Beruflich Dokumente
Kultur Dokumente
C18443 01504
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INSTRUCTION MANUAL
ALTERNATING CURRENT GENERATING SETS
DCA-220,-400ESEI
• 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.
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.
-1-
SAFETY PRECAUTIONS FOR GENERATORS
In order to ensure safe operation, the following symbols are used for explanation of the
machine operation.
The following symbols, found throughout this manual, alert you to potentially dangerous
conditions to the operator, service personnel, or the equipment.
WARNING: This symbol refers to a hazard or unsafe practice which can result in severe
personal injury or death.
CAUTION: This symbol refers to a hazard or unsafe practice which can result in personal
injury 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 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 instruction manual carefully.
• Do not modify the machine at your discretion, as it affects the safety, performance or the life of
the machine.
• If the machine is modified or it is used incorrectly against this manual or unauthorized parts are
used, the warranty of manufacturer will become invalid.
-2-
SAFETY LABEL
CAUTION:
Instruction manual
• Do not use machine before reading the instruction manual.
• Do access to machine in accordance with the instruction manual when machine is in fault.
• Do consult to authorized person for repair or maintenance to avoid incidents.
-3-
DANGER: ELECTRIC SHOCK can kill.
Do not touch the output terminals during operation to prevent decease due to electric shock.
• Never touch the output terminals during operation. If your 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 the electrical parts in the machine during operation, as it may lead to death due to electric
shock.
• Always close the control 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 OFF the circuit breaker and stop the
machine.
DANGER: CAUTION:
ELECTRIC SHOCK MOVING PARTS can
by leak can kill. cause severe injury.
-4-
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WARNING: DIESEL CAUTION:
FUEL can cause fire HOT COOLANT can
or explosion. cause severe scalds.
Fuel and oil are flammable. Incorrect handling If the radiator cap is opened while the water
results in danger of ignition or fire. temperature is high, steam or hot water will spout
• When fuel needs to be supplied to the machine, out.
be sure to stop the engine. Refrain from smoking. • During operation or immediately after stopping
Keep the machine away from fire. the machine, do not open the radiator cap while
• Do not leave flammable objects (paper, wood the water temperature is high.
chips, etc.) and hazardous objects (oil, powder, • When cooling water needs to be checked or sup-
etc.) near the machine. plied, wait until the engine is cooled (50°C or less
• Wipe off spilt fuel and oil. as measured with the water temperature gauge).
High temperature units are located in the machine. Battery generates flammable gases. Improper
(Note that these units are very dangerous if they are handling may lead to explosion or serious injury.
used incorrectly.)
• Be sure to close the door and lock it during • Battery should be charged in a well ventilated
operation. location. Otherwise, flammable gases are accu-
• If the door needs to be opened during operation, mulated which may be ignited and exploded.
do not get your hands and head in the machine to • When connecting a booster cable, do not jumper
prevent unexpected burns. the terminals (+ and -). Otherwise, the flammable
• When making check or maintenance of the gases generated from the battery may be ignited
machine, be sure to stop the machine. and exploded by sparks.
• The bonnet is still hot even after the machine is • For maintenance of the machine, disconnect the
stopped. Be careful until the engine is completely ground cable on the ground side.
cooled.
The battery acid is dilute sulfuric acid. Improper
handling will cause unexpected burns.
CAUTION: ENGINE
EXHAUST can kill. • When the battery acid gets on your clothes or skin,
wash it out with a large volume of water immediate-
ly. If it gets in your eyes, wash with a large volume
of water immediately and consult your doctor.
Insufficient ventilation may lead to death due to In the worst case, it will put out your eyes.
lack of oxygen or poisoning by exhaust gases.
• Do not use the machine in a place of poor ventila- • For checking or handling of the battery, be sure to
tion or in a place where exhaust gases stays. stop the engine and turn OFF the battery switch in
• Do not use the machine indoors or in storehouse, advance.
tunnel, ship hold, tank, etc. of poor ventilation.
• If it becomes necessary 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 nearby
pedestrians and houses.
-5-
CAUTION: Operator. CAUTION:
Noise.
Do not operate the machine if operator is tired too This machine generates large noise if the door is
much or drinks some alcohol or take some drugs. open. Surrounding to large noise may cause hearing
• Otherwise, it may cause unexpected accidents or trouble.
injury. • Close and lock the door during operation.
• If opening the door is necessary during operation,
During checking or maintenance, be sure to put on be sure to put on the ear protector.
suitable clothes and protectors.
• Do not put on baggy clothes, necklace, etc.,
because they are easily caught by projections
which may cause injuries.
