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Denyo DCA-600P, Instruction Manual

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Denyo DCA-600P Instruction Manual Download Page 3

 

 

 

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FOREWORD 

    

 

•  We are very thankful for your special choice of our MACHINE in the market. 

 

•   Please read this manual carefully and understand for proper use this machine. 

 

•   Please keep this manual at your prescribed location where operator can always take this manual. 

 

•   If you have any question or problem on this operation, please contact your nearest Distributors. 

 

•   Pay special attention to statements preceded by the following word. 

 

 

 

  

DANGER

:  indicates an imminently hazardous situation which, if not heeded, will result in 

death or serious injury. 

 

  

WARNING

: indicates a potentially hazardous situation which, if not heeded, could result in 

death or serious injury. 

 

  

CAUTION

: indicates a hazardous situation which, if not heeded, may result in minor or 

moderate injury or damage to the machine. 

 

[ NOTE ]

: indicates useful information for the machine operations. 

 

 
 
 
 
 
 
 
 
 
 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 

Summary of Contents for DCA-600P

Page 1: ...E N G I N E D R I V E N A C G E N E R A T O R DCA 600P IMPORTANT READ AND UNDERSTAND THIS MANUAL CAREFULLY BEFORE USE OF THIS MACHINE KEEP THIS MANUAL FOR YOUR FUTURE REFERENCE 2 8 5 Nihonbashi horid...

Page 2: ...3 2 2 Non liner and sensitive loads 31 3 2 3 Selection of cables 32 3 2 4 connecting the load 33 3 3 Grounding 34 3 4 Before starting 34 3 4 1 Checkup before start up 34 3 4 2 Instruction for Fuel De...

Page 3: ...lease contact your nearest Distributors Pay special attention to statements preceded by the following word DANGER indicates an imminently hazardous situation which if not heeded will result in death o...

Page 4: ...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 CAUTION may also cause death or s...

Page 5: ...nstruction manual B9111 0220 DANGER Electric shock B4510 0250 WARNING Fire explosion B9045 0100 CAUTION Burn B9111 0240 CAUTION Moving parts B9040 0050 CAUTION Hot coolant B9041 0020 CAUTION Engine fa...

Page 6: ...rol panel and tighten the fixing bolts before operating the machine Always close the side door and lock it before operating the machine When opening the control panel for voltage selection etc turn OF...

Page 7: ...the engine is completely cooled Battery generates flammable gases Improper handling may lead to explosion or serious injury Battery should be charged in a well ventilated location Otherwise flammable...

Page 8: ...ecessary during operation be sure to put on the ear protector CAUTION Connection to house wiring Before connecting this machine to any building s electrical system a licensed electrician must install...

Page 9: ...ine operation and maintenance according to the instructions Observe all the safety precautions including ones stated in the manual Entrust the repair to trained personnel of Denyo or its distributor w...

Page 10: ...ipment radiator battery option fuel tank option and other auxiliary equipment See Fig 1 1 3 Machine appearance and internal component devices There are the hanger at the base on its both sides When li...

Page 11: ...in plug 2 Radiator cooling water refilling port 7 Engine exhaust port without muffler 3 Fuel tank refilling port with fuel tank 8 Engine exhaust port with muffler 4 Fuel drain plug with fuel tank 9 Fu...

Page 12: ...trical parts in the control box 1 4 1 Engine start stop controls Fig 3 Model DCA 600P Parts number Parts number 1 Frequency meter 8 Pilot lamp 2 Ac ammeter U 9 Engine indicator 3 A Ac ammeter V 10 Coo...

Page 13: ...tton This button keep on pushing to start the engine 3 Emergency stop button The stop button is a push button to stop the engine in case of an emergency When the button is pressed it must be unlocked...

Page 14: ...0 1800 min 1 is indicated at 50 60Hz 2 Engine Oil Pressure 3 0 to 6 0 100 kPa should be indicated at normal engine operation Higher value would be indicated in cold condition immediately after engine...

Page 15: ...5 to 405 6 295 to 345 5 245 to 295 4 195 to 245 3 165 to 195 2 120 to 165 1 0 to 120 3 Alarm and Memory at Abnormal Condition When any abnormal condition occurs in engine oil pressure battery charging...

