1 * MANUAL No..C48443 00014 INSTRUCTION MANUAL FOR DIESEL ENGINE-DRIVEN AC GENERATING SET MODEL + DCA-500SPK 2 Denyo Co,Ltd.This instruction manual gives a detailed description of the operation, routine inspection, maintenance, and troubleshooting of the generator, and other items required for. proper operation. We therefore reconmend that all users read this manual carefully before actually operating the generator to ensure proper operation. For detailed operation, disassembly, reassembly and repair of the engine, please refer to the "Engine Instruction Manual” supplied by the engine manufacture. 1o. i. 12, 18, 1. CONTENTS PRECAUTIONS FOR SAFE OPERATION - SPECIFICATIONS = PARTS DESIGNATION -~ PREPARATION FOR OPERATION OPERATION PARALLEL OPERATION STORAGE --~ INSPECTION AND MAINTENANCE TROUBLESHOOTING OUTLINE DRAWING CONTROL AND OPERATING PANEL GENERATOR CONNECTION DIAGRAM ENGINE CONNECTION DIAGRAM --~ SAFETY PRECAUTIONS FOR DIESEL GENERATING SETS AND EQUIPMENT1. PRECAUTIONS FOR SAFE OPERATION This machine is designed with highest consideration to safety. Safest and most efficient operation, however, can be attained by paying attention to the following items. (1) Operate Properly Operate the machine properly according to the Instruction Manual to ensure safety. Give proper guidance in operation, In allowing other personnel to use the machine, be sure to give them proper guidance in its operation and advise them to read the "Instruction Manual” before actually operating it. (2) Keep Free From Noisture The operation of the machine in a place exposed to rain, moisture or wetness may cause electrocution. For opera~ tion under such conditions, be sure to ground the machine and the load side. (3) Housekeeping, The First Step Do not place any unnecessary items around the machine. When the machine is to be located on an uneven or soft surface, instell it horizontally so that it will not tilt during operation. (4) Clean Carefully And Frequently The machine must be treated properly as your business partner. Note that the insulation of the generator may deteriorate depending on the place where it is used. If it is to be used in a place where dust and moisture are excessive, be sure to clean and dry it periodically.(8) (8) (1) (8) (9) (10) Pay Attention To Sufficient Ventilation The exhaust gas discharged from the machine contains hazardous substances. When the machine is to be used in such a place as a tunnel, ventilate the place thor~ oughly during operation. When it is to be operated on the road, take care that the exhaust is away from pedes- trians, nearby buildings, etc. Shut Down Operation Immediately If Any Abnormality Occurs If the machine is found to operate improperly, or produce any abnormal odor, noise, or vibration, immediately shut down the operation for troubleshooting to correct the ab- normality. Naintein Electrical Instrument Cables Properly Damaged cables of the electrical instruments are very dangerous, causing electrocution and leakage. Therefore, if such a cable is found, immediately repair or replace it. Avoid Overloading The generator is provided with a breaker for overload protection, which is actuated when it is overloaded. When the breaker has been actuated, reduce the load before restarting the machine. Never Touch The Output Terminal Never touch the output terminal during the operation. Be sure to shut down the operation before touching the terminal for wiring, ete. Pay Attention To Storage And Transportation During Inclement Weather The machine is designed for dripproofing, but not for rainproofing. When it is to be stored or transported on an inclement day, take care to cover it.qi) a2) (18) (4) Wash The Machine Carefully Wash the machine taking care that the control panel and the inlet and outlet ports are not exposed to water to prevent possible failure of the internal instruments. Teke Precautions Against Fire Handle fuel, oils and antifreeze (undiluted) with care because they are dangerous materials with high flammabili~ ty. Do not bring any naked light such as lit tobacco or a burning match close to them. In addition, do not install and store the machine in a place near where fire is used. Connect Securely Damaged cables and loosened screws result in machine failu- re and electrocution. Therefore, immediately repair such cables and tighten such screws securely, if any. Perform Inspection And Maintenance Work Perfectly Keep the machine clean and its inside free from dust and moisture. In addition, perform its inspection and maintenance perfectly in accordance with the "Inst- ruction