Before connecting this machine to any building’s Do not lift the machine at the support hook or the
electrical system, a licensed electrician must install ladder because it is not strong enough for lifting
an isolation(transfer) switch. and may cause a falling accident.
• Serious injury or death may result without this • When lifting the machine, use the hanger located
transfer switch. at the roof center.
• Keep out under the lifted machine.
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SAFETY LABEL
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Model DCA-400ESEI
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SAFETY PRECAUTION:
• The user must carry out all safety precautions stated in the manual.
• If any statement in this book, especially with regard to safety, does not comply
with local legislation, the stricter of the two shall apply.
1. DCA SERIES
1-1 General
• DCA series generator is intended for generating power source where there is no power source.
• For further details, see “7 Principal data”.
• The engine cooling water refilling port and fuel refilling port are located on the top surface of
the machine.
• The drain plugs for engine oil, cooling water and fuel are located at the base side under the
machine. Tags of their respective names are attached there.
Parts number
1. AC generator
2. Diesel engine
3. Control box
4. Fuel tank
5. Radiator
6. Battery
7. Muffler
8. Intercooler
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Fig. 2 Model DCA-400ESEI E
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1-4 Control switches and meters
• The control switches and meters are located inside the door having a window on the rear of
the machine.
• The control panel is mounted on the bodywork with hinges and is fastened by screws.
Loosening the screws has access to repairing or replacing electrical parts in the control
box.
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1. Starter switch E
The switch is 3-position switch which can be operated with its specific key only.
1) OFF
This switch should be set in this position unless the machine is in operation.
The key can be inserted or pulled out in this position.
2) RUN
This switch should be set in this position when the machine is in operation. In
this position, the preheating system is energized. When the preheat indicator
lamp lights up, reaching the set temperature, it goes off.
Then, turn the key to START.
3) START
This is the position to start the engine. When your hand is released from the
key after starting, it is automatically set in the position of “RUN”.
1) REMOTE
This switch should be set in this position when machine starts with an external
device.
2) LOCAL
This switch should be set in this position when machine starts with the starter
switch.
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 by turning it anti-clockwise
before the engine can be re-started.
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1-4-2 Engine indicators
4. Engine monitor
1 - Engine Speed
• Revolutions per minute is indicated. 1500 min-1 is indicated at 50Hz.
[ NOTE ]: If that would indicate higher temperature, disconnect all loads, decrease the
speed for cool - down operation, and wait until the temperature comes down
to normal value.
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(2) Fuel Level Indicator
That Indicates a fuel level in the fuel tank. All the lights are indicated green when the fuel
is full. The green lights stop indicating one by one as the fuel level decrease, finally the
red light will be indicated when it is only one green light is left. 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.
2 - When the abnormal condition is corrected, the on - and - off indication will stop.
3 - If engine would stop urgently and automatically or stop manually with the abnormal
condition, the abnormal value will be memorized, and then indicated even after engine
is started again.
In this case, keep on pushing the button “RESET” for more than 5 seconds, and the
abnormal indication will be reset to normal.
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(4) Warning Lamps
This monitor indicates the following failures, if any one of them occurs.
② If you want to reset the Trip Meters, push the selector button for more than 1 second,
after selecting each meters.
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(6) The hour meter has an internal battery
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The engine monitor incorporates both a rechargeable internal battery as well as a
charging circuit.
While the generator is not in operation, the engine monitor will still indicate the hours
operated via its internal battery.
While the generator is in operation, the internal battery recharges.
When the generator remains unused for a long period of time, the battery will continue to
lose its charge. Once the charge is exhausted, the hour meter will not indicate hours, and
the battery will need to be recharged. From a completely 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 days
without another charge.
Please refer to the table below to see the relationship between battery time charging
versus length of indication by the hour meter.
5. Preheat lamp
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6. Electronic Governor Controller (in the control box)
When the generator is set in a frequency thet will be pointed in condition of NO-LOAD,
the governor controls the frequency constantly regardless of load.
” Droop Governor Control” means that frequency can be alternative depending on load.
When the rated frequency will be reduced at about 2.0 Hz against NO-LOAD.
Therefore, NO-LOAD frequency should be set at 52.0 to 52.5Hz.
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2. If abnormal operation, push the “DIAGNOSTIC BUTTON”. Continue pushing the
“DIAGNOSTIC BUTTON”, and the failure code will appear (Blinking display).
• While the engine is in operation, if a failure occurs, the “DIAGNOSTIC LAMP” will
light, but cannot indicate the failure code.
Check all of the connections. If connections are sound, Contact the Service department
for repairs.