Page 16: ...ressure OIL PRESS If this lamp goes on during operation the emergency stop device immediately operates to shut down the engine automatically 5 Hour Meter When you turn the starter switch to RUN positi...

Page 17: ...etely exhausted state recharging the battery for 30 minutes will only result in a 30 minute charge to the battery However if charged for 3 hours the hour meter will indicate hours for more than 10 day...

Page 18: ...ernor Control Frequency is constant regardless of load When the generator is set in a frequency thet will be pointed in condition of NO LOAD the governor controls the frequency constantly regardless o...

Page 19: ...Warning condition the ECM causes the warning lamp to come ON The warning lamp indicates that a fault has been detected by the engine monitoring system No further action by the ECM or the engine occurs...

Page 20: ...105 C 221 F 10 seconds Engine Shutdown Always On 108 C 226 F 10 seconds Engine Overspeed Warn Operator On 2000 RPM 1 second Action Alert Always On 2050 RPM 0 second Engine Shutdown Always On 2140 RPM...

Page 21: ...device interrupting the mains when an overload or a short circuit occurs at the load side connected to the receptacles It also serves as a main switch for supplying energy from the generator to the l...

Page 22: ...g or refilling them Do not get fire or heated objects near them Do not spill or leave fuel oil anti freeze solution or cleansing agent in or around the machine If spilled be sure to wipe off properly...

Page 23: ...because it is not strong enough to lift Before lifting close and fix the covers and other moving parts and clear away the machine interior and top Do not slip under a lifted machine Before transporti...

Page 24: ...he generator kept unused for a long time remove the plastic bag VCI paper from the openings and silica gel from inside and check the generator thoroughly Further maintain the following items 1 Consult...

Page 25: ...oid a dusty site If it is inevitable provide protective devices 3 Do not operate the machine in an atmosphere containing toxic or combustible gas Otherwise fire or explosion might occur in the machine...

Page 26: ...ngine exhaust gas out directly 7 Check for sufficient ventilation and position the ventilator so that the exhaust from the machine will not be re circulated in the room even if the ventilation is prop...

Page 27: ...25 Model DCA 600P Fig 7 1 Oil level gauge 6 Alternator 2 Oil refilling port cap 7 Fuel pre filter 3 Oil drainr 8 Fuel filter 4 Expansion tank cooling water 9 Air cleaner 5 Fan belt...

Page 28: ...the filler cap NOTE When closing the radiator cap after water level is checked or water is supplied turn the cap fully clockwise so that it can be firmly tightened Otherwise cooling water is evaporat...

Page 29: ...ressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indica...

Page 30: ...ir cleaner muffler turbo charger etc disconnection of electric wiring short circuit and loose terminals 10 Removal of foreign objects in machine Check that tools and cleaning cloth are not left in the...

Page 31: ...Do not operate the machine in an atmosphere containing toxic or combustible gas Otherwise fire or explosion might occur in the machine Example Near volatilizing paint solvent Do not refill fuel or oil...

Page 32: ...shutdown you might get burnt or injured Do not operate the machine beyond the range given in the main specification table In room or environment where the sound pressure level reaches or exceeds 90 d...

Page 33: ...vided on the machine are insufficient provide an auxiliary switchgear and connect it with the output terminals The distribution board must comply with the local rule of power installation Be sure to p...

Page 34: ...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...

Page 35: ...ut terminal V 6 Output terminal W 7 Output terminal O Fig 8 3 When connecting output terminals See Fig 8 Remove the protection cover of output terminals Loosen the cable clamp and push the wire ends o...

Page 36: ...securely and apply insulating tape to the connection Do not burry the connection in the ground 4 Avoid the places within 2m of lighting conductor grounding location for burying of grounding rod 5 Do...

Page 37: ...tank of this machine is the option Check the fuel level Refill if required If the fuel remainder is small dew might be formed in the tank and mix with the fuel To avoid such inconvenience it is recomm...

