Denyo DCA-13ESK, Instruction Manual

Page 1: ...safety Be sure to observe the items under symbol marks WARNING and CAUTION for the sake of safety Always keep this manual at your machine for the sake of safety ＤＣＡ １３ＥＳＫ ＤＣＡ １５ＥＳＫ ＤＣＡ ２０ＥＳＫ ＤＣＡ ２５ＥＳＫ HEAD OFFICE 4 2 2 KAMITAKADA NAKANO KU TOKYO 164 8510 JAPAN TEL 03 3228 1111 FAX 03 5380 7171 Printed in Japan ...

Page 2: ...ct operation and maintenance of the machine to ensure its performance Incorrect handling of the machine may lead to a serious injury or decease Before using be sure to read this manual carefully Particularly the items under Safety precautions WARNING and CAUTION must be read thoroughly Keep this manual in the case behind the rear or side door for future reference Read the contents of the warranty ...

Page 3: ...ce 6 Lubrication cooling water and fuel 6 1 Engine oil 6 2 Cooling water 6 3 Fuel 7 Handling of battery 7 1 Caution on battery charge 7 2 Connection of booster cable and installation 8 Periodical checking and maintenance 8 1 Maintenance schedule 8 2 Checking first 50 hours 8 3 Checking every 100 hours 8 4 Checking every 200 hours 8 5 Checking every 400 hours 8 6 Checking every 500 hours 8 7 Checki...

Page 4: ...AC generator specifications for custom voltage 11 3 Outline drawing 11 4 Generator connection diagram 11 5 Engine wiring diagram 12 Options instruction Manual 12 1 Earth leakage relay 12 2 Instruction for Fuel source changeover Device 46 47 47 49 50 54 57 58 58 60 ...

Page 5: ...oduct 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 in...

Page 6: ...ct 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 1 Warning exhaust gas B9042 0000 5 Caution high temp B9052 0020 2 Warning output voltage B9211 0250 6 Support hook B9121 0020A 3 Warning fire accident B9055 0070A 7 Warning radiator cap B9051 0030 4 Warning moving part B9050 0050 ...

Page 7: ...r 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 t...

Page 8: ...or explosion 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 WARNING HOT COOLANT can cause severe scalds...

Page 9: ...achine Using square timbers as shown right put each machine making sure that the weight is even Do not operate the machines in the state of stacking to prevent falling or dropping accidents CAUTION HOT PARTS can burn skin 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 ...

Page 10: ...ill cause unexpected burns When the battery acid 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 CAUTION Operator Do n...

Page 11: ... install an isolation transfer switch Serious injury or death may result without this transfer switch CAUTION Transportation 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 hanger located at the roof center Keep out under the lifted machine Do not lift or do not transport the mac...

Page 12: ...tline 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 ...

Page 13: ...9 1 AC GENERATOR 2 DIESEL ENGINE 3 AIR CLEANER 4 FUEL TANK 5 FUEL FILTER 6 OIL INLET 7 OIL FILTER 8 OIL LEVEL GAUGE 9 RADIATOR 10 COOLANT RESERVE TANK 11 BATTERY 12 THREE WAY VALVE OPTION ...

Page 14: ...R 4 VOLTAGE REGULATOR 5 AC CIRCUIT BREAKER 6 AC CIRCUIT BREAKER for RECEPTACLE OPTION 7 EARTH LEAKAGE RELAY OPTION 8 STARTER SWITCH 9 THROTTLE LEVER 10 FREQUENCY ADJUST SCREW 11 ENGINE MONITOR NUMBER INDICATION RUN HOURS LAMP INDICATION FUEL LEVEL PREHEAT WARNING LAMPS WATER TEMP OIL PRESS CHARGING ...

Page 15: ...or of lamps changes from green to red 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 Color of lamps Fuel level L 6 all green 55 to full 5 all green 45 to 54 4 all green 35 to 44 3 all green 27 to 34 2 all red 19 to 26 1 all red 0 to 18 2 Hour meter This meter indicates the t...

Page 16: ... into the connected load Make sure that it is always 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 ...

Page 17: ...rgency stop device immediately operates to shut down the engine automatically Oil pressure failure If this 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 ...

Page 18: ...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...

Page 19: ... 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 cloc...

Page 20: ...firmly by support hooks on the both side The detail as machine size is referred to 11 1 Specifications See p 47 48 3 2 Installation of machine WARNING 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 ventilation or in a place where exhaust gases stays Do not use the machine indoors or in...

