No. C1843 00904 INSTRUCTION MANUAL DENYO DIESEL GENERATING SETS Before using, be sure to read this manual for the sake of 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-—-220ESM 4-2-2, Kamitakada, Nakano-ku, Tokyo, 164-8510, JapanFOREWORD * Your machine is a portable type diesel generating set. * Do not install, operate or repair this machine without reading this operating manual. * This generator set (machine) must be operated by a person having sufficient knowledge and skill for the sake of safety. Notes on instruction manual * This instruction manual explains correct 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" "AX WARNING? and "ZA\CAUTION’ must be read thoroughly. * Keep this manual in the case behind the rear door for future reference. * Read the contents of the warranty card attached to the machine. + If this manual becomes illegible by spot or damage, contact distributor or our office to get new manual.10. I. 12. 13. Safety Precautions = - Construct jon 2-2 Operating panel gt — Contents — jutline and part nan con jeter: a 2-5 Fuel piping selector Trans} Cont Opes Pare yy Han Peri Trot Lon: Sy ie ogy In HL 2 3 4 r J hecking pr “3 5 ra “1 If 1 ies trol se. OL switches and controllers portation and installation rtation of machine cL [nstaflation’3°natht the load ec Yelbod for, select ing output voltage Cables, to be used fomect ing the: [oad Earth Teak ation Startup {andl ng during operation ut down Protection device 11g) operation — ‘reparation for paral aralle] operation recault ions Shut down 4 4 fgite oif ol Ing ra Sele Wa | ling of battery Caution.on battery charge Connection of booster cable, and installation odical checking and maintenat i 1 Maintenance schedule 4 Ghecking/Lirst 0, bo 3 Chee! kingvevery a hi 1 fheckine/every 9 6 ine el urs ours: 0 hours: brication, cooling water and fuel Shecking/every {Bb Rots Table o1 ubleshoot ing g-term storage dati > [spiel ications a ) fenerator, specifications (for custom voltage) lu ine drawing ions instruction manual Automatic oiler Generator conection diagr Engine wiring diagra Controller wiring diagram m ge relay and Grounding periodical maintenance and checking1. Safety Precautions 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. A\ WARNING: ‘is symbol refers to a hazard or unsafe practice which can result in severe personal injury or death A\ 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Safety label Safety labels are attached to the following positions of the machine. * Keep these safety labels clean at all times. * When safety labels are spoiled or lost, contact 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 : electric shock [C9211 0120_[ 6 [Warning : hot coolant —|B9051 0020 2 [Warning : hot surfaces [B9052 0010 | 7 [Warning : diesel fuel [C9015 0000 3__|Caution : support hook |B9121 0020A] 8 [Caution : exhaust gas |B9052 0000 4 [Caution : stacking [C9111 0020 | 9 [Safety instruction fB92tt 0110 5_|Waming : moving parts [B9050 0010 Ll c BESS. [e aa] Ok SAH \ onnm [J lewA\ 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 storehouse, tunnel, ship hold, tank, ete. of poor ventilation, * Tf 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.ZX WARNING 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.A\ WARNING ELECTRIC SHOCK by leak can kill. Improper grounding may lead to death due to electric shock. * Be sure to execute the grounding of the machine and the load according to the local rule. A\ WARNING MOVING PARTS can cause severe injury. WH 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 the door needs to be opened during operation, do not get your hands and head in the machine to prevent them from being caught in the machine which may lead to injury. * When making check or maintenance of the machine, be sure to stop the machine in advance.A\ WARNING DIESEL FUEL can cause fire or explosion. @ Fuel and oil are flammable. Incorrect handling results in danger of ignition or fire. (‘Z * When fuel needs to be supplied to the machine, 4 4 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, ete.) near the machine. * Wipe off spilt fuel and oil. A\ WARNING HOT COOLANT can cause severe scalds. Wi ii the radiator cap is opened while the water temperature is high, 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 (60°C or less as measured with the water temperature gauge).A\ CAUTION Stacking I Improper stacking of machines may cause falling or dropping accidents. When stacking other machines on this machine, be sure to observe the following points. * Check that the bonnet of the machine is free from damage and that the fixing bolts are not loosened and missing. * Put the machine horizontally on a solid foundation which withstands the weight of stack ed machines. * Machines can be stacked up to 2 stages. ‘The weight and size of stacked machines should be less than those of this machine. “el | * Using square timbers as shown right, put each 4 machine making sure that the weight is even. a I Do not operate the machines in the state of phe WT stacking to prevent falling or dropping accidents. A\ 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 the door needs to be opened during operation, do not get your hands and head in the machine to prevent unexpected burns, * When making check or maintenance of the machine, be sure to stop the machine. * The bonnet is still hot even after the machine is stopped. Be careful until the engine is completely cooled.Z\ CAUTION BATTERY MH Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * Battery should be charged in a well ventilated location, Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and —). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. * For maintenance of the machine, disconnect the ground cable on the ground side. I 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. Ml For checking or handling of the battery, be sure to stop the engine in advance.A\ CAUTION Operator ® Do not operate the machine, if operator is tired too much or drinks some alcohol or take some drugs. * Otherwise, it may cause unexpected accidents or injury. I During checking or maintenance, be sure to put on suitable clothes and protectors, * Do not put on baggy clothes, necklace, ete., because they are easily caught by projections which may cause injuries. A\ CAUTION Ne e WM This machine generates large noise, if the door is open. Surrounding to large noise may cause hearing trouble. * Close and lock the door during operation. If opening the door is necessary during operation, be sure to put on the ear protector. A\ CAUTION Connection to house wiring @ Before connecting this machine to any building's electrical system, a licensed electrician must install an isolation(transfer) switch. * Serious injury or death may result without this transfer switch.A\ CAUTION Transportation HH 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. WH Do not lift or do not transport the machine during operation, as it may cause damage to the fan or serious trouble. * When loading the machine on the truck or the like, fix the machine firmly by support hooks on the both side,2. Construction 2-1 Outline and part names2-2 Operating panel, control panel and part names DELLOGIPOOH O_O Be sod [al uit per) fs Te CONTROL PANBL OPERATING PANEL No, NAME Me, NAME 1 [Reaugncy werex 3 1[encie TwprcatoR 2 [ac smecoree Tadicater cee aneren coms-ovee SwITC3] TT Thane "Ou present ac vounenee Pua aeiag rete (CLUDE WOLTER cHANGE-OvER SHTTE| Ws jOLTAGE REGULATOR 3 [a] 5 [ciacuit SRBAKeR G-PHASE) a 6 [CIRCUIT BREAKER (1-PHASE) | Fuel Level Indicator T 6 7 PILOT LANP, [3 2[StaRTER SWITCH EARTH LEAKAGE RELAY [33 PREHEAT LAMP PANEL LIGHT 3 4[eMeRGENCY STOP BUTTON) OfPaNeL Ligur switca 35] THROTTLE swiTcA i] sinGte-paR ance-oven swiTesi [3 6] SPHRD CHANGE-OvRR SHITE i 2|svwcHROWIZING LAMP 3|FREQUENCY CHANGE-OVER SWITCH Erte2-3 Meters Engine indicators Number [adicator 5 Unit Indicator Indicator Sel Button Warning Lamp Indicator Q) Number Indicator ‘That indicates the numerical values of engine speed, engine oil pressure, run hours, battery charging voltage, or engine coolant temperature, Each indication is selectable by pushing the " SELECT " button Unit Indicated Items min engine speed X 100KPa engine oil pressure hour integrating time Vv battery charging voltage °C (WATER) _| engine coolant temperature C (on) engine oil temperature AUTO automatic indication change Unless " SELECT " switch is pushed, " Engine Speed" is always indicated immediately after engine starts SeWith "AUTO" selected, indication is automatically changed every three (3) seconds. -1- Engine Speed Revolutions per minute is indicated. 