow 30 hrs initial run time for max efficiency.

TECHNICAL SPECIFICATIONS AND DATA
1-3 Standard features
Electric start, recoil start and remote control with preheater (cold start)
Large fuel tank with 12 hours continuous operating capability
Automatic shutdown for low oil pressure
Vibration isolation mounting between engine/alternator base align
AC circuit breaker protection
Overload protection and convenience
AC voltmeter
120V/240V switch
12VDC charging system
Operation status indicator lamp and low oil alert lamp
Dependable, brushless alternator
Advanced direct fuel injection system
Provides low fuel consumption
All American standard receptacles
Battery and hour meter included
1-4 Basic operating parameters
1-4.1 Under the given conditions, the generator will output
the specified power in the table listed below.
Table 2 0
Height above sea level (ft) Ambient temperature ( F) RH
<3280.8 (1000 m) 41-104 (5-40 C) 90%

TECHNICAL SPECIFICATIONS AND DATA
1-5 General dimensions and overview of the
generators
1-5.1 DP7100 dimensions of the series generator.
Fig 1
1-5.2 Generator model number code
Remote start
Silent
Model
Diesel engine
Engine set
DYNAMO
929mm
(36.6inch)

OPERATING THE DIESEL GENERATOR
CHAPTER 2 OPERATING THE DIESEL GENERATOR 2-
1 General main points of safety during operation
of the generator set.
In order to operate the generator set safely, please follow all the
instructions provided in this manual carefully. Doing so otherwise may lead
to accidents or equipment damage.
2-1.1 Fire prevention
The proper fuel for the diesel generator set is light diesel fuel. Do not
use gasoline, kerosene or other fuels other than light diesel fuel.
Keep all flammable fuels away from the generator as the generator
may spark and ignite these gases. In order to prevent fires from
occurring and to provide enough ventilation for people and the
machine, keep the diesel generator at least 1.5 meters away from
buildings and or other equipment. Always operate your diesel generator on
a level site. If the generator is operated on an incline, the lubricating system
within the engine will not perform well and may lead to failure of the engine.
2-1.2 Prevention from inhaling exhaust gases.
Never inhale exhaust gases emitted by the engine. Diesel engine
exhaust emissions have the potential to cause a range of health
problems. Diesel engine exhaust emissions (commonly known as diesel
fumes) are a mixture of gases, vapors, liquid aerosols and substances
made up of particles. They contain the products of combustion including:
Carbon (soot)
Nitrogen
Water
Carbon monoxide
Aldehydes
Nitrogen dioxide
Sulphur dioxide
Polycyclic aromatic hydrocarbons
The carbon particle or soot content varies from 60% to 80% depending on
the fuel used and the type of engine. Most of the contaminants are
adsorbed onto the soot. Petrol engines produce more carbon monoxide
but much less soot than diesel engines.
Never operate your generator in places with poor ventilation. In
order to operate this machinery indoors, a suitable ventilation system for
the building is required to draw the poisonous exhaust gases out.
2-1.3 Prevention from accidental burns
Never touch the muffler and its cover when the diesel engine is running. Never
touch the muffler and cover after the diesel engine has been used, as the
muffler remains hot for a good period of time.
5

OPERATING THE DIESEL GENERATOR
2-1.4 Electric shock and short circuits
Never touch the generator if the generator is wet. Also never touch the
generator if your hand is wet. Never operate your generator if the weather
conditions call for any type of precipitation such as rain, snow, or fog. To
prevent electrical shocks, the generator should be grounded. Use a lead to
connect the grounding end of the generator to the grounding surface of choice.
Please refer to Fig. 2 before beginning to use the electric generator.
NOTE
When connecting devices to the generator, make sure all other devices are
rated lower than the generators output. Do not over load outlets.
Fig 2 Control panel with grounding terminal
2-1.5 Other safety points Grounding terminal in
the control panel
Prior to operation the operator should read and understand all satety
precautions.
2-1.6 Battery
The electrolytic liquid of the battery also known as battery acid contains sulfuric
acid. In order to protect your eyes, skin, and clothing, wears protective gear
when working with the battery. If you come in contact with the electrolytic liquid,
wash it immediately with clean water. Also, if the electrolytic liquid comes in
contact with your eyes, see a doctor immediately.
6