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1-4-3 Generator controls and indicators
7. Frequency meter
This meter indicates the frequency of the outputted voltage. Make sure that it reads
50Hz when running.
8. Ammeter
This meter indicates the current going to the connected load. It must not exceed the
rated current.
9. Voltmeter
The voltmeter indicates the outputted line voltage.
• Be sure to connect the machine to earth. If not connected to earth, the earth leakage
relay would not work.
• This relay detects a leakage and trips the mains of the three-phase circuit breaker.
The earth leakage relay sensitivity is 30mA. At this time, the red lamp lights
indicating a leakage occurrence. Eliminate the cause of the leakage, press the reset
button, turn the tripped circuit breaker manually to OFF and then to ON.
1-5 Noise
In room or environment where the sound pressure level reaches or exceeds 90dB(A),
use ear protectors.
The maximum sound pressure of the machine is the value specified in EN 31201.
• Model DCA-220………. dB(A)
• Model DCA-400………. dB(A)
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2. TRANSPORTATION, STORAGE AND INSTALLATION
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2-1 Safety precautions for transportation, storage and installation
WARNING
• When lifting or transporting the machine, use only appropriate devices which comply with
the local safety codes and regulations.
• When lifting the machine, use the hanger located at the roof center.
• Before lifting, close and fix the doors, covers and other moving parts and clear away the
machine interior and top.
• The engine exhaust gas is lethal and toxic. Do not operate in tunnel, indoors or others where
the aeration is poor. If it is absolutely obliged to operate in such a place, discharge the exhaust
sufficiently by a ventilating system. Never direct the engine exhaust towards passers-by.
• 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.)
• Fuel and oil are combustible and undiluted anti-freeze solution is inflammable. Do not
smoke while handling 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.
CAUTION
• Install the machine on a well ventilated, horizontal, flat, dry and solid floor. If the floor is
not horizontal enough to keep the machine leveled, consult your sales distributor. When
installing the machine on a trailer, fasten the trailer and fix the wheels by stoppers.
• Do not remove or unduly modify safety devices, guards, covers or insulating materials from
the machine.
• When servicing batteries, always wear protecting clothing and glasses. The battery electrolyte is
a diluted sulphuric acid which can cause severe burns. Get it away from eye, skin and clothing.
• When charging batteries, an explosive gas forms above the cells and escapes through the
vents. Do not smoke near batteries just after having been charged. Never make or break
live circuits or battery terminals, because a spark usually occurs.
• Before checking the machine, stop the engine and wait for at least 10 minutes so that it will
cool down completely. If done while running or immediately after shutdown, you might get
burnt or injured.
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2-2 Transportation
• When lifting or transporting the machine, use only appropriate devices which comply with
the local safety codes and regulations.
Fig. 5
Model L W H
DCA-220ESEI 2120 725 950
DCA-400ESEI 2720 730 990
• When lifting the machine, use the hanger located at the roof center.
Never use the rope hanger because it is not strong enough to lift.
• Before lifting, close and fix the doors, covers, and other moving parts and clear away the
machine interior and top.
• Before transporting by truck or others, wind ropes on the machine to fasten it securely.
• Put covers so as to protect the machine from rain or moisture when transporting.
2-3 Storage
1. Store the generator in a sufficiently ventilated, dry room which is free from frost, salt and dust.
Storage environment: Atmospheric temperature -5 to 35°C (220ESEI : -5 to 40°C),
humidity 85% or lower, altitude 1000m or lower.
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3. If it is impossible to run the engine regularly, extra precautions must be taken.
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1) Consult the instruction manual for the engine.
2) Remove the battery. Store it in the same environment as for the machine. Keep the
battery clean and coat its terminals lightly with petroleum jelly. Recharge the battery
regularly.
4) Clean the generator. Oil or fuel spillage is not allowed. Protect all electrical components
against penetration by moisture.
5) Place silica gel bags, VCI paper (volatile corrosion inhibitor) or another drying agent
inside the generator and close the doors.
6) Close all openings on the bodywork by sticking sheets of VCI paper with adhesive tape.
Before operating again the 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.
2. Measure the insulation resistance of the generator with a 500-V insulation resistance tester.
The resistance must exceed 1 MΩ.
In case of measuringwith an insulation resistance tester over 500VDC current, disconnect
all connectors from the AVR located in the control box before measuring.
3. Replace the fuel filter cartridge and fill the fuel tank.
Vent the fuel system.
