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