1500min ~! is indicated at 50Hz and 1800 min ~* is indicated at 60Hz. -2- Engine Oil Pressure 3 to5 X 100 kPa (3 to 5 kg/cm!) should be indicated at normal engine operation. Higher value would be indicated in cold condition immediately after engine starts. Conduct a warming - up operation until it indicates normal value. - 3 - Integrating Time ‘That indicated total running hours. - 4 - Battery Charging Voltage ‘That should indicate more than 26V at engine running. -5 - Engine Coolant Temperature ‘That should indicate a temperature between 75 to 95 °C at engine running. 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. - 6 - Engine Oil Temperature That should indicate a temperature between 70 to 120 °C at engine running. 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. 1 Automatic Indication Change Each of the above - started indications from the - 1 - to - 6 - changes by turns every 3 seconds.(2) Fuel Level Indicator ‘That Indicates a fuel level in the fuel tank. Green lamps will turn on with full tank. ‘As the fuel level drops, the numbers of the turn - on lamps decrease and at the sametime the color 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 feul level. | ‘Numbers of Fuel level Jamps turned-on | Color of lamps oO | 6 all green 320 to full | 3 all green 280 to 320 4 all green 220 to 280 ted on Ist lamp from bottom 3 green on 2nd & 3rd lamps | 165 to 220 2 all red 120 to 165 1 red 0 to 120 (8) Alarm and Memory at Abnomal Condition When any abnormal condition occurs in engine oil pressure, battery charging voltage, engine coolant temperature or engine oil temperature, the indication will change as the followings ; = 1 - The indication changes to "AUTO" , and the abnormal value and unit will be indicated lighting on and off. -2- When the abnormal condition is corrected, the on - and - off indication will stop. =3- Iengine 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 "SELECT" button for more than § seconds, and the abnormal indication will be reset to normal,Generator indicators (1) Frequency meter ‘This meter indicates frequency of the output voltage. Make sure that it indicates 50Hz or 60Hz during operation. ‘This meter indicates AC current flowing 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. meter change-over switch When running either the three phase or single phase load, this meter indicates the current flowing into the load. ‘The current of each phase can be checked using the ammeter change-over switch. (3) AC voltmeter This meter indicates AC output voltage. Make (— sure that it indicates rated voltage. Line-to-line voltages can be checked using the voltmeter change-over switch. Voltmeter change-over switch = 16 -Indication/alarm lamp (1) Preheat lamp Preheating starts automatically once the starter switch is turned to the "RUN" position, ‘The preheat lamp will automatically turn on once the preheat lamp turns off, preheating is completed. (The preheat lamp will not turn on when the engine water temperature is 10°C or more. ‘The lamp will turn on whenever the engine water temperature is 10°C or less, and will turn on for 20 seconds or less depending on the temperature. ) (2) Warning Lamps ‘This monitor indicates the following failures, if any one of them occurs. ® High jacket water temperature (WATER TEMP) WATERTEMP his lamp goes on when the water temperature rises abnormally. If ® Oil pressure failure (OTL PRESS) If this lamp goes on during operation, the emergency stop device the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. OIL PRESS immediately operates to shutdown the engine automatically. AIRFILTER © Al filter blinding (AIR FILTER) When the air element is blinded, this lamp goes on. Indicating that ES the element should be immediately cleaned or replaced. @ Oil fiter blinding (OIL FILTER) When the oil filter is blinded, this lamp goes on. Indicating that the OIL FILTER oil filter should be immediately replaced and also replace the engine oil concurrently.2-4 Use of switches and controllers Switches ()Starter switch Be Functions: © Stop Wie . ; ‘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. 3 ae @ Run SS se This switch should be set in this position when the @ Start ; ; ser ae This is the position to start the engine. When your hand is 3% ae ee released from the key after starting, it is automatically set in the position of "RUN". (2) Emergency stop button Use this button in case of emergency that makes the engine stop. In case that this button is pushed, a point of contact is locked and the engine stops. [Note] ‘This button is a push-locked type and the contact is released in case of rotating it to clock direction. (See the fig of the left) The engine doesn't re-start unless the contact is, released. aie(3) Speed change-over switch Functions: START ® START / AUTOMATIC IDLING ee When the engine is started with the speed change~over Low Sy HIGH switch set at this position, the engine idles for about 20 ® seconds and then automatically changes over to high speed operation. When starting the engine, set the switch in this position. @ Low ‘When the switch is turned to this position, the engine continues to idle. When stop of the engine, turn the speed change~over switch to this position and put the machine in cooling operation for a few minutes before turn the starter switch to "OFF" position. ® HIGH Setting the switch to this position releases the automatic idling function, allowing the engine to be run at the speed set by the throttle switch (4) Single parallel change-over switch Tn case of operation of single unit, turn this switch to the simett ramet] side of "SINGLE". In case of parallel operation, turn the switch to the side of "PARALLEL", In the parallel mode, the synchronizing lamp and the cross current compensation circuit function to enable the parallel operation, If the switch is in the parallel mode at the time of single operation, output voltage will drop according to load size While, if the switch is in the single mode at the time of parallel operation, cross current will occur between the generators to trip the circuit breaker.(5) Frequency change-over switch Cee ‘This is for switching the frequency fromyto 50Hz or (atc tron toffrom 60E2. | s0He 60H (6) Panel light switch ‘This is the switch to tum on the panel light. (7) Circuit breaker This is a main switch to supply power to a load. (ow) When the load is shorted or in the state of overload, it trips to protect the generator against trouble. [Note] Ea? Do not use this circuit breaker to turn ON/OFF the load, to prevent damage to the circuit breaker. When it trips with overcurrent, 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 and overcurrent relay (1) Voltage regulator ‘This regulator is used to control the output voltage. Turn the regulator to clockwise to increase the voltage and counter clockwise to decrease it. Adjust the voltage to the rated voltage with this regulator. ounce nesuaon (2) Throttle switch ‘Turn the switch toward the "HIGH" side to increase the WEAF cara Se speed and toward the "LOW" side to decrease it. ae This relay is used to trip the circuit breaker (for 3 phase) when overcurrent flows into the circuit. [Note] Do not change the set value unnecessarily.ELECTRONIC GOVERNOR CONTROLLER (ECU Control Panel) This machine is equipped with an electronic governor. ‘The control box contains the Electronic governor controller, adjustment switch, & trimmer. You should not try to adjust the electronic controller for it has already been set in the factory. (1) Isochronous - Droop Change-Over Switch