Manual”.2. SPECIFICATION 2-1 AG Generator Generator model Type Exeitation Continuous duty rating Voltage Current Frequency Speed Power factor Phase Winding connection Insulation Cooling system 2-2 Diesel Engine Maker and nodel Rated output No.of cylinders Bore X Stroke Displacement Direction of rotation Governor Cooling system Lubricating system Starting motor Charging generator Battery Fuel Fuel tank Lubricating oil DF-5500 Rotating-field,protection type(JP20) synchronous generator Brushless type (with AVR) 450 / 500 KVA 200 / 220 V or (380){415}400 / 440 ¥ 1299 / 1312 A or (684)(626}650 / 866 A 50 / 60 Hz 1500 / 1800 rpu 0.8 (lagging) 3 (4 wires) Star Armature-winding ~~ F class Field-winding -- F class Self-ventilation KOMATSU LTD. SA6D170~-B 4 cycle, water cooled diesel engine, direct injection, turbocharged with aftercooler. 520 / 680 ps, 1500 / 1800 rpm 6 170mm X 1700m 28150 co Clockwise (viewed from the fan side) ALL speed governor Weter cooling by radiator with fan Gear pump 24V - 11 kW 24 V- 254 12 ¥ - 200AH X 2 Diesel fuel (JIS No.2 or equivalent) Approx. 490 1 API service class (CD class or higher)S. PARTS DESIGNATION 3-1. Description of Devices (1) Starter Switch (2) Tachometer © stop Keep the switch at this position except during operation. This position allows the key to be inserted into and removed from the switch. ® RUN Keep the switch standing at this position during operation. @® START Turn the switch to this position for start- up. then the key is released after startup, it automatically returns to "RUN” position. The tachometer indicates engine revoluti- ons per minute. Set the engine speed so that the meter indicates 1500rpm at 50lz and 1800rpm at 60lz. The tachometer has a builtin integrating hour meter. The integrating hour meter has been set for use at 1500rpm. Accordingly, when the meter is used at 1800rpm, it indicates an integrated hour value approximately 20% more than the actual operation tine. (3) Cooling Water Temperature Gauge If machine is in normal operation, the in- dicator should between 75 - 95 C. If it indicates temperature ebove this range, turn off the load and turn the speed change over switch to "LOW" position for cold operat~ ion to reduce the cooling water temperature.(4) Lubricating Of1 Pressure Gauge If the machine is in normal operation, the pressure gauge indicates 8~65 ke/es? When the engine is cold, the pressure may ise above this range just after startup In such cases, perform warming-up until the normal pressure is attained. (5) Lubricating Oil Temperature Gauge Indicates the oil temperature of the engine oll. The temperature of 100 C or less is recomnen- ded. (6) Fuel Level Gauge : Indicates the fuel level (7) Charging Ampere Meter in the fuel tank. operation, the If the machine is normal meter points to 0 or + range values (ind- fcating its changed state ). (8) Preheat Lamp O (9) Heater Switch Refer to the item 5-3. Refer to the item 5-3(10) Speed Control Handle (Throttle handle) Turn the handle tovard the “HIGH” side to Lov ZX Hish increase the speed and toward the "LOW side to decrease it. (11) Battry Switch During operation, never turn the switch to "OFF" position, keeping it at "on", orF, on ‘If the engine is shut down, be sure to place the switch in "OFF” position. (12) Speed Changeover Switch ® AUTO. IDLING When the engine is started with the "SPEED" changeover switch set at this position, the sa) START engine idles for about 20 seconds and then BTA BY yo automatically changes over to high-speed AUTO, IDLING ‘$8 t LOW y operation. When starting the engine, set the switch in this position, ®@ Low When the switch is turned to this posi- ton, the engine continues to idle. ® HIGH Turning the switch to this position relea- ses the "automatic Idling” function, allowing the engine to be run at the speed set by the throttle handle. (18) Running Caution Lamp This lamp goes on during low-speed operation. (14) Emergency Stop Button This is @ pushbutton to stop the engine urgently on emergency case Do not push the button without emergency case.(15) OK Monitor This monitor indicates the following failures, if any one of then occurs. © Overheat This lamp goes on when the cooling water i) temperature rises abnormally. If the lanp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. @ Oi! Pressure Failure If the machine is in normal operation, o this lamp stays off. When the starter switch is turned to "RUN” position to start the engine, the lamp goes on, and when the oil pressure rises after startup, it goes off. If this lamp goes on during operation ,the emergency stop device imme diately operates to shut down the engine automatically, After the engine stops, the lamp stays on unless the starter switch is turned to "STOP" position. ® Fuel Level Failure When fuel Is running low, this lamp goes on, and the tank should be filled. @ Battery Fluid Level Failure When battery fluid runs low, this lamp ae] goes on, and distilled water should be supplied to the battery.