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2-4 Installation
2-4-1 Installation
1. Install the generator on a well ventilated, horizontal, even and solid floor. If the floor is not horizontal
enough to keep the machine leveled, consult your sales distributor. When installing the machine on a
trailer, fasten the trailer and fix the wheels by stoppers. Avoid a site exposed to rain or high temperature.
The operating ambient conditions are atmospheric temperature of
-5 to 35°C (220ESEI : -5 to 40°C), humidity of 85% or lower and altitude of 1000m or ower.
If the machine do not conform with the above conditions, consult your sales distributor.
3. 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.)
4. Leave space for operation, inspection and maintenance; at least 1200 mm each on machine
front and rear and sides. See Fig. 6
Fig. 6
[ NOTE ]: If the machine is operated in a smaller space than that shown above, the room
temperature will rise. Please reduce the generator output in such condition. Therefore
proper power reduction is necessary.
If the space required above the machine is not uniform when it is operated indoors, make a decision
so that:
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5. Do not direct the exhaust towards passers-by or residences, etc.
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6. If the generator is operated indoors;
• Install an exhaust pipe of sufficient diameter to let the engine exhaust gas out directly.
• 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 proper.
7. Check that the inner earthing system is in compliance with the local regulations.
• If the machine is earthed in a way different from below, follow the local rule.
• The machine is TN system which must conform to IEC 364-3 and must directly be earthed at
one neutral point.
① Be sure to connect to earth the earthing bar connected to the PE earthing terminal.
1. Near underground utilities such as gas pipe, city water pipe, electric wires, underground
cables.
3. Do not use the high voltage circuit earth commonly earthing the machine.
③ Precautions in earthing
1. Drive the earthing lugs as near the machine as possible in shady and humid soil so that its
top end will sufficiently be buried inside.
2. Be sure to connect the lead-wise securely if the hanger is buried in a place of heavy traffic.
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Model DCA-220ESEI
Model DCA-400ESEI
Fig. 7
- 24 -
2-4-2 Checking after installation
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(1) Check engine oil
(Read the instruction manual for the engine furnished separately.)
① Check the level of engine oil by the dipstick. Make sure the oil level
is always between H and L.
② When it is below the low limit, supply oil immediately.
③ At the same time, check condition of oil by the dipstick.
① Check (to see) that cooling water in the reserve tank is within the
range of FULL-LOW.
② When it is below the low limit, supply (additional) water immediately.
③ Normally, only the water level of the reserve tank needs to be
checked. But, the radiator cap should be opened once a week to
check that water is full in the radiator.
[ 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 evaporated which results in serious
damage to the engine.
① Check the belt for tension and elongation. Also, check it for damage.
Replace if necessary.
② For adjustment or replacement of the belt, refer to the instruction
manual for the engine.
Press (about 6kg) the position shown by arrow mark (middle of belt) with
your thumb.
The bend should be within the range of 10 mm.
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CAUTION
Battery
• 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 immediately
and consult your doctor.
• In the worst case, it will put out your eyes.
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3. OPERATION
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3-1 Safety precautions for operation
DANGER
• When the machine is running, never touch output terminals, internal wiring or other electrical
parts.
• Do not use the machine in a humid place. An excessive humidity is very dangerous.
Never touch the machine if the machine or your body is wet.
• Never fail to perform a test running for the earth leakage relay prior to operation.
• Use cables which are not damaged. Make sure that all electrical connections are securely
fastened. Damaged cables or loose connections might cause electric shocks.
WARNING
• The engine exhaust gas is lethal and toxic. Do not operate in tunnel, indoors or others where the
aeration is poor. If it is absolutely obliged to operate in such a place, discharge the exhaust by a
ventilation facility. Do not direct the engine exhaust towards passers-by, residences, etc.
• 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 while the machine is running but after stopping the engine.
• Fuel and oil are combustible and undiluted anti-freeze solution is inflammable. Do not smoke
while handling or refilling them. Do not get fire or heated object near them.
• Do not spill or leave fuel, oil, anti-freeze solution or cleansing agent in or around the machine.
• Never remove the cover of the output terminals during operation. Before connecting or
disconnecting the cables, switch off the load and machine circuit breakers, stop the machine
and make sure that the machine cannot be started inadvertently.
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CAUTION
• Do not connect the output voltage from the machine to facilities wired to the commercial power
supply.
• Before connecting a load, turn off a corresponding circuit breaker and make sure that the
frequency, voltage and power factor of the load to connect match the generator ratings.
• Before checking the machine, stop the engine and wait for at least 10 minutes so that it will cool
down completely. If done while running or immediately after 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 dB (A), use ear
protectors.
[ NOTES ]: • Do not remove any of, or tamper with, the sound-damping material.