This switch is used to select the control characteristic of Pees the electronic governor. rapete? The governor is set to Isochronous Control when it is tena! shipped. For a detailed explanation of how this works, refer to “5, Method of Operation”. (2) Droop Adiustment Trimmer a= ‘This device is used to adjust the Droop (Speed Regulation Ratio). (8) Failure Diagnosis Switch ‘This switch is used to find engine faults. fow It is set to the “OFF” position in normal use. O)se or (@) Failure Diagnosis Display Lamp ‘These lamps indicate engine failures. a MR BS AT ‘The Failure diagnosis switch is normally in the “OF! DIAGNOSTIC. LAMP position, 6 Normally, when the starter switch is tured to the “RUN” © position, the RED and GREEN lamps will initially turn on, but once the engine is running, both lamps should turn off. When either the “RED” or “GREEN” lamp remains on, it indicates some faults in the engine. When the “RED” lamp remains on: The engine can NOT be driven due to a major fault. When the “GREEN” lamp remains on: The engine can be used despite having a minor failure, but it may influence the longevity of the engine. ‘When the red lamp blinks, Stop the engine and repair the fault. The fault can be located by turning the failure diagnosis switch on and reading the code for said failure. For a more detaited explanation, refer to the “10,Cause of Breakdown and Corrective Measures” (6) Reset Button ray This button allows for access to past faults and for resetting RESET the Failure Diagnosis Display Lamp. on2-5 FUEL PIPING SELECTOR (2) Description of the device ‘The "Fuel piping selector" selects the supply of fuel to the engine from the machine loaded fuel tank or directly from the out side machine tank through its change~over valve. (2) Operating procedure © The fuel piping and the change—over valve lever are set as shown in Fig.1 before the machine is shipped. If the fuel is to be supplied from the machine loaded tank, operate the machine with setting left as such, @ If the outside machine tank is to be used for fuel supply, remove the two plugs for connection of the outside machine tank and pipe it as illustrated in Fig.2, then turn the change~over valve in the arrow indicated direction before operating the machine. @ If the outside machine tank is not used with the piping removed from it, be sure to return the change-over valve lever to the position as shown in Fig.1 and screw in the two plugs. (8) Precaution in piping and operation @ For the piping, use an oil resistant pipe with an inside diameter of approximately 10 to 16 mm, @ Install the outside machine tank as near to the machine as possible and as the fuel level is within from 0 to +3m for the ground. @ In piping the outside machine tank, leave the position of the change-over valve lever as shown in Fig.1 until the piping is complete before turning it to the position as shown in Fig.2 @ Set the suction pipe 15 to 20mm above the tank bottom to prevent it from drawing in water and/or foreign matter present in the tank. (See Section A in Fig2 .) © Take good care to avoid entry of water and or foreign matter into outside machine tank. =a -To loaded fuel tank 7 o engine —Teide of machine Outside of machine / connection of outside fuel tank Fig.1_ Use of loaded fuel tank. To engine Ga Inside of machine Outside of machine Outside fuel tank Fig.2 Use of outside fuel tank Outside of inside of Suction pipe machine, machine inlet outlet Outside fuel tank Retum pipe APT 5~20m a -3. Transportation and installation 3-1 Transportation of machine A\ 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 machine during operation, as it may cause damage to the fan or serious trouble, * When loading the machine on the truck or the like, fix the machine firmly by support hooks on the both side. ‘The detail as machine size is referred to T12-1. Specifications See p. 81) ~-3-2 Installation of machine ZA\ WARNING ENGINE EXHAUST can kill. I 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 storehouse, tunnel, ship hold, tank, etc. of poor ventilation, * If it becomes necessary to use the machine in the above places, the exhiaust 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. [Note] vibration: ‘The engine, running, generates vibration during operation of the machine. When installing the machine, be sure to observe the following points. © Install the machine horizontally on a solid foundation. Operation on an uneven place will generate unusual vibration. @® The machine should be installed on a substantial base to prevent claims from nearby living people. For details of the vibration level of the machine and foundation work, contact distributor or our office. [Note] noise: ‘The engine is running during operation of the machine. If the door is open, much noise will be generated. But some noise will stay, when door is closed. When installing the machine, be sure to observe the following points. * Close and lock the door after installation. * We recomend to execute the measure for sound level to prevent claims from nearby living people. ~ 6 -Installation procedure * Install the machine horizontally on a solid foundation. * Provide a space of more than about 1.2m 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 allow hot air (exhaust ait) from the radiator and exhaust gases to be discharged and to supply water to the radiator. * When the machine is operated in a place with much dust or salt, careful maintenance is, required to prevent clogging or damage to the radiator or poor insulation of electric parts. Indoor installation * Exhaust gases should be discharged outdoors using an exhaust pipe. * Exhaust air should also be discharged outdoors using a duct or the like. “ Insufficient indoor ventilation will raise the (indoor) temperature and affects the performance of the machine. * For details of required volume of ventilation, contact distributor or our office.4, Connecting the load 4-1 Method for selecting output voltage AX WARNING “, ELECTRIC SHOCK can kill. Do not touch the circuit inside the machine during operation to prevent decease due to electric shock. * When open the control panel or the like for changing the output voltage, turn OFF the breaker and stop the machine in advance. In the parallel operation, be sure to shut down the other machine, Load Connection (Method For Selecting Output Voltage Select voltage according to the voltage of the load to be used. 200/220V 400/440V (196V) [240V) (380V) l415VI [480V] * Method For Selecting Output Voltage ‘The output voltage of 200/220V or 400/440V can be selected with the voltage change over plates. ‘These generators are shipped from the plant with their output voltage set at 200/220V unless otherwise specified, Change over to the desired output voltage according to the following procedure, if necessary. @ The voltage change over panel is located on the in side of the control box. Open the control panel to remove the fixation bolts. @ Change over to the desired output voltage by setting the change over plates. Note that insecure tightening of the locking bolts results in burning eae@® In changing the output voltage over to 400/440, take care not to lose superfiuous change over plates by, for example, setting them together with the actually used ones. @® Close the control panel to tighten the fixation bolts [Note] Incorrect reconnection of the change-over plates may cause a burning accident in the generator. For reconnection, be sure to tighten the plates to prevent the burning accident. Be sure to close the control panel before starting engine again. 4-2 Cables to be used 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 faidlure 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. 