® Oil filter Blinding @ Air filter Blinding (16) Frequency Meter (17) AC Anneter When the engine oll filter is blinded, this lamp goes on. As filter blinding way cause engine burning, when the lamp is lights replace the filter. Also replace the engine oil concurrently with the filter replacement. When the air element is blinded, this lamp goes on, indicating that the element should be immediately cleaned or replaced. Setting the starter switch at the "STOP" position causes the lamp indication to be automatica~ lly reset. This meter indicates the power frequency. Make sure that the meter pointer stands at 50 or 60Hz during operation. The ammeter indicates the value of curr- ent flowing in the load connected. Nake sure that the current value is below that rated. Use the ammeter change-over switch to check each phase for current value. 0E(18) AC Voltmeter (19) Voltage Regulator (20) Breaker on a OFF (21) Overcurrent Relay The voltmeter indicates the output volt~ age. Make sure thet the voltmeter pointer stands at the rated voltage. Use the voltmeter change-over switch to check each phase for voltage value. This regulator is used to control the output voltage. Turn the regulator clockwise to increase the voltage and counter-clockwise to decrease it. Adjust the voltage to the rated voltage with this regulator. This breaker seryes both as the main switch for power generated from the generator to the load connected to the output terminal, and as the protector of the generator when @ short or overload occurs in the load side. Do not use this breaker to turn the load ON or OFF. If the actuation of the overcurrent relay causes the breaker not to be turned on, open the control pane! and press the reset button as shown in the following drawing. Reset button -u-4. PREPARATION FOR OPERATION ate Precautions In Installation Instell the machine horizontally on solid ground, In addition, when the machine is to be installed in a place where dust and salt are excessive, pay close attention to its maintenance and care to prevent radiator clogging and failure, and electrical-part Insulation failure possibly caused by operation under such circunstances. (1) Precautions In Outdoor Installation When the machine is to be install outdoors such as on the road, pay attention to the wind direction and the exhaust port position so that the exhaust gas it away from pedest- rians and nearby buildings. (2) Precautions In Indoor Installation @ Leave enough space for easy operation and control on the control-panel side ( at least 1 m ) @® Leave enough space for engine inspection, lubrication, connection of cable to the load, fuel supply and other operations both on the right and left sides viewd from the control panel (at least 1 m ). @ Install an exhaust pipe so that exhaust gas is discharged through it to an open area. @® Leave enough space for exhaust of warm air discharged through the radiator, supply of water to the radiator, and arrangement of the exhaust pipe above the machine. © Note that the connection of the generator to indoor wiring not only infrings the law, but also may cause electrocution or generator failure. © Note that the machine can be installed directly on found- ation such as concrete. ® Install the machine in such a’place as can be thoroughly ventilated to prevent a considerable rise in the indoor temperature, which has an adverse effect on the engine generator. -12-4-2. Check Before Startup Be sure to check the machine especially for the follwing points before startup to minimize machine failure. (1) Check O11 x Be sure to check the oil level before startup every day. 1H iH H fi IL je ° x x Good Too high Too low Note : Some engine manufactures provide a level gauge with such H/L marks on both sides, which allows the oll level to be checked during idling. When using such a level gauge, carefully check which of the two H/L narks is used at downtine or during idling. x Check engine oil with an oil level gauge to see that the oil level is in between marks H and L of the level gauge, and replenish or replace it if necessary. * For oil replenishment, supply @ given emount of oil from the oiling port provided on the engine. x After e specified anount