• Whenever an abnormal condition arises, e.g., excessive vibration, noise, odour,
etc., switch the circuit breakers to OFF and stop the engine. Correct the faulty
condition before re-starting.
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3-2 Connecting the load
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3-2-1 Precautions in connecting the load
• The switchgear, switching equipment, load and generator in the plant must be connected in
compliance with local codes of low voltage power installation (1000 or less).
• Before starting or before connecting a new load, make sure that the generator is earthed.
Use the earthing rod or, if effective, use an existing earthing installation. Any protective devices
against electric shock and leakage would be useless if earthing is poor.
• Avoid overloading the generator. The generator is provided with circuit breakers for overload
protection when a breaker has tripped, reduce the concerned load before restarting.
• Never connect the generator output voltage to an installation which is also connected to a
commercial power supply.
• Before connecting a load, turn off the corresponding circuit breaker, and check whether
frequency, voltage and power factor comply with the ratings of the generator.
• Distribution board
If the outlets provided 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 provide a load ON/OFF switch between the power outlets and load. Do not use the
generator circuit breaker to turn on/off the load.
• Before connecting the load, stop the engine and turn off the generator circuit breaker.
• The load connecting cable must not get in contact with other output terminals on the terminal
board.
Non-linear loads draw currents with high contents in harmonics causing distortion in the wave form
of the voltage generated by the synchronous generator.
In general, non-linear type loads generate a high frequency current which adversely affects the
performance of inverters used to feed power voltage to variable speed motors or loads such as
thyristor/rectifier controlled UPS.
Loads most sensitive to voltage distortion include incandescent lamps, discharge lamps,
computers, X-ray equipment, audio amplifiers and elevators.
Consult your sales distributors for measures against the adverse influence of non-linear and
sensitive loads.
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3-2-3 Selection of cables
Use cables having sufficient size in consideration of the allowable current of the cables and the
distance between the machine and the load.
If the load current exceeds the allowable current of cables, 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 and size of cable
and operating current is as follows.
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3-2-4 Connecting the load
1. Check whether frequency, voltage and current conform with the ratings of the generator.
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2. Install for the load cable, without excessive length, and lay it out in a safe way without forming
coils.
3. In case of single-phase load, engage the specified plugs with the specified receptacles (Fig. 8).
220ESEI 400ESEI
Fig. 8
1. Cable clamp
2. Rubber cover
3. PE earthing terminal
1. Output terminal L1
2. Output terminal L2
3. Output terminal L3
4. Output terminal N
5. External protection conduct
terminal PE
Fig. 9
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5. When connecting output terminals (See Fig. 9.)
• Loosen the cable clamp and push the wire ends of the load cable through the clamp and
rubber cover.
• Check the engine oil level or contamination by the dipstick. The oil level must be near to,
but not exceed, the high mark on the dipstick. If required, refill or change the oil.
• If necessary, pour oil up to the specified level through the oil refilling port provided on the
engine.
• For oil change, loosen the oil drain plug from the generator base to drain and, thereafter, pour
oil the same as refilling. Dispose of the discharged oil in compliance with the local regulations.
• After supplying oil, run for several minutes, then stop the engine and make sure that the oil
level is between the high and low marks.
• For the oil volume, see the lubricant volume in the specification table.
• Check that the water level is near the Full mark on the auxiliary tank. Refill if short.
• Use soft water as engine cooling water. Use anti-freeze solution where the atmospheric tem-
perature is low.
Mixing volume of anti-freeze solution = total cooling water volume×mixing anti-freeze solution
concentration. For the total cooling water volume, see the engine specification table.
For anti-freeze solution concentration at the temperature, see “Fuel coolant and lubricants”.
• For making up water, remove the radiator cap. Thereafter, securely install the cap so as to be
airtight.
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3. Checking the fan belt tension E
• Check the fan belt tension and elongation. By a thumb, depress (approx. 6kg) the middle point
of the belt. The deflection must be 10-15 mm. At the same time, check whether the belt is
scratched or not. If abnormal, adjust or replace it. For belt checkup, adjustment and
replacement.
• If the fuel remainder is small, dew might be formed in the tank and mix with the fuel.
To avoid such inconvenience, it is recommended to refill the tank fully after the day’s work.
• Loosen the drain plug from the fuel tank to drain water and sediment from the tank.
Dispose of the sediments, etc. in compliance with the local codes.
• Check whether the electrolyte level is within the specified range or not. If short, add distilled
water.
• If plates are exposed to air for a long time, the battery life would shorten. Keep them dipped.