OPERATING THE DIESEL GENERATOR
2-2 Preparation before operation
2-2.1 Fuel choices and fuel treatment
Use only light diesel fuel.
The fuel should be filtered clean. Never let dust and water mix with fuel in
the fuel tank. Otherwise it will clog the fuel lines and oil nozzles. It may
also damage your pressure pump.
WARNING: It is dangerous to overfill the fuel tank. Do not overfilI.
a. After purchasing fuel, put it into a drum and let it sit for 3-4 days
b. 3-4 days later, insert half of the fuel sucker into the drum, (water and
impurities stay in the lower portion of the drum)
NOTE
Never smoke near the opening of the
fuel tank. Do not let sparks get near
the fuel or fuel tank and do not
overfill tank. After filling, tighten the
fuel cap.
CAUTION
Do not overfill tank. After filling, tighten the fuel cap. Never let fuel or fuel tank
expose to sparks. Be careful not to spill fuel when filling, if any fuel is spilled,
make sure to clean up all the spilled fuel before starting engine.
2-2.2 Charging battery
We recommend the use of accumulators rated 20 hours shown in table 3.
Table 3 Specifications of recommended accumulators for electric start
MODEL
Amps-hours
DP7100
36
Your generator cones with either a maintenance free or dry cell battery (see fig 4).
Ensure the battery is fully charged before installation to prevent damage to
electrical circuits. Use trickle charge for 8 hrs.
Fig 3
7

OPERATING THE DIESEL GENERATOR
Fig 4 Maintenance free battery (left) and dry battery(right)
If it is dry battery, the battery must be filled with battery acid to required level.
Acid can be purchased at a local automotive supply store. To properly maintain
your dry battery, check the height of the battery acid once a month. If the level
of the liquid drops too low, fill it with distilled water until it reaches up to
maximum level mark. If there is not enough battery acid, diesel engine cannot
be started. It is important to keep the liquid level between the high and low
limits. If the level in the battery is too high, the liquid may flow out and corrode
surrounding parts.
2-2.3 Filling engine oil
Make sure the generator is on level ground and remove the dipstick from
the engines.
Check if the oil level is between the high limit and low limit. If the engine is
new or oil is not enough, fill the engine with the right engine oil.(see fig 6)
Put the dipstick back into the hole to check the engine oil level.(see fig 5)
Fig 5 Schematic for filling engine oil Fig 6 Choose the right engine oil
Be sure to use oil GRADE
CC or CD A.P. I Diesel
Engine Service
Sugz-3.qtraed Value
q
t.:V.
00d
Unlit V'alUe
E
- _______
-1 7.11 A n Po- -

OPERATING THE DIESEL GENERATOR
Engine oil is the most important factor in determining the life of your generator
engine. If you use poor engine oil or if you don't change the oil regularly, the
piston and cylinder will wear easily or seize up. Also, the life of the other parts in
your engine such as bearings, and other rotating parts will shorten
considerably.
NOTE
Although there is an alarm system to check for low oil pressure, it is always a
goodideatocheckthe amountof oilinsidethe engine. Iftheoillevelislow,fill it
before starting the engine.
A good time to drain the oil from the engine is when the diesel engine is still hot. If
the engine is fully cooled, it is more difficult to drain all the oil out or some impurities
will remain in the engine.
WARNING: DO NOT fill engine oil when the machines are
running.
The following procedures help you start our generator with ease:
1. If dry battery comes with your generator, please add enough acid to required
level;
2. Fully charge battery prior to cranking diesel engine;
3. Add engine oil to the required level(use the dipstick to check);
4. Add enough diesel in FUEL TANK, turn knob fuel shutoff valve (down) ON
position. This is under FUEL TANK.
5. Pull off the fuel hose connected to the fuel pump and LET FUEL DRAIN
OUT FREELY, then replace the fuel hose;
6. Connect fully charged battery to generator;
7. DO NOT apply any load at this point and put the CIRCUIT BREAKER to the
OFF position;
8. Push RED lever next to oil level check stick to the RUN position;
9. Turn on to the START position and release the electronic key to the ON
position(for electric start);
10. Turn electronic key to the ON position, and then press the "ON" button of
the remote starter key to start the genset(for remote start).
11. In cold winter area please turn key counterclockwise to HEAT and hold
about 10 seconds to preheat cold air, then turn clockwise to START engine,
release the key to ON position after engine starts: it helps start the engine in
9