Page 38: ...g and change the connection as shown in the Fig 9 2 Caution on Setting For the piping use oil resistant hose of 9 6 mm or more internal diameter Under Cold environ ment use the hose of lager diameter...

Page 39: ...eliminate the cause Check the engine indicator for normal readings 3 Check whether the frequency meter read as shown below or not Frequency Isochronous Droop 50Hz operation 50 0Hz 51 3 51 8Hz 60Hz op...

Page 40: ...ration switch off the load and stop the engine Check and if necessary decrease the load 3 7 Stopping 3 7 1 Stopping method 1 Switch the load circuit breakers to OFF 2 Switch the generator circuit brea...

Page 41: ...ent flows the device acts fuel level failure FUEL LEVEL Optional apparatus When fuel supply is necessary because of fuel shortage the device acts air filter blinding AIR FILTER When replace or cleanin...

Page 42: ...e fuel the minimum TBN of the new oil must be 10 times the fuel sulfur level The TBN is defined by ASTM D2896 The minimum TBN of the oil is 5 regardless of fuel sulfur level Illustration 19 demonstrat...

Page 43: ...f normal Fuel selection The following specific advantages are required for the diesel fuel 1 Must be free from minute dust particles 2 Must have adequate viscosity 3 Must have high cetane value 4 Must...

Page 44: ...uel should also be free biological growth For long term storage of fuel the recommendations given in ASTM D975 must be followed where appropriate The use of fuels which do not conform to the above sta...

Page 45: ...aintaining cover the replacing parts and generator openings with clean cloth paper tape etc so that the parts and generator interior will not he contaminated or moist ened Particularly the air cleaner...

Page 46: ...cleaner element Measurement of generator insulation resistance once a month Checking on battery specific gravity 500 hours Checking every 500 hours Inspection adjustment and replacement of alternator...

Page 47: ...he control box before measuring Remove the load cables and earthing cable for the leakage relay Turn on the 3 phase circuit breaker connect the insulation resistance tester between bodywork earthing t...

Page 48: ...It should be 625 N 461 lbf To Adjust the tension proceed as follows Loosen the alternator to obtain the correct belt tension and tighten the bolt setscrews to 70 Nm 51 63 lbf ft Fit the access panel...

Page 49: ...seal on the drain plug If necessary replace the O ring seal Remove the filter bowl 1 and the filter element from the engine Discard the old filter element and the old O ring seal Clean the filter bow...

Page 50: ...hape as the tab 2 Align the insert to the tab Install the element into the filter bowl Install the new O ring seal 4 Lubricate the threads on the bowl assembly with CV60889 Special Lubricant Install t...

Page 51: ...ediately NOTE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system componen...

Page 52: ...lace about 1 5m away to prevent damage to the fin or tube 6 Replacement of air cleaner element The element should be replaced referring to Cleaning of air cleaner element Parts number of air cleaner e...

Page 53: ...ng every 1000 hours Checking every 250 and 500 hours is also required Cleaning inside fuel tank Only with fuel tank Drain the fuel in the fuel tank completely and wash out deposits and water collected...

Page 54: ...of battery Inspection and adjustment of engine valve lash Inspection Adjustment and Replacement of alternator and fan Belt Replacement of engine oil Replacement of engine oil filter element Cleaning...

Page 55: ...53 6 TROUBLESHOOTING...

Page 56: ...is cold the pressure may be higher during starting 7 2 Setting of switches Switch Function Breaks at Unit Engine oil pressure Alarm 3 0 100kPa Shut down 2 0 100kPa Engine coolant temperature Alarm 108...

Page 57: ...age V 24 Capacity 210H52 2 Oil circuit capacity 62 Cooling circuit capacity 61 Fuel tank capacity approx 490 Optional opparatus 2 Generator Type DF 6600P Rated output 50 60Hz kVA 550 600 Voltage range...

Page 58: ...ry approx kg 4790 7 6 Conversion list of SI units into UK US units Voltage class 200V 400V 3 Unit without optional part and lifting hunger 1 bar 14 504 psi 1 kW 1 341 hp UK and US 1 m 3 281 ft 1 N 0 2...

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