• Give attention to the connection of battery plus (+) and minus (-) terminals. Reverse wiring of
the terminals will cause damage to generator instruments.
• Check whether the piping is securely tightened or leaky. Make sure that the hoses are not
worn. If abnormal, repair or replace.
• Check whether bolts and nuts are securely tightened or not especially for the air cleaner,
muffler mounting section. If loose, retighten them.
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3-3-2 Instruction for Fuel Source Changeover Device (Three-Way valve)
② Where fuel source is a separate tank placed outside the machine, disconnect the tank
connection plug and change the connection as shown in the Fig.11. And also switch the
lever of three-way valve to the direction of the arrow mark as shown in the Fig.12.
③ Reconnect the piping for the separate tank while the lever of three-way valve is unswitched
as shown in the Fig.10. Switch the lever after completing the reconnection work.
④ Set the suction end in the separate tank at the position of 15 to 20 mm upper than the
bottom level (as shown in Section-A of the Fig.11), so that water or sediment may not
come into the suction.
⑤ While feeding the fuel into the separate tank, do not allow water or dust to come in.
3-4 Starting
1. Insert the key in the starter switch. Turn the key to RUN and the PREHEAT LAMP lights up.
When the lamp goes off, turn the key to START. The switch automatically returns to RUN. If the
key does not automatically return to RUN, manually return it. Otherwise, the starter motor might
be damaged. The duration of preheating differs according to the temperature of cooling water.
And if the temperature of cooling water is high enough, the preheat lamp does not light because
no preheating is required.
• Do not engage the starter for more than 10 seconds at a time; if the engine does not fire, wait
2 minutes before restarting.
• If the engine would not start after several tries, check whether the fuel level is too low, air is
not bled sufficiently or the battery is discharged.
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2. Make sure that the engine warning lamps is extinguished. If alight, stop the engine, check the
item for which it is alight and eliminate the cause. E
• Check the engine indicator for normal readings.
Frequency
50-Hz operation 52.0~52.5 Hz
• Check the voltmeter indication and, when the voltage is deviated from the rated voltage,
please contact your nearest Distributor.
4. Check the voltmeter indication and, if required, adjust with the voltage regulator knob.
Turning clockwise increases the voltage and vice versa.
5. When three-phase voltage is supplied, switch the three-phase circuit breaker to ON.
With single-phase voltage, switch three-phase and single-phase circuit breakers to ON.
6. Test the earth leakage relay for operation. Testing the operation.
2) Normally, the earth leakage relay red lamp lights up and the circuit breaker operates.
3) Press the reset button of the earth leakage relay. Switch the circuit breakers to OFF and then
to ON.
A tripped earth leakage relay is kept tripped until the reset button is pressed or the generator is
suspended.
7. Switch on the load and check the frequency meter and voltmeter once more.
Adjust voltage if necessary.
8. After starting, close the rear frame door. During the operation, keep all the doors closed.
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3-5 During operation
• Indications of the engine monitor, indicator lamps and meters are normal.
• Oil, fuel and cooling water do not spill.
• The engine exhaust color is normal. There are no unusual sound and vibration.
• A light load is not applied for a long time. Otherwise, the engine output might drop.
• Each single-phase load is connected in balance whenever it is used.
• The engine oil level checked weekly is normal. Refill if necessary.
[ NOTE ]: If the circuit breakers are tripped during operation, switch off the load and stop the
engine. Check and, if necessary, decrease the load.
3-6 Stopping
5. If the machine is not used any longer, withdraw and keep the key.
6. Close and lock the rear frame door so as not to be tampered with by third person.
Protection devices and emergency stop devices are provided for protection of the machine against
trouble during operation.
When the warning lamp lights, stop the engine immediately. Check and remove the cause of
trouble.
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Table of protection device
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4. REMOTE CONTROL
This machine is equipped with remote function so as to start and stop by the external signals.
Turn the LOCAL-REMOTE CHANGE-OVER SWITCH to “ LOCAL ” , and start the engine with
the starter switch on this machine.
Refer to P.33 3-4 “Starting” of instruction manual for the details.
ENGINE GENERATOR
(1) Set the starter switch to “ RUN ” position.
(2) Set the voltage regulator to the rated voltage position.
(3) Turn the circuit breaker to “ ON ” position.
(4) Turn the REMOTE-LOCAL CHANGE-OVER SWITCH to “ REMOTE ” position.
Note: External signals must be “ OFF ” during the setting of these switches on this engine generator.
4-4-2 Starting
If the engine cannot start after 3 times of cranking, it will stop the cranking. Then it will send
generator fault signal to external devices. Check and remove the cause of trouble.