1 JL ax txix ong X g XIX where e: voltage drop (V) L: dength (m) S: cable thickness(mm *) I: doad current (A) |+-— Cabie tength (rm) —+| 19 -4-3 Connecting the load ELECTRIC SHOCK can kill, @ Do not touch the output terminals during operation e to prevent decease due to electric sho “ When a wiring work is required, be sure to turn OFF the cireuit breaker and stop the machine. * When operating the engine, close the output terminal cover. Tighten the fixing bolts before operating the machine. I 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. A\ CAUTION Connection to house wiring @ Before connecting this machine to any building's electrical system, a licensed electrician must install an isolation(transfer) switch. * Serious injury or death may result without this transfer switch. 30 -(2) Fastening the output terminal [Note] In connecting the load, tighten locking bolts securely with a spanner or the like to prevent burning. (2) Connecting three phase output terminal Connect the load to the output terminal after confirmation of load phase and voltage. uvVwo @oe 9d o} ° ° Ic I< = S Ter «¢ ¢( 20 Ic I< OE s Use U/V/W for three phase load 200/220V or 400/440V (gov) (80) {415V} (240V] —[480V] Use 0/U,0/V,0/W for single phase load 115/127V or 231/254V qov) (219) {240} (39v]277V1 Use U/V,V/W,W/U for single phase load 200/220 or 400/440V (agov)—@80v) {415V} i240v] [480] Payee(8) Single-phase Output (100/110V } The output terminal section is Receptacles equipped with two receptacles Cutout torial for S-phase (50/60Hz, 100/110V). e lo SL. exe —o 6, (4) 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. @® Don't contact the connecting cable to the output terminal of other phase on the output terminal block, @ When the load connection is finished, close the cover of output terminal and tighten by the bolts.4—4 EARTH LEAKAGE RELAY and Grounding A\ WARNING ELECTRIC SHOCK by leak can kill. Improper grounding may lead to death due to electric shock. Because the device for e leakage protection does not operate effectively. * Grounding terminal for the earth leakage relay, case grounding terminal and case of the load are grounded. () Description of the device ‘The machine is provided with an earth leakage relay to detect any leakage EARTH LEAKAGE RELAY produced due to such trouble as insulation failure of the load during operation and to cut off the circuit for protection against @ any accident such as electrocution resulting from the trouble. O wesrauTON TEST BUTTON ‘This relay detects any leakage on either three phase or single phase output and it immediately trips the circuit breaker where that leakage occurs. ‘The current sensitivity of this relay is 30 mA. Improper handling of the relay may lead to unsafe condition in comparison with that does not use the relay. To ensure further safety, install a leakage relay for each load at the position near the load. - 33(2) Grounding Ground as following to operate the earth leakage relay certainly. WM Grounding of the machine Ground the grounding terminal for earth leakage relay and case grounding terminal according to the below. soungg tein or earth ieakage relay case grounding @ Grounding of the grounding terminal for ternal earth leakage relay Tf grounding described below does not comply with the local rule, stricter of the ‘two shall apply. Use the grounding wire which sectional area is 5.5mm ? of larger. Usually it is possible that using attached grounding rod. But if grounding resistance is over 100 Q, provide the grounding rod which surface area contacted the ground is large. @ Grounding of the case grounding of the machine Use the grounding wire which sectional area conforms to the local rule. Provide the grounding rod to satisfy the grounding resistance which conforms to the local rule. Wl Grounding of the load equipment As in the case of the machine, execute grounding work on the load equipment case. Provide the grounding rod to satisfy the grounding resistance which conforms to the local rule, - Me[Note] The installation of a leakage relay on the machine can not become a reason for elimination of the need for the load side grounding. The load side grounding is indispensable for earliest possible detection of any leakage caused in the generator. The absence of stich grounding requires any leakage to be detected by current flowing through the human body and is very dangerous because the sensitivity of leakage relay provided on the machine is not sufficient for detection of such current. MW 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 enough for the connection, connect it as directed below: @ Connect the lead wire and the extension wire by soldering or sleeve coupling securely and apply insulating tape to the connection, (2) Do not burry the connection in the ground. @ Avoid the places within 2m of lightning conductor grounding location for burying of grounding rod. ® Do not use a telephone set grounding conductor.1 Operation check For safety reasons, check on the operation of the leakage relay at the startup of the machine according to the procedure described below: @ Start up the machine according to 5-2 Startup J @ Make sure that all breakers of the load side are "OFF". @ Set the breaker of three phase and single phase to "ON". @ Press the TEST button on the leakage relay. If this causes the LEAK lamp (red) on the leakage relay to go on and the breakers to be activated, the leakage relay can be regarded as operating, normally. © Press the RESET button and return the breaker to the "OFF" position. This allows the breaker to be turned to "ON" again. ‘The leakage relay, once it is activated, holds its activated state until the RESET button is pressed or the machine is stopped. (8)Action for operation of the leakage relay When the leakage relay is activated, then stop the engine, and measure the insulation resistance several parts and repair the leak spot before restart the engine. = 365. Operation ELECTRONIC GOVERNOR CONTROL Features This machine is equipped with an electronic governor. It is possible to switch to the Isochronous and the Droop control by using the “Isochronous - Droop Change-Over Switch” located in the control box. ‘The governor is set to Isochronous Control when it is shipped. * Use is usually by Isochronous Control. * Once the “Single - Parallel Change-Over Switch” is turned to the “Parallel” position, it will automatically set Droop Control at each position of the “Isochronous - Droop Change-Over Switch’. * Droop control will improve the starting efficiency when starting with a heavy load. ‘Therefore, operate this machine using Droop Control in such case. ‘The explanation of each control is as follows. Explanation of Control I Isochronous Control: (The frequency is constant regardless of the load size.) The frequency is constantly controlled regardless of load size once the frequency is set at NO-LOAD. (The last set frequency is recorded and saved in the controller even though the engine is stopped) However, once the “Single - Parallel Change-Over Switch” is turned to the “Parallel” position, it will automatically set Droop Control at each position of the “Isochronous - Droop Change-Over Switch”. Operation Method © After the engine warms up, set the machine using the throttle switch (pictured at right) once the machine is running at high speed. @ Sot the unit to the required voltage using the e regulator. = rF ‘oltage regulate (Cao) FE I @ The unit will enter the state of power —— a “| |S transmission once the circuit breaker is turned cote ‘zaowioy “On”. aTDroop Control: (The frequency changes depending on the load size) Droop control is the control whereby the frequency changes depending on the load size. ‘There is about a 2-2.5Hz frequency drop to the Rated Load compared with NO-Load. Operation Method @ After the engine warms up, set the machine using the throttle switch (pictured at right) once the machine is running at high speed. @ Set the unit to the required voltage using the voltage regulator. @ The unit will enter the state of power transmission once the cireuit breaker is turned “ow Installation of the switch Only operate the switch when the engine is stopped Open the control box and turn the “Isochronous- Droop Change-Over Switch”. After turning the switch, close and tighten the control box using the fixation bolts. = 98 -— From pre-start check to shut down — Be sure to check the machine prior to starting. 