of oil engine is supplied, run the engine for several minutes and then stop it to check again to see that the oil level stands in between marks H and L of a level gauge. Notes : For specified quantity of lubricating ofl,refer to the Specifications Table. ~ 13 -(2) Check Cooling Water (/]| Put water 7} to "FULL" In checking or supplying cooling water, make sure that the engine is cold. For cooling water in winter, refer to the "Engine Instruction Manual”. Use tap water as cooling water and put it up to the root of the filling port. some machines are provided with # reserve tank. put tap water in it up to the "FULL” mark. In setting the radiator cap after the cooling water check or supply, take care to turn it clockwise to full position so that the radiator can be used with its inside kept in a pressurized state. Insecurely-tightend radiator cap may result in serious engine trouble. Notes : For specified quantity of cooling water, refer to the Specifications Table. (3) Check Fan Belt Check the belt for tention and elongation. Adjust them if necessary. If any abnormality is found on the belt, re- place it. Perform the adjustment and replacement as dire- ected in "Engine Instruction Manual”. The belt tention is considered to be proper if the flexing level is within 10-15 mm when the arrow-indicated portion (belt center) is pressed with the thumb (approximately 6k). ~14-(4) Check Fuel Be sure to check the fuel level before startup to prevent fuel shortage during operation. Occasionally remove sedi~ nent and contaminated water collected in the bottom of the fuel tank by loosening its drain plus. Frequency 5olz 6onz Fuel Consumption(1/hr) 92 108 (5) Check Generator Case Grounding When the generator is Installed In a moist place, or on highly conductive material such as Iron plates or steel~ work, be sure to connect the grounding wire terminal provided near the output terminal block and bury the wire 50 on or deeper in the ground securely. Do not directly sround terminal "0". Recomended grounding wire sectional area: 5.5 maf or larger Case grounding terminal Grounding wire wre |——__ 00m or nore U (8) Check For Hater And Oil Leakage Check the engine periphery for water and oil leakage. If such leakage is found, identify the leak spot and repair It (1) Check Bolts And Nuts For Looseness Check bolts end nuts, especially on the air cleaner, muffler and turbo-charger mounting portion, for looseness and tighten them if necessary. (8) Check Electrical Wiring For Disconnection, Short And Ter~ ninal Looseness. ate4-8. Load Connection In connecting a load, tighten locking bolts securely with a spanner, etc. to prevent burning. (1) Three-phase Output bs z 8 ro Use U/Y/¥ for three-phase load 200/220V or 400/440 (380V) (415v) Use 0/U,0/V,0/H for single-phase load 116/127 or 281/254V (220¥) (240V) Use U/V,V/¥,4/U for single-phase load 200/220¥ or 400/440V (380¥) (415V) ~ 16 -Select voltage according to the voltage of the load to be used. WN 200/220¥ 400/440¥ (380¥)(415V) x Method For Selecting Output Voltage The output voltage of 200/220¥ or 400/440V, (880V), (4151) can be selected with the voltage changeover plates. These generators are shipped from the plant with their output voltage set at 200/220Y unless otherwise specified. Change over to the desired output voltage according to the following procedure, if necessary. @ The voltage changeover panel is located on the center of the control box. Open the control panel to remove the set screw. ® Change over to the desired output voltage by setting the changeover plates and the changeover switch on its side as shown in the aboye drawing. Note that insecure tightening of the locking bolts results in burning. @® In changing the output voltage over to 400/440, take cere not to lose superfluous changeover plates by, for example, setting them together with the actually used ones. yy Precautions In Load Connection ® Be sure to provide « switch for turning the load ON and OFF between the output terminal block and the load. Note that the use of the generator breaker 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 control-panel and output-terminal-block (single-phase auxiliary output) breakers before load connection. erie4-4, Cable Selection Select a properly-thick cable taking into consideration its allowable current and the distance between the generator and the load. The load current flowing through a cable in excess of its allowable current may cause overheating with resultant burning, and the use of a cable that is too thin for its length may result in decreased input voltage to the electrical instruments, causing them to operate with low power or be inoperative. Coble size $ (ni) Load current F~ Coble longih L(m)—4 The voltage drop across a cable can be determined from its load current, length and thickness according to the following simpll~ fied equation for three-phase three-line system: e = 1/68 x L/S x 1x v8 where e} Voltage drop (V), L; Cable length (m) 3 Cable thickness (mm ) and I; Load current (A). Select the cable length and thickness so that the voltage drop can be held to within 5%. ~ 18 -5. OPERATION 5-1, Automatic Idling Device This device automatizes the idling of the engine for its warm ing-up after startup . 