Page 21: ...ple Installation procedure Install the machine horizontally on a solid foundation Provide a space of more than about 1m at the side of the control panel and fuel feed port to ensure correct operation and supply Provide a space of more than about 1 2m on the left and right sides for check of the engine oil supply and cable connection work A sufficient space is required at the top of the machine to ...

Page 22: ... the cable may be damaged by overheat Also if the cables are too small in size for the length the input voltage of the load drops which lowers the working efficiency or causes failure in operation Select the length and size of cable so that the voltage drop e obtained by the following equation is within 5 of the rated voltage Equation to obtain 3 phase 3 wire system voltage drop e from the length ...

Page 23: ...olts before operating the machine Do not use damaged cables to prevent electric shock Insufficient tightening of bolts will generate heat at connections which may result in fire accidents When connecting make sure the connecting cables are normal and connected firmly to the output terminals CAUTION Connection to house wiring Before connecting this machine to any building s electrical system a lice...

Page 24: ...U for single phase load 200 220V 50Hz 60Hz 3 Precaution in load connection Be sure to provide a switch for turning the load ON and OFF between the output terminal block and the load Note that the use of the breaker of the machine for turning the load ON and OFF may result in breaker failure In connecting the load be sure to stop the engine and turn OFF the breakers on the control panel and the out...

Page 25: ...ovide the grounding rod to satisfy the grounding resistance which conforms to the local rule 3 Precaution in grounding Select a shady and highly moist place and burry the grounding rod in such way that its top end is completely hidden in the ground If burying the grounding rod on the place that many pedestrians walk on clamp the lead wire to prevent catching on it If the lead wire is not long enou...

Page 26: ...k the cause of it Note Check for leaks of oil water exhaust gases and for unusual noise 5 Shut down 5 1 Checking prior to operation WARNING MOVING PARTS can cause severe injury 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 making check or maintenance of the machine be sure ...

Page 27: ...gh 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 or less as measured with the water temperature gauge Check to see that cooling water in the reserve tank is within the range of FULL LOW When it is below...

Page 28: ...65 97021 4 Check on fuel Be sure to check the quantity of fuel prior to operation to prevent lack of fuel during operation Loosen the drain plug of the fuel tank from time to time and remove sediment s and water at the bottom of the tank 5 Check on battery acid CAUTION Battery The battery acid is dilute sulfuric acid Improper handling will cause unexpected burns When the battery acid gets on your ...

Page 29: ... Check for loose bolts and nuts Loose parts should be tightened firmly Particularly make check on the fitting of air cleaner muffler turbo charger etc disconnection of electric wiring short circuit and loose terminals 9 Removal of foreign objects in machine Check that tools and cleaning cloth are not left in the machine Remove if necessary Check the surroundings of the muffler and engine for prese...

Page 30: ... already warm starter switch PREHEAT keep more than 5 sec preheat lamp check the preheat lamp goes off starter switch START starter switch RUN engine startup warm up operation about 5 minutes sufficiently when it is cold throttle lever RUN position adjustment of speed adjustment of voltage circuit breaker ON supply power to load ...

Page 31: ...ation is not required 4 If engine starts up set free the starter switch Make sure that Oil Pressure Failure and Insufficient charge in the warning lamp unit goes off 5 Drive the machine for warming up the engine for about 5 minutes at the START IDLING position of the throttle lever 6 After warming up the engine set the throttle lever to the RUN position And check on the idling speed is as specifie...

Page 32: ...l incomplete combustion White Abnormal combustion of oil due to failure of oil 2 Adjustment during operation Set the frequency meter to the rated by the frequency adjust screw Set the voltmeter to the rated by the voltage regulator Note Do not set the throttle lever in START IDLING position or do not decrease the speed by the frequency adjust screw during operation of the load or else the generato...

Page 33: ...about 5 minutes 4 Set the starter switch in STOP position The engine will stop immediately 5 Remove the key from the starter switch and keep it at hand 6 After engine is shut down turn the fuel filter cock sideways to CLOSE 7 Check the amount of fuel Supply additional fuel if necessary 8 Check for leakage of oil fuel and water circuit breaker of the load circuit breaker of the machine starter swit...

Page 34: ...the engine indicate by warning lamp function Oil pressure failure low lubricating oil OIL PRESS When the oil pressure falls abnormally the device acts Set point 0 049MPa High jacket water temperature WATER TEMP When the cooling water temperature rises abnormally the device acts Set point 115 Insufficient charge When insufficient charge the device acts Fuel level failure FUEL LEVEL When fuel supply...