1. Pre-start check : Check oil, cooling water, fuel and so on. 2, Periodical check: Check each part of the machine according to operating time. 3. Startup: Check the surroundings of the machine for safe operation. Use a sign before startup. 4. Operation: /A\, tn the machine there are moving parts, high temperature parts and high voltage parts. Before operating, close the door and lock the side door for safe operation and for prevention of noise. [Note] 1 the warning lamp lights, stop the engine and check 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 A\ WARNING MOVING PARTS can cause severe injury. I 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 to stop the machine in advance.— To prevent unexpected trouble, be sure to check the following points. (Q)_ Check on engine oil (lubricating oil) (2) Check on engine cooling water (3) Checking on fan belt (4) Checking on fuel (5) Checking on battery acid (6) Checking on grounding for electric shock protection (7) Checking for leakage of oil and water (8) Checking for loose parts (Removal of foreign objects in machine Inspection: @ Checking on engine oil (Read the instruction manual for the engine furnished separately.) ® Checking the level of engine oil by the dipstick. Make sure the oil level is always between H and L. ® When it is below the low limit, supply oil immediately. @ At the same time, check condition of oil by the dipstick. | oO O° x [Note] Oil is consumed gradually during operation. When the machine is to be used a x continuously for a long time, be careful with lack of oil. = 40 -(2) Check on engine cooling water (Read the instruction manual for the engine furnished separately.) A\ WARNING HOT COOLANT can cause severe scalds. Hi Ii the radiator cap is opened while the water temperature is high, 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 (0 °C 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 the low limit, supply (additional) water immediately. ® 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. sora] [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.3) Check on fan belt (Read the instruction manual for the engine furnished separately.) @ Check the belt for tension and elongation. Also, check it for damage. Replace if necessary, ® For adjustment or replacement of the belt, refer to the instruction manual for the engine. ‘The belt should deflect by approx. 10 ~ 15mm (with fan drive) or approx. 17 ~ 22 mm (without fan drive) when pressed with the finger (with a force of approx. 98 N (10 kgf) at a point midway between the fan pulley and alternator pulley. (4) Cheek 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 sediments and water at the bottom of the tank. - 42(8) Check on battery acid A\ CAUTION BATTERY I 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. Remove the battery acid plug(cap) and check the liquid level (10- 12mm above the electrodes). Supply distilled water if necessary. - 43 -(6) Check grounding for electric shock protection Make sure that the case grounding of the machine and the load are certainly. Do not ground directly [01 terminal. (2) Check for leak of water and oil Check the machine for the trace of leak of oil or water. Ifa leak is found, check the location of leak and stop it, When the leak cannot be stopped, contact our service factory. (8) Check for loose parts 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 presence of dust and flammable objects. Remove if necessary. * Check that the cooling air inlet and the cooling air outlet of the machine are not clogged with dust or other objects. Remove if necessary. eae5-2 Startup ‘This machine is equipped with automatic idling device. This device automates the idling of the engine for its warming—up after start up. Following is flow of start up. circuit breaker : OFF v Frequency change-over swite 50H or 60H ‘Single parallel change-over switch : single starter switch : RUN preheat lamp : check preheat lamp going off. starter switch : START engine start up starter switch : RUN When it is cold, speed change-over switch : LOW warm up operation : about 20 seconds warm up operation : sufficiently high speed operation (automatic) speed change-over switch : START, {-———_ AUTOMATIC IDLING adjustment of speed adjustment of voltage circuit breaker : ON supply power to load - 45 -A\ CAUTION * Do not start the engine when the machine and the load circuit breaker are ON, or else, power is supplied to the load at the start of the engine which causes electric shocks or trouble in the load. Startup procedure: (1) See both the circuit breakers on the generator side and load side are all OFF. (2) Turm the speed change~ over switch on the control panel to the position of HIGH "START / AUTOMATIC IDLING’. (@)Tum the frequency change-over switch switch to ESE either 50Hz or 60Hz. Sone soe (4) Turn the single parallel change~ over switch SINGLE PARALLEL to single side, (6) Set the starter switch in "RUN" position. [Note] If the engine is warm, it needs no preheating. The duration of preheating differs according to the temperature of cooling water. When the temperature of cooling water is high enough, the PREHEAT lamp for preheating does not light because no preheating is needed. ages(©) Tum fully the starter switch up to "START". Immediately after engine starts up, release the starter key, and it comes to the "RUN" position automatically. Right after engine stopped, engine dones not, restart for about 20 seconds that engine shut down functions. (7) Allow engine to run for warming up for a while. See all the alarm lamps are all off after starting engine. Soon after the engine starts up, it comes in idling automatically and the running caution lamp turns on. After about 20 seconds, engine speed increases automatically to the high speed as set by the throttle switch. [Note] In the cold weather, turn the speed change-over switch to the position of "LOW" for warming up for longer time. If the high speed run is required sooner and the engine is warm enough due to former running, turn the speed change-over switch to "HIGH’. In this mode, automatic idling system is neglected and engine rpm will follow the setting of throttle switch. -4a- START(8) Adjust the engine speed. When engine runs at a high speed after warming up, set the speed to the 1pm shown in the table, Frequency (No load speed) Operation at 50Hz S0Hz (1500rpm) Operation at 60Hz 60Hz (1800rpm) (® Adjust the out put voltage to the rating by the voltage regulator. (10) Turn on the circuit breaker, and electrical power is feed to load. (es wEats> Ba5-3 Handling during operation (2) Checking after startup @ Make sure that each meter and lamp are normal. normal : warning lamp is all off ® Make sure that the color of exhaust gases from the engine is normal. Check for unusual noise and vibration. Color of exhaust gases — Colorless or light blue: Normal — Black: Abnormal, incomplete combustion — White: Abnormal, combustion of oil due to failure of oil @ Check on the operation of the earth leakage relay. (2) Adjustment during operation Set the tachometer and frequency meter to the rated by the throttle switch. Set the voltmeter to the rated by the voltage regulator. [Note] * Do not turn the speed change-over switch to "LOW " position during operation of the load, or else, the generator voltage and frequency will go down, resulting in failure in operation of the load device or any other trouble. = 49 -5-4 Shut down (1) Turn OFF the circuit breaker of the load, (2) Turn OFF the circuit breaker of the machine. (3) Turn the speed change~over switch to "LOW" position and put the machine in cooting operation for a few minutes. (A) 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. (©) Check the amount of fuel. Supply fuel if necessary. (7) Check for leakage of oil, fuel and water. [Note] circuit breaker of the load fe circuit breaker of the machine eel ES START * For emergency stop, keep pushing the "EMERGENCY STOP" button until the engine stops. This button is a push-locked type and the contact is released in case of rotating it to clock direction. ‘The engine doesn't re-start unless the contact is released. * Check the panel light goes