5-2. Opeation For and After Startup (1) Automatic Operation @® Set the Throttle Handle at the desired high-speed position. ® Turn the Speed Changeover Switch on the control panel to "AUTO. IDLING” position. © Turn the Baterry Switch "ON". At this time, check the Running Caution Lamp is off. If the lamp goes on, turn the Battery Switch to the "OFF” position and then to the "ON" position again before checking that the lamp is "OFF". @ Turn the Starter Switch to “START” position slowly to start up the engine. When the engine starts to run, release the Starter Switch. After engine startup, make sure that the OK monitor "Oil Pres- sure Failure” lamp is off. Note: Refer to the item 5-8 for starting at cold period. Check that, upon startup, the engine automatically begins idling at a low speed and the Running Caution Lamp goes on. Check that, in about 20 seconds, the low-speed idling automat- Joally changes over to operation at the high speed preset with the Throttle Handle. © If the idling speed is found not to be as specified, correct it according to the following table. Idling Speed (Frequency) 50Hz Operation 1575rpm (52. 5Hz) 60Hz Operation 1875rpm (62, 5H2) © Set the voltage to that specified with the Voltage Regulator end turn the Breaker "ON” for power transmission. -19-@ Adjust the Throttle Handle and the Voltage Regulator so that the Tachometer, Frequency meter and AC Voltmeter will stand as in upper drawing for 50Hz operation and as in the lower for 60Hz. ob ee 4 Techoneter Frequency meter AC Voltmeter 1500rpm 50Hz 200/400V (380¥) (415) Tachometer Frequency meter AC Voltmeter 1800rpm 6onlz 220/440 (2) Continued Low-Speed Operation Turn the Speed Changeover Switch on the control panel to "LOW" position. If the above changeover is made after startup, the Idling perforned for a given tine after startup is followed by the low-speed operation continuing until the changeover switch is turned to "AUTO. IDLING” position. (8) To change over to high-speed operation soon after startup (for restart when it is sufficiently warmed up) Turn the Speed Changeover Switch on the control panel to the HIGH” position. This switch setting releases the automatic idling function, allowing the engine to be run at the speed set by the Throttle Handle. ~ 20 -5-3 Starting method at cold period This machine has the starting-assist device(APS) for easy starting at cold period. Please start as following procedure. (1) Open the fuel valve for APS(Automatic Priming System). x Keep it opened throughout the winter while the APS is used. (2) Set the battery switch to "ON", and turn the Speed Changeover Switch to the "LOW” position. (3) While depressing the Emergency Stop Button, turn the Starter Switch to "START" position for approx. 10 seconds, and set the Starter Switch to "RUN” position. (4) Pull the Heater Switch to "ON. Preheat Lamp lights and the preheating starts automatically. After about 80 seconds, the Preheat Lamp goes out and the preheat has completed. (5) After Preheat Lamp went out, turn the Starter Switch from "ON” to "START". (8) Take your hand off the key as soon as the engine starts up. (7) Return the Heater Switch to "OFF" as following table. Temperature | Time from engine starting to Heater Switch "OFF". ioc ~ OC] I~2 nin | After starting, turn the Heater Switch gif when the engine rotates sxoothly snd under 0 °C | 8~5 min | the color of exhaust gas become nornal. If you connect the load under the condition Heater Switch "ON” the color of exhaust gas shall be become abnormal end the out put shall be lowered. And the life of glowplug shall be shortened. Therefore please turn the Heater Switch to “OFF”. CAUTION: For the item (4), if you turn the starter switch to “START” when the preheat lemp is lighting, it shall be unable to start the engine because no-spark of glowplug by wet. When engine shall be unable to start, turn the heater switch to "OFF" and repeat the item (3)~ (6) after 2 minutes interval. ~ a -In the case of temperature over 13°C even outer low temperature, the preheat lamp shell be not lighted and the starting-assist device(APS) shall be not operated. The’ engine shall be able to start without starting~ assist device(APS) at the condition over 13°C temperature. 