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4-4-3 Stopping
(1) Stop-signal ( OFF ) is sent from external devices.
(2) The engine will stop, and it will confirm stop-condition for T4 sec.
E
If the engine cannot stop by the stop-signal, or if you need to stop the engine during remote
operation, turn the LOCAL-REMOTE CHANGE-OVER SWITCH to “ LOCAL ” position, and
turn the starter switch to “ STOP ” position.
(1) In case of remote operation, Keep people away from this machine because it may start
suddenly without prior notice.
(2) While this machine is running, don’t operate the local-remote changeover switch except an
emergency case.
The following protective devices are provided against abnormalities during the operation.
Starting failure : In case that engine cannot start within the setting time.
Low oil pressure : In case that the oil pressure becomes lower than the setting value.
High water temp : In case that the cooling water temp. becomes higher than the setting value.
Emergency shutdown : In case of emergency engine shutdown by the emergency stop
button on this machine.
Overcurrent : In case that the circuit breaker trips.
Overspeed : In case that the engine speed becomes higher than the setting value.
Earth leakage : In case that the eletctric leakage the device act.
Mark ○ : Action
Mark △ : Action after engine shutdown
ASSORTMENT Generator Engine Circuit
Fault Shutdown Breaker
Output trip
Starting failure △ ○
Emergency shutdown △ ○
Overcurrent ○
Earth leakage ○
Overspeed △ ○
If these protective devices have acted, check these causes, and remedy them.
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(1) In case of shutdown due to action of engine protective devices, turn the starter switch
“ OFF ” position to reset these protective devices.
When making inspection and remedy on defected part, close the fuel cock, and disconnected
the battery cable on negative side of this machine for safety sake.
(2) The engine cannot start immediately after the engine stop due to the engine stop
confirmation time ( for T4 sec. ) . The engine can start after T4 sec.
(1) Engine cannot start even after receiving start-signal at remote operation.
(2) The starter motor cannot work, poor cranking. Or the starter motor stopped just
after the starting of engine cranking, etc.
(3) Others
Note
Please refer to the outline drawing and the engine wiring diagram in the delivery
specification of the separate volume.
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4-8 Attached time chart
E
T1 : Preheating time 3S
T2 : Cranking time 5S
T4 : Stopping time 15S
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5. FUEL, COOLANT AND LUBRICANTS
Oil viscosity:
Engine oil viscosity largely affect engine startability, performance, oil consumption, speed of
wearing and occurrence of seizure, etc. Using lubricants whose viscosity selected according to
the atmospheric temperature is important.
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 have high fluidity at low temperature.
5) Must have low sulfur content.
6) Must have little residual carbon.
In fuel other than the specified one is used, engine function will be lowered.
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This machine is designed to use either Number 1-D or Number 2-D diesel fuel.
However, for better fuel economy, use Number 2-D diesel fuel whenever possible. E
At temperatures less than -7℃, (20oF), Number 2-D fuel may pose operating problems
( see “Cold Weather Operation” which follows). At colder temperatures, use Number
1-D fuel (if available) or use a “winterized” Number 2-D (a blend of Number 1-D and
Number 2-D). This blended fuel is usually called Number 2-D also, but can be used in
colder temperatures than Number 2-D fuel which has not been “winterized”.
Check with the service station operator to be sure you get the properly blended fuel.
Note that diesel fuel may foam during a fill-up. This can cause the automatic pump
nozzle to shut off even though your tank is not full.
Cooling water :
Always refer to the chart to determine the correct cooling water to antifreeze solution
mixing ratio.
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6. PERIODIC CHECKUP AND MAINTENANCE
WARNING
• Before checking or maintaining the machine, stop the engine, wait for it to cool down and
remove all loads from the machine. Make sure that the machine would not accidentally start.
Otherwise, you might be dead or injured by electric shock, burn, catching of hand or clothing,
etc.
• Do not carry out work which will produce heat near fuel, oil, anti-freeze solution or combustible
substances. If such is absolutely required (steam washing, for example), keep away combustible
substances. Keep a fire-extinguisher in the vicinity.
• Take safety precautions against fire. Fuel, oil and anti-freeze solution are combustible. Handle
them with care. When handling them, do not smoke or do not get naked flame near them. Keep
a fire-extinguisher in the vicinity.
CAUTION
• Do not use combustible solvents or carbon tetrachloride for cleaning the machine or parts. Take
safety precautions against toxic fumes of cleansing agent.
• When checking or maintaining, protect the air filter, electrical parts, meters, etc. from moisture or
humidity. Pay attention so that moisture humidity will not penetrate any part.