OPERATING THE DIESEL GENERATOR
cold weather; if your remote control unit has remote preheater function, please
see refer to operating procedures for remote start for your reference(for electric
start)
12. Turn electronic key to ON position and then press the “ ” button of the
remote starter to preheat the genset. After 10 seconds, press the “ ” button of
the remote starter key to stop preheating the genset. Finally, press the “ON” button
of the remote starter key to start the genset (for remote start).
13. lf the engine does not start; wait 1 to 3 minutes and repeat step 9 or 10:
14. Only try to use remote control after you successfully start the engine using a
electronic key.
NOTE
This generator comes with recoil starter. If you want to pull start your generator,
please refer to Section 2-6 procedures for recoil starting.
2-2.4 Checking the air filter
(1) Loosen the butterfly nut, take the cover of the air filter off and take the air
filter element out. Fig 7
NOTE
Do not use detergent to wash the air filter element.
•When the performance of the engine decreases or when the color of the
exhaust gases is bad, exchange the filter element.
Never starttheenginewithouttheair filter asforeignobjectsmayenter the
intake and damage the engine.
(2) After replacing the air filter element, tighten the butterfly nut firmly.
Air filter cover
10

OPERATING THE DIESEL GENERATOR
2-2.5 Checking the generators
Before starting the generator, make sure the breaker is in the "OFF" position,
Starting the generator with the breaker in the "ON" position is very dangerous.
Use dry compressed air (with pressure about 1 96 x 105 Pa) to blow the dust
out in the control panel and at the surface of the alternator.
According to the electric wiring diagram, check to see whether the connecting
wire is correct and the connected place is firm.
WARNING
The generator should be grounded in order to prevent electric shock.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
Dynamo Power diesel engines have a low-pressure sensor system where if the
oil pressure drops too low, the sensor will shut the engine off. The purpose
of having this system is to ensure that the engine does not seize up. If there is not
enough oil in the engine, the temperature of the oil will be raised too high. On
the contrary, if there is too much oil in the engine, the engine oil can slow the
engine down considerably.
2-3.2 How to open the case door/cover Fig 8
(1) Open the case door: Pull the
handle outward and open the
door. Do these checks daily. —
(2) Loosen the outer cover bolt of the air
filter and outer cover of the oil
nozzle, and then check the air
filter.
(3) Check the outer cover of the oil
nozzle. Loosen the butterfly nut and
open the outer cover.
When you purchase a brand new
engine, the engine must be properly broken in. The break in period is about 20
hours.
(1) Avoid overloading the engine when brand new. After primely start the
genset, please make the engine warm-up about 5 minutes. Do not load a
high-power device to the genset during breaking in. A speed of 3600rpm and 50%
load are recommended for breaking in.
(2) Change the engine oil according to specifications. An oil change for a brand
new engine is about 20 hours or one month, an older engine, the oil change is
about 100 hours or three months.(see fig 9)
2-3.3 Engine break in
Knobhandle
11