out. - 50 -5-5 Protection device Protection devices and emergency stop devices are provided for protection of the machine against trouble during operation. When the running caution lamp lights, stop the engine immediately. Check and remove the cause of trouble. Table of protection device action | tum OFF the | stop indicate by ] warning circuit breaker | the engine | warning lamp| function cil pressure T failure - @ | set point : 130kPa (OIL PRESS) stop ° set point :78kPa high jacket | | water - , = set point : 970 | temperature | (WATER TEMP) xO stop | set point : 101°C “igh lubrication | oil temperature - - set point : 120°C Battery charging a failure - 26.0 overcurrent of When overcurrent generator |} o = - flows, the device acts | fuel tevel | | ‘When fuel supply is failure le fo} necessary because of (FUEL LEVEL) fuel shortage, the device acts. xO stp | 0 ‘ir Biter Binding ‘When replace or deaning of (AIR FILTER} - O | air fiter is necessary because of blinding of fier, the device acts oil fiter blinding When replace of ol filter is (OL FILTER) e © | necessary because of blinding of fiter, the device acts. ‘earth leakage When electric leakage, ° . O |e device acts [Current sensitivity : 40mA 3@ Abnormal value and unit will be indicated lighting on and off. ‘O. When the single-parallel change-over switch is parallel side, device acts. - 516. Parallel operation [Note] ‘This section is to explain only the procedures for parallel operation that are different from the general single unit operation. For the same procedures with those for single unit operation, read [4. Connecting the load | and [5. Operation | . In the case where the capacity of the load exceeds that of a generator. The parallel operation is useful by paralleling electrically generators of 2 units or more. However, note that the stable parallel operation requires the equality of output voltages, frequencies, engine governor characteristics, etc. For this reason, it is requested for easy paralleling to select the quite same type of the generating sets for manufacturer, model, ete. Study this manual carefully before paralleling the units. 6-1 Preparation for parallel operation (1) Turn off the main circuit breakers on all the units, and stop the engines. (2) Set the voltage change— over board on each unit to the same voltage. (8) Connect each unit and load as shown below, referring the terminal symbols. Use a phase tester to check the sequence of the phases. Generator | Generator 2 Generator... uvW uvw luvwof g 99 : No.1 No.2 [N85 cis eae -—~o—| Load [Note] Connect the cables in the correct sequence of the 3~ phases, seeing the terminal symbols, (4) Turn the single— parallel change—over switch on each control panel to "PARALLEL" eile6-2 Parallel operation (1) Turn off the breakers on the load side. (2) Start engine and keep it in warming up. (3) Equalize all the voltages and frequencies on the units by adjusting the throttle switch @[ 2 3 and voltage regulator. D| ase | | swnnie || vaewor Qommee (4) First turn on the circuit breaker on the No.1 generating set. (6) Adjust the throttle switch on the No.2 set so that the two synchronizing lamp on the No.2 set turn on and off synchronizing when the two phase sequences are in the same direction, while the two turn and off alternately when the sequences are in the different direction. In case the two lamps turn on and off alternately, recheck the cable connections for correct phase sequence. (©) At the instance when the synchronizing lamps turn off, turn on the breaker on the No.2 set. [Note] ‘The generators can damaged due to shorteireuit current if the breaker is turned on when the lamps turn on. (7) Upon the above procedure, the No.1 and No.2 sets are in parallel operation. The AC ammeters are to indicate zero in this no load condition. If the meters indicate some current, it is an uneffective cross current dué to voltage difference. Make it zero by adjusting the voltage regulator. a(8) In the same procedure as the above items (6),(6) and (7), parallel the generating sets of No.3 and so on if any. (9) Turn on the breakers on the load side. If each AC ammeters show an imbalance in loading, make it in equal loading by adjusting the throttle lever for engine rpm. The set is to undertake more load sharing when the engine rpm. is adjusted higher, while less sharing when adjusted lower. [Note] AC ammeter indicates the current including a cross current. Watt meter (Option) is required to know the correct load sharing. - 546-3 Precautions () Keep each generating sets in equal toad sharing by adjusting the throttle switch for engine rpm. The set is to undertake more load sharing when the engine rpm. is adjusted higher, while less sharing when adjusted lower. (2) Keep the single~paralle! change-over switch in the position"PARALLEL" [Note] Ifit is turned to "SINGLE", a cross current occurs between the alternators and trips the circuit breakers due to over current. (3) Watch the fuel level during parallel operation, [Note] If fuel runs out during parallel operation, the running set must undertake all loading and may result in an accident in the set or a tripping on the breaker. START AUTO. IDLING (4) Never turn the speed change-over switch to the "LOW' side. Low ~ HIGH [Note] If it is turned to "LOW" during parallel operation, the running set must undertake all loading and may result in an accident in the set or a tripping on the breaker. - 556-4 Shut down (1) Turn off the breakers on the load side. Pe T (2) Turn off the main circuit breaker on each oa SS ne generating set. J (3) Shut down each engine referring to concur aaron [5—4. Shut down! MACHINE ~ 56 -7. Lubrication,cooling water and fuel 7-1 Engine oil Use specified engine oil, otherwise, it greatly affects the startup operation and life of the engine. (1) Kind of oil Use oil, CD class or higher, classified 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 (C) -30 =20 -10 0 10 20 30 +— SAE 20—— +#—sAB30——» +-$——S AE 5 W- 20-5 10W-3 0-——__—_ ——— sa SAE15W-40 [Note]: Do not mix with different kind of oil, or else, it deteriorates the oil quality. (3) Quantity of replacement oil ‘Total oil quantity 37L (4L) (Value in parentheses is filter capacity.)7-2 Cooling water (1) Water for cooling Use the mixture of the good quality soft water like city water and the Long Life Coolant (LLC) of anti-freeze and anti-rust for the aluminum radiator. Percentage of LLC must be 30% to 50%, Under the 30%, the anti-rust effect will decrease, and over the 50%, the anti-freeze effect will decease. ‘The following percentages are recommended for each ambient temperature; 30%: -10°C 40%: —20°C 50%: -30°C In case of replenishment, use LLC of the same brand and the same density. Normally LLC should be replaced every 2 year. (2) Total quantity of cooling water Total cooling water quantity 421 (2.3L) (Value in parentheses is reserve tank capacity.) 7-3 Fuel (2) Fuel to be used #2 Diesel Fuel [Note] If other kinds of fuel is used or fuel being used contains water or dust, it deteriorates the engine performance or leads to a serious trouble, — 58 =8. Handling of battery A\ CAUTION BATTERY ™@ Battery generates flammable gases. Improper handling may lead to explosion or serious injury. ™ Battery should be charged in a well ventilated location, Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and —-). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. * For maintenance of the machine, disconnect the cable on the ground side. ME 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. Ml For checking or handling of the battery, be sure to stop the engine in advance, 59 -8-1 Caution on battery charge Charging of loaded battery * Disconnect the wiring cable from the battery terminals before charging. (Otherwise, the alternator may be damaged due to unusual voltage applied to the alternator) When disconnecting the wiring cables from the battery terminals, remove the ground cable first. (If a tool touches the space between the '+" terminal and the machine, electric spark will occur which is very dangerous) When connecting the wiring cables to the battery terminals, connect the ground 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 °C), stop charging for a while. * At the completion of charging, stop charging immediately. (The relation between battery charge condition and specific gravity See p.67) If the battery is still charged, the following trouble will occur. 