• When checking or maintaining, 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, electrical parts and terminals shall not be splashed with water.
• Before removing the radiator cap, stop the engine and wait for at least 10 minutes for it to cool
down. If done while, or immediately after the end of, running, you might get burnt or injured.
• When servicing batteries, always wear protection clothing and glasses. The electrolyte is a
sulphuric acid which can cause severe burns. Get it away from eye, skin and clothing.
• When charging batteries, an explosive gas forms above the cells and escapes through the vents.
Do not smoke near batteries being, or just after having been charged. Never make or break live
circuits or battery terminals, because a spark usually occurs.
• Do not leave tools, parts, rags etc. in or on the machine. Do not leave rags, paper, etc. near the
air intake port of the machine.
• All sound-damping materials of the machine shall be normal. If damaged, repair them to prevent
the sound pressure level from rising. Do not remove or tamper with them.
[ NOTES ]: • Do not reuse gaskets, O-rings, packings, etc. removed for checkup or maintenance.
• Do not remove, tamper with or remodel covers, protective devices, etc. without our
permission. Use only genuine parts for replacement, repair, supply, etc.
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• Use only the correct tools for maintenance and repair work. After checkup or
maintenance, carry out a test run to make sure that the generator, controls, circuit E
breakers, etc. operate properly.
The periodic checkup and maintenance are outlined. Read the relevant section
beforehand. Only personnel so qualified are allowed to carry out checkup and
maintenance.
• Routine checkup and maintenance items for the engine are described here.
For further details, see the instruction manual for the engine.
• The “Long Interval” checks must include the “Shorter Interval” checks.
On the engine system, main checking items only are shown in this manual.
For details, refer to the instruction manual for the engine furnished separately.
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6-2-2 Checking/every 250 hours
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 terminal and output terminal for measurement.
The result must be more than 1 MΩ. Otherwise, there is a risk of electric shock or fire.
Consult the distributor.
In determining the specific gravity at a temperature other than 20℃, use the following formula:
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6-2-3 Checking/every 500 hours
DCA-
DCA-400
400ESEI
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(4) Replacement of partial oil filter element (400ESEI)
① Loosen the oil drain plug on the filter and drain
oil in the filter. Then tighten the drain plug to the
specified torque after draining oil.
Torque : 44 Nm (4.5 kgm)
② Remove the center bolt and replace the element.
Discard the used element.
③ Clean the oil passage of the center bolt.
④ Apply engine oil to the gasket and install it in the
groove. Install the new element in the case and
tighten the center bolt to the specified torque.
⑤ Install the oil filter with the drain plug of filter
case faced rear. Drain plug
Torque : 49 Nm (5.0 kgm)
DCA-
DCA-400ESEI
400ESEI
① Wipe clean around the PCV filter cap taking care so that
no foreign particles entry. Remove the PCV filter cap.
② Remove the PCV filter element.
③ Install the new PCV filter element.
④ Install the PCV filter cap.
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(6) Replacement of fuel filter element (pre filter and main filter)
① Loosen the drain plug and air bleeding plug, and drain the fuel in
the filter.
E
② Use a specified filter wrench to remove the cartridge.
③ Replace the O-rings of the cartridge and drain plug with new ones.
Insert a new element into cartridge and apply fuel to the O-ring.
Turn the new fuel filter until the filter O-ring comes in contact with its
sealed face.
Use a specified filter wrench to turn in the fuel filter.
Torque (Cartridge) : 29.4 Nm (3 kgm)
Torque (Drain plug) : 1.5 to 2.5 Nm (0.15 to 0.25 kgm)
DCA-
DCA-220ESEI
220ESEI DCA-
DCA-400ESEI
400ESEI
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6-2-4 Checking/every 1000 hours
- 50 -
6-2-5 Table of periodical maintenance and checking
E
: Check or Clean 〇: Replacement
- 51 -
7. TROUBLESHOOTING
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8. PRINCIPAL DATA
E
8-1 Readings on gauges
Frequency 50 Hz
Voltage indicates
Phase-to-phase
voltage V
8-4 Limitations
Maximum ambient
temperature………………………………………...........................................40°C(220ESEI)
35°C(400ESEI)
Maximum altitude……………………………………………………………… 1000m Maximum relative
air humidity………………………………………….................................…...85%
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8-5 General specifications
1. Engine
Electrical system……………………………..V 24
Batteries:
• Number 2
• Voltage……………………………..……....V 24
2. Generator
Frequency…………………………………...Hz 50
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DCA type 220 400
E
Insulation………………………………....Class F
3. Unit
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