5-4. Check After Startup (1) Check the gauges and lamps for normal operation. (2) Check the engine for exhaust color, sound and vibration. (3) Check for oil, fuel and water leekage. (4) Precautions During Operation ® Do not change the switch over to "LOW” during load operation. In addition, do not start up the engine with the generator and load-side breaker set at "ON” position. Note that the generator voltage and frequency stand so low during idling operation that the loading instruments may operate but function improperly. During this period, the Running Caution Lamp stays on to warn of this state. © Do not turn off the Battery Switch or remove the battery during operation. ® If the operation, stopped by operations other than the Starter Switch "STOP” operation (eq. use of Emergency Stop Button, actuation of the emergency stop device, fuel shortage, engine failure ) is to be restarted, first turn the Starter Switch to "STOP” position or the Battery Switch to "OFF” position before performing the ordinary startup operation. oa)5-5. Shutdown (1) Turn the load-side beaker to the "OFF” side. (2) Turn the generator beaker to the "OFF” side. (3) Place the Speed Changeover Switch in the “LOW” position, and continue to run the engine for about several minutes. Note 1: No Throttle Handle adjustment is required to provide the idling speed. (4) Turn the Starter Switch to the "OFF" position. The engine Inmediately stops. (5) Finely, turn the Battery Switch "OFF". (6) For exergency stop, press the Emergency Stop Button. 5-6. Emergency Stop Device If any abnormal engine oil pressure failure or water temperature rise occurs during operation, this device shuts down the engine automatically. 5-7. If Automatic Idling Device is defective With the Speed Changeover Switch set at the “HIGH” position, operate the engine from startup to stop. The engine always runs at the speed set by the Throttle Handle. 2% Adjust the startup speed, and high-speed operation speed with the Throttle Handle, (The Throttle Handle allows the engine speed to be ad~ justed in the range of approx. 1300 to 1875 rpm. ) The engine will not stop if the Starter Switch is turned to the "STOP” position. To stop the engine, press the Emergency Stop Button. aoe6. PARALLEL OPERATION This section describes the parallel operation It should be noted here that an efficient parallel operation of engine generators can be attained using the same type. 6-1. Preparation For Parallel Operation (1) Nake connection between generators and wire them to the load according to the terminal symbols as shown in the following drawing. x The generators ere shipped with the phase sequence set in the order of U, VY and W. Check the phase sequence with @ phase meter. Generotor} Generator? ¢ a yw yyy 1 Ne = = load (2) When generators designed for double voltage ( 200/220V or 400 /440 ) are to be used, change all of their output voltages over to the operating voltage. (3) Turn the "SINGLE-PARALLEL” changeover swiches on the control panels of all the generators to "PAR” position. (4) Turn the breakers of all the generators "OFF". Synchronizing lamp Single-Parallel changeover switch aaa8-2. Operation (1) Turn the load switch "OFF". (2) Warm up all the generators. (8) Set the all-generator frequency (speed) and voltage to the respective same values with the Throtle Handle and Voltage Regulator, respectivety. This setting requires little sub- sequent adjustment with the Voltage Regulator. (4) Turn the Breaker of No.1 generator "ON". (5) Adjust the Throttle Handle so that the Synchronizing Lamp of No.2 generator goes on and off at intervals of as long as 5 to 10 seconds. Then , turn the Breaker of No.2 generator "ON” the moment the Synchronizing Lamp of this generator goes off for parallel operation. Repeat the same operation to put No.3 and the following gene~ retors, if any, in parallel operation. Note: The Synchronizing Lamp of No.2 generator goes on and off simultaneously with that of No.1 generator if both are synchronized with each other in the phase sequence. If not, they alternately go on and off. In such cases, reverse any two of connections U , V and W between the generators. Not (6) Note that the generators should have no load applied to them under this condition with no AC current flow. If the AC Anmeter