Page 35: ...ied by API service 2 Oil viscosity Recommended oil viscosity is SAE 10W 30 all season type Use oil according to ambient temperature referring to the table below Ambient temperature 30 20 10 0 10 20 30 SAE 20 SAE 30 SAE 5W 20 SAE 10W 30 SAE 15W 40 Note Do not mix with different kind of oil or else it deteriorates the oil quality 3 Total quantity of replacement oil DCA 13 15ESK 5 6 L DCA 20 25ESK 7 ...

Page 36: ...he following percentages are recommended for each ambient temperature 30 15 40 20 50 30 In case of replenishment use LLC of the same brand and the same density Normally LLC should be replaced every 2 years 2 Total quantity of cooling water DCA 13 15ESK 6 4 L 0 9 L DCA 20 25ESK 7 9 L 0 9 L Value in parenthesis is reserve tank capacity 6 3 Fuel 1 Fuel to be used 2 Diesel Fuel Note If other kinds of ...

Page 37: ...le gases generated from the battery may be ignited and exploded by sparks For maintenance of the machine disconnect the 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 immediately If it gets in your eyes wash with a large volume of water immedi...

Page 38: ...round cable last While the battery is being charged open all the liquid plugs to discharge the gas Keep the battery away from fire to prevent unexpected explosion Handle the battery carefully to prevent electric sparks If the battery is overheated liquid temperature above 45 stop charging for a while At the completion of charging stop charging immediately The relation between battery charge condit...

Page 39: ...nnected to the engine block of the machine in trouble Remove the clip of the booster cable B connected to the terminal of the normal machine Remove the clip of the booster cable A connected to the terminal of the normal machine Remove the clip of the booster cable A connected to the terminal of the machine in trouble 3 Caution on handling of booster cable Use booster cables and clips of the size t...

Page 40: ...machine Care should be taken during operation When the machine needs checking or maintenance be sure to stop it in advance CAUTION HOT PARTS can burn skin High temperature parts are located in the machine Care should be taken during operation When the machine needs checking or maintenance be sure to stop it in advance Even after the machine stops the inside of the bonnet is still hot Wait until th...

Page 41: ... and protectors Do not put on baggy clothes necklace etc because they are easily caught by projections which may cause injuries CAUTION Handling of waste liquid Waste liquid from the machine should be received in a vessel Do not dispose of waste liquid recklessly as it causes environment pollution Do not throw it on the ground or in rivers lakes sea etc Lubrication fuel cooling water coolant and o...

Page 42: ...ent of fuel filter element 500 hours Checking every 500 hours Replacement of air cleaner element Cleaning of radiator 1000 hours Checking every 1000 hours Cleaning inside of fuel tank Adjust fuel injection nozzle 2000 hours Checking every 2000 hours Measure the engine compression pressure Check the valve clearance Replacement of radiator water if LLC is used Check on nylon and rubber hose Checking...

Page 43: ...ween H and L 2 Replacement of engine oil filter cartridge Replace the engine oil filter cartridge at 50 hours only first time and every 200 hours after second time Remove the drain plug and discharge oil completely in advance Remove the cartridge using filter wrench Insert the new cartridge Screw in the cartridge by hand Once the gasket comes into contact with the face of the seal tighten the cart...

Page 44: ...g the air cleaner wipe off dirt on the element cover When insert the element insert the element completely pressing equal edge of element Parts number of air cleaner cartridge parts number 06020 46335 2 Checking of fan belt Refer to the instruction manual for the engine furnished separately 3 Replacement of engine oil Refer to 8 2 1 Replacement of engine oil See p 39 4 Cleaning of fuel filter elem...

Page 45: ...y Battery Charging Over 1 28 Over charged need adjustment 1 25 1 28 Optimal charging 1 24 1 25 Average Below 1 24 Low charged need adjustment In determining the specific gravity at a temperature other than 20 use the following formula Ｓ20 St ０ ０００７ ｔ ２０ where Ｓ20 is the calculated specific gravity at 20 St is the measured specific gravity ｔ is the battery solution temperature reading 2 Replacement...

Page 46: ... and wash out deposits and water collected inside the tank 2 Adjust fuel injection nozzle 8 8 Checking every 2000 hours 1 Measure the engine compression pressure 2 Check the valve clearance 3 Replacement of radiator water if LLC is used 4 Check on nylon and rubber hose Check on the nylon and rubber hose whether they are hardened or deteriorate Contact distributor or our office to replace the nylon...

Page 47: ...hecking on fuel Drain the fuel tank Checking on battery acid level Replacement of engine oil Replacement of engine oil filter Cleaning on air cleaner element Checking on fan belt Cleaning of fuel filter element Replacement of fuel filter element Checking on battery gravity Cleaning of radiator Replacement of air cleaner element Adjust fuel injection nozzle Cleaning inside of fuel tank Measure the ...