OPERATING THE DIESEL GENERATOR
Fig 9 Interval of changing engine oil
Start: About one month or 20 hours. / Then every 3 months or 100 hours.
-
2 - 4 Starting the generator set
2-4.1 Electric starting
Start the engine in accordance with procedures below:
(1) Put the switch of fuel filter in the ON position.
(2) Turn the speed handle of the engine to the
"RUN" position.
(3) Turn the start switch clockwise to the
"START" position and release the electronic key to
the ON position.
(4) In cold winter area please turn electronic key
counterclockwise to HEAT and hold about 10
seconds to preheat cold air, then turn clockwise to
START engine, release the electronic key to ON
position after engine starts; it helps start the engine
in cold weather.
(5) After the diesel engine is started remove your hand from the switch handle;
the switch will automatically reset itself to the "ON" position.
(6) If the engine is not starting after 10 seconds of cranking, wait about 15
seconds before trying it again. If you crank too long, the voltage of the battery
will drop. This can lead to improper ignition. When the diesel engine is
operating, let the ignition remain on the "ON" position.
Fig 10
12

OPERATING THE DIESEL GENERATOR
2-4.2 Remote starting
There are ON OFF, Preheat ( ) and Stop Preheat ( ) buttons in Remote
Starter Key. Your remote start unit (with 8 wires on) has remote glow plug
function, the operating procedures are as follows:
1. Please refer to above generator operation instruction for start using
electronic key;
2. If you want to use remote start, please make sure that your electronic key
switch is put on "ON" position;
3. Press the ON button to start the genset, and press the OFF button to stop the
genset;
4. If you use electronic key to start the generator and then use Remote Starter
Key to shut it down, make sure that you need turn electronic key switch to OFF
position; otherwise, your generator battery will drain charge gradually;
5. In case your remote control unit fails and a remote jumper comes with your
user's manual package, please unplug your remote control unit first, then plug
the remote jumper; this will enable you to use electronic key to start your
generator; if there is no remote jumper with your package, please follow the
order shown in the picture of remote jumper to electrically shorten the two
corresponding wires coming out of your control unit, then you shall us e
electronic key to start your generator.
2-4.3 Battery
NOTE:
If you crank the starter too long, the battery may be drained too much to
provide enough energy for proper engine ignition.
Also, when the diesel engine is operating, let the electronic key remain in
the "ON" position.
13
Fig 11 Remote starter and remote jumper
Preheat
ON
Stop Preheat
Remote Starter
Key
Remote Starter antenna
i 1
1
1
Remote Jumper
Remote Starter
Signal Receiver

OPERATING THE DIESEL GENERATOR
IMPORTANT NOTE
2-5 How to use glow plug
Fig 12 Control panel with preheater knob
Diesel generator will be very hard to start in cold winter. However, glow plug
will help start dies& generator much easier. Please turn electronic key
counterclockwise to HEAT position and hold about 10 seconds to preheat cold. If
your diesel generator comes with 8-wire remote control unit (it needs special
order, extra charge applies), you can remote control glow plug. The operating
procedures are as follows:
ON and OFF buttons used for remote starting engine; Preheat ( ) and Stop
Preheat ( ) buttons used for controlling glow plug respectively (see Fig 11).
They are interlocked with each other and only one set works at a time, preheat
set is programmed for powering on glow plug 10 seconds and you can press
the( ) button for power off also glow plug will automatically power off after 20
seconds.
Some of our units come with a dry battery for shipping safety purposes. In
order to get your generator started for the first time, the battery must be filled
with battery acid which can be purchased at a local automotive supply store
and slowly charged (trickle charged) for a day. After charging, the battery
may be used.
,