1) Battery overheat 2) Decrease in battery acid 3) Deterioration of battery performance * Do not connect the battery polarity in reverse (connection of "+" and "=" or "~" and "++" to prevent damage to the alternator or the like. ce8-2 Connection of booster cable, and installation ‘When the engine is started using booster cables, connect the cables as follows. @) Connection of booster cable © Connect the clip of the booster cable "A" to the terminal "+" of the machine in trouble. ® Connect the other clip of the booster cable '+" of normal machine. "A" to the terminal ® Connect the clip of the booster cable "B" to the terminal "B" to the terminal "—" of tay femal in tei normal machine. 2 = 7 ‘engine block of the mechine in trouble ® Connect the other clip of the booster cable "B" to the engine block of the machine in trouble. (2) Removal of booster cable @® Remove the clip of the booster cable"B” connected to the engine block of the machine MY ng in trouble. ® Remove the clip of the booster cable "B' connected to the terminal "~" of normal machine, @® Remove the clip of the booster cable "A" cogs Sock of aioe a HOE connected to the terminal "+" of normal machine, @ Remove the clip of the booster cable "A" a] otter ote mace a trou @ ® connected to the terminal "+" of the machine in trouble. (8) Caution on handling of booster cable @ Use booster cables and clips of the size that matches the size of battery. ® The battery used for normal machine should be the same in capacity as the battery of the machine in trouble. @ After connection, check that clips are firmly connected. @ When connecting booster cables, make sure that the terminal "+" does not touch the terminal "—", @® The engine block should be connected at a place more than 30cm away from the battery. -61-9. Periodical checking and maintenance (Read the instruction manual for the engine furnished separately) ZX WARNING — MOVING PARTS can cause severe injury. MH Rotary unit which moving parts at a high speed is located in the machine. Care should be taken during operation * When the machine needs checking or maintenance, be sure to stop it in advance. ZX WARNING ELECTRIC SHOCK can kill. @ High voltage units 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. eeA\ CAUTION HOT PARTS can burn skin. HH High temperature parts are located in the machine. Care should be taken during operation, * When the machine needs inspection or maintenance, be sure to stop it in advance. * Even after the machine stops, the inside of the bonnet is still hot. Wait until the engine is cooled sufficiently. A\ CAUTION BATTERY WH Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * For maintenance of the machine, disconnect the cable on the ground side. 63 ~A\ CAUTION Sign for maintenance * During checking or maintenance, be sure to put up a sign "Under maintenance" at a conspicuous place such as the starter switch to prevent the machine from being operated by other persons. A\ CAUTION Safety clothes * During checking or maintenance, be sure to put on suitable clothes and protectors. * Do not put on baggy clothes, necklace, etc., because they are easily caught by projections which may cause injuries. ZX CAUTION Handting 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 other harmful objects such as filter, battery, etc., should be disposed of according to the related regulations. 649-1 Maintenance schedule 50 hours: Checking/first 50hours * Replacement of engine oil 250 hours: Checking/every 250 hours Replacement of engine oil * Cleaning of air cleaner element Measurement of generator insulation resistance (once a month) * Checking on battery specific gravity 500 hours: Checking/every 500 hours * Replacement of engine oil filter element * Replacement of fuel filter cartridge * Cleaning of radiator and intercooler Inspection of injection nozzle Checking for terminal and connection of the circuit Checking/every 250 hours is also required. 1000 hours: Checking/every 1000 hours * Cleaning inside fuel tank * Replacement of air cleaner element * Adjustment of fuel injection timing Checking on rubber suspension Checking on nylon and rubber hose * Checking on lining * Checking/every 250 and 500 hours are also required 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9-2 Checking/first 50 hours (1) Replacement of engine oil Replace the engine oil at 50 hours only first time and every 250 hours after second time. @® Remove the engine oil drain plug and discharge oil completely. It can be discharged easily when the engine is warm. @® Aiter engine oil is discharged, tighten the plug firmly. @® Charge new engine oil from the oil filler until it reaches the notched line of the "H" on the dipstick. @ After engine oil is supplied, run the engine for a few minutes, Check that oil is supplied to the level between H and L . 9-3 Checking/every 250 hours (1) Replacement of engine oil Replacement is refer to [9—2.(1) Replacement of engine oil | (2) Cleaning of air cleaner element This element should be cleaned, regardless of operating time, when the warning lamp of “Air filter blinding" goes on. ~ Dry dust clings on element — a) \ Remove the outside air cleaner element and clean the element with dry and clean compressed air, * While it is being cleaned, check the both (f | ay. * Before installing the air cleaner, wipe off dit element for any damage. Replace if neces on the element cover. * When insert the element, insert the element a |__ +O° f +x +o completely pressing equal edge of element. ie(8) Check on battery specific gravity. If battery is likely to be discharged due to failure in startup of the engine, measure the specific gravity of battery acid. The relation between battery charge condition (charging rate) and specific gravity is as shown below. Liquid Charging temp. | 2 0 0 }-10 rate (96) c 100 128 | 1.29 | 1.30 90 126 | 1a7 | 128 80 Lad | 1.26 | 126 75 aa | ad | 15 Each value has a deviation of = 0.01. When the charging rate is below 75%, the battery needs to be recharged. 18-1. Caution on battery charge -6r-(4) Measurement of insulation resistance. A\ WARNING ELECTRIC SHOCK can kill. * Measurement should be made after the machine stops. — Using a 500V megger, make a check once a month to ensure that the insulation resistance is more than IM Q. ‘Measurement: Disconnect the load side cable from the output terminal as shown at below. Turn ON the circuit breaker and measure the insulation resistance between the output terminal bolt and the bonnet. — If the measured resistance is less than 1M Q, it may cause electric leakage or fire accident. Wipe off dirt and oil on the output terminals, circuit breakers and generator leads (cables) and dry them thoroughly. If the insulation resistance is not recovered after cleaning, contact distributor or our office. — 68 -9-4 Checking/every 500 hours Checking/every 250 hours is also required. (1) Replacement of engine oil filter element Mi Element type (Element type separates filter case and element, so replace only the element.) ® Loosen the drain plug in the lower part of filter lenent case and discharge the oil completely. tate serine @® Loosen the center bolt and remove the filter sting Filter case case, element and spring or the like. Bat: @® Wash each parts except the element by drains washing oil. ee ee @® Mount the element for replacement and sashe cater els ring in reverse order. Tighten the center cei tlt bolt in regulation torque certainly. ® After the element is replaced, run the engine for a while, Then, check to see that oil is supplied to the level between x Hand L. deain stat “Grain aug Parts number of oil filter element kit : Parts number | manufacture _| Parts number of manufacture 06020 41139 | MITSUBISHI ME064356 ~ 89 -(2) Replacement of fuel filter cartridge. @ Remove