pointer stands out of "0", mark the zero~ point adjustment with the Voltage Regulator ~ 25 -(1) 6-3. (1) (2) (3) (4) Turn on the load switch. If the generators are found not to be uniform in load current, make adjustments by changing the engine speed with the Throttle Handle. Turn the Throttle Handle to "HIGH side to increase the load shere and to “LOK” to decrease it. Precautions Adjust the Throttle Handle so that the generators are equal in their load shares during parallel operation. Turn the lock of the Throttle Handle lock clockwise to lock the handle so that it won't loosen and turn during operation. ez In operating the generators Individually, be sure to turn the "SINGLE-PARA” changeover switches to “SINGLE” side. Do not turn the Speed Changeover Switch to “LOW” position during parallel operetion. a7. STORAGE T-1, Daily Storage Store the generator horizontally in @ place where it will not be exposed to moisture, salt and dust. 7-2, Long-term Storage Observe the same precautions as taken for daily storage. For long-term storage of the engine, refer to "Engine Inst~ ruction Manual” supplied by the manufacture. 7-8, Two-tier Stacking Of Generators The generator is designed for two-tier stacking to allow effective place utilization. In stacking the generators in two tiers, observe the following points. (1) Stack the generators horizontally on @ firm ground. (2) Do not stack any machine heavier than this machine. (3) Place square bars between the generators as illustrated in the drawing. (4) Stack the generators so that the weight of the upper is applied to the lower uniformly. (5) In stacking the generators, place one on the other as gently as possible. -21-8. MAINTENANCE AND INSPECTION 8-1. Generator (1) Bearing The generators, supply grease to the bearings every 260 hours so that the grease quantity is about 1/9 of the bearing-chamber volume. (2) Insulation Resistance Neasure the insulation resistance with a 500V-megger at least once every month to check for not less than one negohn. * Measuring method and allowable limit As illustrated in the following drawing, remove the load-side wire from the output terminal block, turn the breeker "ON” and measure the insulation resist~ ance between the output terminal bolt and bonnet. If the insulation resistance thus measured is found to be 0.6 megohn or below, repair the trouble spot to prevent electrocution and fire possibly caused otherwise. 8-2. Control Box Check the measuring instruments for normal operation, 8-3. Engine Perform daily and periodic inspections according to the attached "Engine Instruction Manual”. - 28 -TROUBLESHOOTING 9. pay — unpre goed sopases oy LO souereg — see cones ay dent eories ey souiday — svaz00 ‘usd sopases OL oot dog ‘urd eopases of eonydey co pourm aq 300 Hb to sores a0 coxp axmyyos aL sumo00 army sesum9 soyesen29 eauoagy ror parisay omy | eMgsyy <= 2uyusyYaT} sedoxaN] 4 300 TTT ‘eyT0n pone ‘oneye ooetcag = wep amrey seyennqo4, i aoeqdas 20 ‘suyponoas sedoxds] sasra paods sea 112) va you TTT 00 189 a sums aura dn anys Gee mhoD A HZONZR ~ 29 -OUTLINE DRAWING 10. yo0a Nivea Tag ‘Sard BSHLVESE \ (acis aursogeor Taisao Tans Nivad Weiva Taint Teas r Toes peat 00 moves xeséev “HOLS AUC 1087 POUNVE Tana axavol ASGLLVE 00sS-aa + HOLVEENEO A-OLIGOYS ASLVWON + SNIONE wt soot [ee mara Vv Gvainead inzino ost | fost ay TOs a} 400 ONY MIV GaiveH Fp @ NIaiy NI BIW Me svo-Esavaxs @ Tiviag veer ~ 30 -11. CONTROL AND OPERATING PANEL CONTROL PANEL [OPERATING PANEL. a T | PREQUENCY METER | 1[ TACHOMETER 2 | AC_AMMETER [3 2| THROTTLE HANDLE 3 [AMMBTER CHANGE |[3 3|01L PRESSURE GAUGH OVER SWITCH 3 4[OTL TEMP. GAUGE T[AC VOLTNETER _ [35| WATER TEMP. GAUGE VOLTMBTER CHANGE |2 6| CHARGING AMMETER OVER SWITCH | 7/FUEL GAGE PILOT LAMP 13 8| OK MONITOR CIRCUIT BREAKER |? 9] BATTERY SWITCH WOLTAGE REGULATOR[4 0| STARTER SWITCH PANEL LIGHT [PREHEATING SWITCH] fT O|PANBL LIGHT SWITCH|4 2| PREHEAT LAMP [L-1SYNCHRONTZING LAMP| 3 [EMERGENCY STOP BU’ 1 2|SINGLE-PARALLEL It 4]RUNNING CAUTION LAMP| IcHANGE OVER SWITCH | 5| SPEED CHANGE OVER SWITCH CONTROL PANEL OOO CoP DO, OPERATING PANEL -31-vies anezsoot cas a8 h BOLVEENSO OV SSAIKSAUG ~ 32 - 1 2. GENERATOR CONNECTION DIAGRAMOo ore bowse ele. HOLSOENOD “MS HALVES SNITGI o1LYNOLOY, ‘SKIN 1 8. ENGINE CONNECTION DIAGRAM DOZEMOA DAME14. SAFETY PRECAUTIONS FOR DIESEL GENERATING SETS AND EQUIPMENT To be read attentively before installing, operating or repairing the unit In addition to general safety rules whitch should be observed with diesel generating sets and equipment, the following safety directions and precautions are of special importance. When operating this unit, the operator is expected to employ safe working practices and to observe all related local work safety requirements and ordinances. The owner is responsible for maintaining the unit in o safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation. Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent personnel. If any statement in this book, especially with regard to safety, does not comply with local legislation, the stricter of the two shall apply. These preceutions are general and cover several machine types and equipment: hence some statements may not apply to the unit(s) described in this book. amo14-1. Installation Apart from general engineering practices that conform with the local safety regulations, the following directives are especially stressed: @® Engine exhaust contains noxious elements, Therefore, pay close attention to ventilation when operating the generator set inside tunnels, buildings, or other enclosed areas. ® For outdoor operation, install the generator set so that the exhaust is not discharged in the direction of nearby hones or other enclosed areas. @ When the generator sets is installed in a dusty or corrosive atmosphere, frequently inspect it for radiator clogging and other abnormal conditions. ® Provide adequate space for engine inspection, lubrication, refueling, cable connection to the load, and operation. ® Never remove or tamper with the safety devices, guards or insulations fitted on the unit. © Be sure that the generating set is on secure and level ground. 14-2. Operation © Select cables of proper thickness while referring to the load capacity and distance to the load. Then, securely connect them. Do not use any cable whose cover is broken and degraded. In connecting the cable, be sure to shut down the operation. Cover or tape the connections to prevent leakage and direct contact with the human body, ® Always set voltmeter and frequency meter at the rated. Set ammeter below rated current. ® All canopy doors should be shut during operation. ~ 85 -@® People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear protectors. © The following itens should be checked before startup: a) All guards should be in place and securely fastened. b) Water, engine oil or fuel leakage c) That all fasteners are tight d) That all electrical leads are secure and in good order e) Oil level and cleanliness f) Cooling water level (radiator and overflow tank ) end radiator cap securely tightened 8) Fuel level h) Tension of all V-belts © Provide a switch between the generator and load to operate or stop the load. ® Always keep battery switch turned ON while operating the engine, Also, always keep it OFF when engine is not running. Do not wire the generator set the interior circuit. Avoid low-load operation for long periods of tine. eo@ Coolant: Use clean water. When the temperature drops to (82 F) or below, the following measures must be taken! a) Use antifreeze b) When antifreeze is not used, Open drain cocks of the engine and radiator to completely drain off cooling water after engine operation. @ Fill the fuel tank frequently. Periodically open the drain plug to drain moisture and con- taninants. @® Avoid high speed operation immediately after starting. @ Never turn the starter switch to "START” position while the engine is running. @ Never stop the engine suddenly except in an emergency. ® Never touch any rotating, hot, and live parts during operation. Bie14-3. @ ® © @ ® Maintenance Waintenance and repeir work shall only be carried out under supervision of someone qualified for the Job. Use only the correct tools for maintenance and repair work. Use only genuine spere perts. All maintenance work, other then routine attention, shall only be undertaken when the unit is stopped. Never use flammable solvents or carbon tetrachloride for cleaning parts. Teke safety precations against toxic vapours of cleaning liquids. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape. Nake sure that no tools, loose parts or rags are left in or on the unit. Protect the electrical and regulating components, etc. to prevent moisture from entering these parts, e.g. when stean~ cleaning. Do not remove or tamper with the sound damping material in order to naintain the proper sound pressure level. All responsibility for eny damage or injury resulting from neglecting cation and or repair, disclaimed these precations or by non-observance of ordinary due care required in handling, operating, maintenance even if not expressly mentioned in this book, will be by Denyo Co.,LTD. ~37-