Fig 13
Fig 14
SPEED HANDLE
HIGH-PRESSURE FUEL PIPE BLET
OPERATING THE DIESEL GENERATOR
2-6 Proper operation of the generator set
2-6.1 Operating the diesel engine
1. Pre-heat the diesel engine for 3 minutes under
no load conditions.
2. First check the height of the lubricating oil level, if
it is low, refill it. Our diesel engines are equipped
with an alarm system that will notify you if the oil
pressure is too low. The alarm system will shut
down the engine if the oil pressure is too low.
3. Do not adjust the speed limit regulation bolt or
the fuel adjustment bolt. These bolts have been set
by the factory already, changing them will affect the
properties of the engine performance.
2-6.2 Checks during engine operation
1. Check to see if there are abnormal noises.
2. Check to see if the performance is good or bad
3. Check the color of the exhaust gases (whether it is too black or too white). If
any of these conditions exist, stop the engine and find the cause of the
problem. If no problems are found, please contact your local dealer or our
nearest company branch.
2-7 Loading
2-7.1 Load conditions
Exert loads in accordance with the specified parameters
2-7.2 Applying Load to your Generator
After generator is started, push circuit breaker to ON position and you should
read 120V in voltage meter when voltage selector is set for 120V output or
240V in voltage meter when voltage selector is set for 120V/240V output.
When applying loads to generator, make sure to apply loads in order. Apply
larger load onto the generator first. If the generator labors great with applied
load, smaller load can then be added. Never overload generator. Otherwise,
generator will black smoke or circuit breaker will be stripped. In this event,
decrease the number of small loads until generator labors normally. Please see
the technical specifications of generator for your reference. If the indication of
the voltage meter is too high or too low, adjust the engine speed (capacitor
used for brushless alternator) accordingly. Special skills are required to perform
speed adjustment. An authorized professional is recommended to perform this
work. If there are problems, stop the generator immediately and fix the issue.
15

OPERATING THE DIESEL GENERATOR
NOTE: During operation, the generator should be put in a place with good
ventilation. Never cover open frame generator using your own cage to solve a
noisy problem, as this will cause overheating problem and then damage your
generator. You must obtain our prior authorization for any change in our
generator. Otherwise, the warranty for your generator will be voided.
Do not apply more than two loads simultaneously. Each load should be started
one by one to avoid overloading generator The generator should be running at
3600 revolutions per minute in order to achieve the frequency of 60Hz. The
speed of engine can be adjusted through speed governor.
CAUTION: A alternator consists of windings, namely R2 & R1 and L2 & Li,
each set of winding gives 120V output. A voltage selector is used to obtain
120V and/or 240V output. Two sets of windings are in parallel when a selector is
set at left while two sets of windings are in serial when a selector is set at
right. If you push voltage selector left for only 120V output, you can apply full
rated load at 120V outlet; if push selector right for both 120V & 240V outputs,
you can apply full rated load at 240V outlet from four-prong socket; however,
you can only apply HALF RATED LOAD at either 120V outlet (total two 120V
outlets) from four-prong socket.
Fig 15 Wiring diagram for alternator Fig 16 Parallel connection
Grounding(White)
Fig 17 Serial connection
R2(Black) —
1—
R1{Yellow)
1_2(Green)
Ll(Recl)
P-1
•_L A A

OPERATING THE DIESEL GENERATOR
Fig 18 Wiring diagram of electric output for control panel
2-7.3 AC application
1. Ensure engine is running properly and is warmed up for 3 minutes.
2. The voltmeter should point to 240V±5%. Turn circuit breaker on. The AC
voltage from the socket of the power supply can be output.
3. When connecting devices to the generator, make sure to connect these
devices in order. Connect the large loads onto the generator first. If everything is
functional, smaller loads can then be added. If the generator shuts off, it may be
because the load being drawn by all the various devices are too high. In this
event, decrease the number of small devices until everything is functional. The
total drawn power should not exceed the maximum output power of the
generator. Please see Table 1 for technical specifications of what the generator
can output. In order to reset the generator after overdrawn power, let it sit for
several minutes. If the indication of the voltmeter is too high or too low, adjust
the speed accordingly. If there are problems, stop the generator immediately
and fix the issue.
4. During operation, the generator should be in a place that has very good
ventilation. Never cover the engine to solve a ventilation problem, as this will
damage your equipment.
NOTE
Do not start more than two devices simultaneously. Each device should be
started one by one to prevent overloading the generator.
The generator should be running at 3600 revolutions per minute in order to
achieve the (60 Hz) frequency. The speed of the engine can be adjusted from
the speed governor.
L1(Red)- R1(Yellow)
L2
(GREEN)
R2
(
,40410{, - (Green)
R2
- (Black)
te,
17