the cartridge type element (cartridge) using filter wrench. @® Clean the filter base. Coat the packing of new cartridge with engine oil thin. Then, mount the cartridge. — When mounting, tighten the cartridge about from 2/3, to Iturn by hand after the packing is fitted to the seal of the filter base. ® After the cartridge is replaced, discharge air in the fuel piping. — For details, refer to the instruction manual for the engine, A nameplate showing the fuel filter element method of discharging air is also attached to the machine. remove “tighten Parts number of fuel filter element : Parts number | manufacture _| Parts number of manufacture 06020 42158 MITSUBISHI ME056670 (Two element are used. } Eri(3) Cleaning of radiator and intercooler When the fin or tube is blinded, it should be cleaned with steam or high pressure water. eS [Note] When a high pressure washer is used, spray water from a place about 1.5m away to prevent damage to the fin or tube. (4) Checking for terminal and connection of the circuit. Check for main and sub circuit, whether there are no abnormality such as loosening, corrosion and burning, etc. -n-9-5 Checking/every 1000 hours Checking/every 250 and 500 hours is also required. (J) Cleaning inside fuel tank Drain the fuel in the fuel tank completely, and wash out deposits and water collected inside the tank. (2) Replacement of air cleaner element ‘The element should be replaced referring to "Cleaning of air cleaner element" . Parts number of air cleaner element : Parts number | manufacture _| Parts number of manufacture 06020 46316 | MITSUBISHI ‘ME0S8741 (3) Checking on rubber suspension Check on the rubber suspension, whether it is damaged or deformed by the oil. Contact distributor or our office to replace the rubber suspension, if necessary. (4) Checking 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 hose and rubber hose, if necessary. () Checking on lining Check on the lining, whether it deteriorates greatly, or it is stained by clinging of oil or the like, or it is removed. Contact distributor or our office to replace the lining, if necessary.9-6 Table of periodical maintenance and checking ©:Check or Clean O:Replacement +*:Only first time List of maintenance first Jevery Jevery Jevery every and inspection caily | 50h | 250%} 500h) 1000h |2 year Checking on oil level and stain of oi! Checking on cooling water Checking on fan belt Checking on fuel and drain Checking on battery acid level Checking on for water and oil leakage Checking on bolts and nuts for looseness ‘Checking on exhaust color, sound and vibration ‘Checking on meters and warning lamps Engine | Replacement of engine oil fe Of 0 Replacement of engine ol filter ° Clean ait cleaner element ° Checking on specific gravity of battery 2 Cleaning radiator and intercooler 2 Replacement of fuel filter ° Cleaning fuel tank Replacement of air cleaner element Oo]o]olo}ojolo}o ojolo ‘Enspection of engine valve clearance * S| ¥ Adjust fuel injection nozzle ° ‘Inspection of timing of fuel injection Checking on rubber suspension Checking on nylon and rubber hose Checking on lining | Checking on generator case grounding 2 | (Generator | ‘Checking on insulation resistance ° ‘Checking on terminal and connected section ° Checking on the operation of the leakage relay | © oololo 3 Contact distributor or our office. ‘¥ This symbol represent first time of inspection, next time is ordinary schedule. | Inspection time is different by the engine,in detail, please refer "Engine Instruction Manual" furnished separately. -1B-10. Troubleshooting A\ WARNING — MOVING PARTS can cause severe injury. I Rotary unit which moving parts at a high speed is located in the machine. Care should be taken during operation. ow * When the machine needs checking or maintenance, = be sure to stop it in advance. ZX WARNING _ ELECTRIC SHOCK can kill. @ High voltage units 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. -4-A\ CAUTION HOT PARTS can burn skin, @ High temperature parts are located in the machine. Care should be taken during operation. * When the machine needs inspection or maintenance, be sure to stop it in advance. * Even after the machine stops, the inside of the bonnet is still hot. Wait until the engine is cooled sufficiently. A\ CAUTION BATTERY MM Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * For maintenance of the machine, disconnect the cable on the ground side. -%-Phenomenon ‘Assumed cause ‘Action Discharged battery Charge or replace Cell motor Detached or loosened or corroded Repair will not run | battery terminal Engine will | or revolution | Fuse blow Replace not start up | speedis low | Improper starter switch Replace Improper starter Replace Broken lead wire Repair Fuel shortage Supply Cell motor runs | Blinded fuel fiter Replace element, Ar in fuel system Remove Ai in fuel system Remove Speed will not rise Blinded fuel filter Replace element ‘Compression feifure ‘Repair engine Blinded air cleaner Replace element Oil shortage ‘Supply Engine stop by oil failure Oil pressure switch failure Replace Blinded oil filter Replace element Cooling water shortage Supply Over heat Fan belt looseness Adjust (water temperature) Blinded core of radiator Clean Engine thermostat failure Repair Voltmeter failure Replace AVR faire Contact Voltmeter will not operate Quenched residual magnetism distributor or Burned rotary rectifier our office Disconnected rotor wiring Burned generator witing Voltmeter failure Replace AVR failure Contact Rated voltage will not be VR failure distributor or reached Burned rotary rectifier our office Bumed generator wiring Low speed Tnerease 6 —Phenomenon Assumed cause ‘Action Voltmeter failure Replace Voltage goes too high AVR failure Contact distributor VR failure or our office Bumed rotary rectifier Contact Applied load causes load AVR failure disteibutor or voltage drop Burned main field excter field wiring | our office ‘Unbalanced load Balance TeTROUBLESHOOTING CHART FOR ENGINE Engine faults can be found using the Failure diagnosis display located on the control board. normally in the “OFF” position. When the starter switch is turned to the “RUN” position, the RED and GREEN lamps will initialy turn on, but once the engine is running, both lamps should turn off. ‘This would indicate “normal” conditions. When either the “RED" or “GREEN” lamp remains on, the Failure diagnosis switch should be turned to the “ON” position. After locating and correcting the fault according to the error code table below, confirm that the problem has been corrected by restarting the unit. When the “RED” lamp remains on: The engine can NOT be driven due to a major fault. When the “GREEN” lamp remains on: The engine can be used despite having a minor failure, but it may influence the longevity of the engine. Repair after locating the fault. Locating the fault is found by placing the Failure diagnosis switch in the “ON” position and starting the engin 1) After turning on the starter switch, the RED lamp turns on for about 2.4 seconds, and then the code is displayed. 2). The code is displayed with two digits. The digit of ten tums on for 1. 2 seconds and turns off for 1. 2 seconds. ‘The digit of one turns on for 0. 4 seconds and turns off for 0.4 seconds. 3) In cases where there are multiple faults, the display will return to the first code after each. code is repeatedly displayed three times. digit of ten ist of one__| ‘turns on tunsog WO ET 2. dsec | Lasee | Ltsee = J df Os} Oat od | Ca - Cz - Recall and deletion of past faults Past faults can be recalled by pushing and holding down the reset button, After pushing in the reset button for a second or more, all the past faults in the ECU memory I be displayed and you can release the button. If you want to retain this information in the E CU, you should not push the button again and let go for this will delete all past defaults from t he memory. If you want to retain the past defaults in the memory, then push the reset once more and hold in while turning the starter switch to the “OFF” position. -OrO- I sec 3 sec a —] recall past faults pushing t delete