Denyo DCA-150LSKE Instruction Manual

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－１５０ＬＳＫＥ 2-8-5 Nihonbashi-horidomecho, Chuo-ku, Tokyo, 103-8566

* 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" " WARNING" and " 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.

1. Safety Precautions ---------------------------------------------- 1 2. Construction ---------------------------------------------------- 11 2-1 Outline and part names ------------------------------------ 11 2-2 Operating panel, control panel and part names ------------- 13 2-3 Meters ---------------------------------------------------- 14 2-4 Use of switches and controllers --------------------------- 21 3. Transportation and installation --------------------------------- 27 3-1 Transportation of machine --------------------------------- 27 3-2 Installation of machine ----------------------------------- 28 4. Connecting the load --------------------------------------------- 30 4-1 Voltage selector switch ------------------------------------- 30 4-2 Cables to be used ---------------------------------------- 31 4-3 Connecting the load --------------------------------------- 32 4-4 Grounding --------------------------------------------------- 35 5. Operation ------------------------------------------------------- 37 5-1 Checking prior to operation ------------------------------- 39 5-2 Startup --------------------------------------------------- 44 5-3 Handling during operation --------------------------------- 47 5-4 Shut down -------------------------------------------------- 48 5-5 Protection device ----------------------------------------- 49 6. Parallel operation ---------------------------------------------- 50 6-1 Preparation for parallel operation ------------------------ 50 6-2 Parallel operation ---------------------------------------- 51 6-3 Precautions ----------------------------------------------- 53 6-4 Shut down ------------------------------------------------- 53 7. Lubrication, cooling water and fuel ----------------------------- 54 7-1 Engine oil ------------------------------------------------ 54 7-2 Cooling water --------------------------------------------- 56 7-3 Fuel ------------------------------------------------------ 56 8. Handling of battery --------------------------------------------- 57 8-1 Caution on battery charge --------------------------------- 58 8-2 Connection of booster cable, and installation ------------- 59 9. Periodical checking and maintenance ----------------------------- 60 9-1 Maintenance schedule -------------------------------------- 63 9-2 Checking/first 125 hours ---------------------------------- 64 9-3 Checking/every 250 hours ---------------------------------- 65 9-4 Checking/every 500 hours ---------------------------------- 67 9-5 Checking/every 1000 hours ---------------------------------- 70 9-6 Table of periodical maintenance and checking -------------- 72 10. Troubleshooting ------------------------------------------------- 74 11. Long-term storage ----------------------------------------------- 82 12. Service data ---------------------------------------------------- 83 12-1 Specifications ------------------------------------------- 83 12-2 Outline drawing ------------------------------------------ 84 12-3 Generator connection diagram ----------------------------- 85 12-4 Engine wiring diagram ------------------------------------ 86 12-5 Controller wiring diagram -------------------------------- 87 13. Options instruction manual -------------------------------------- 88 13-1 Earth leakage relay -------------------------------------- 88 13-2 Instruction for fuel source changeover device （Three-way value) ---------------------------------------- 93 13-3 Single-phase output receptacles ---------------------------- 95

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. WARNING: This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. CAUTION: This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. [Note] : This symbols show handling precautions for effective operation and many years of satisfactory operation. Some of the items shown by " CAUTION" may also cause death or serious injury. Be sure to observe all the items, as they are important for safe operation. * If the machine is used by an outsider, you are requested to explain him correct handling and advise him to read this instruction manual carefully. * Do not modify the machine at your discretion, as it affects the safety, performance or the life of the machine. * If the machine is modified or it is used incorrectly against this manual or unauthorized parts are used, the warranty of manufacturer will become invalid.

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 １ Safety instruction B9211 0140 ２ Warning：moving parts B9040 0100 ３ Warning：hot coolant B9041 0030 ４ Warning：exhaust gas B9052 0000A ５ Warning：hot surfaces B9042 0040 ６ Warning：diesel fuel B9045 0220 ７ Warning：electric shock B9211 1160 8 Caution：support hook B9121 0020B B 9 0 5 2 0 0 0 0 A C 9 0 4 5 0 0 3 0 A C 9 2 1 1 0 2 0 0 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, etc. of poor ventilation. * If it becomes necessary to use the machine in the above places, the exhaust pipe should be extended to a well ventilated place. In this case, use a ventilator to ensure proper ventilation. * Do not direct the exhaust outlet to nearby pedestrians and houses.

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.

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. WARNING MOVING PARTS can cause severe injury. ■ Rotary unit which runs at a high speed is located in the machine. (Note that it is very dangerous if you touch it.) * Be sure to close the door and lock it during operation. * When 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.

WARNING DIESEL FUEL can cause fire or explosion. ■ Fuel and oil are flammable. Incorrect handling results in danger of ignition or fire. * When fuel needs to be supplied to the machine, be sure to stop the engine. Refrain from smoking. Keep the machine away from fire. * Do not leave flammable objects (paper, wood chips, etc.) and hazardous objects (oil, powder, etc.) near the machine. * Wipe off spilt fuel and oil. WARNING HOT COOLANT can cause severe scalds. ■ If 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 (50℃ or less as measured with the water temperature gauge).

WARNING Stacking ■ 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 stacked machines. * Machines can be stacked up to 2 stages. The weight and size of stacked machines should be less than those of this machine. * Using square timbers as shown right, put each machine making sure that the weight is even. ■ Do not operate the machines in the state of stacking to prevent falling or dropping accidents. WARNING 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.

WARNING 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 ground cable on the ground side. ■ The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. * When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. - In the worst case, it will put out your eyes. ■ For checking or handling of the battery, be sure to stop the engine in advance.

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. ■ 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. CAUTION Noise ■ 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. 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.

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.

2. Construction 2-1 Outline and part names 1. oil drain plug 2. exhaust gas outlet 3. hanger rod 4. support hook 5. coolant in 6. output terminal 7. fuel in 8. fuel drain plug 9. control and operating panel 10. fuel level gauge 11. environmental base drain

1. air cleaner 2. oil filter 3. fuel filter 4. reserve tank 5. AC generator 6. diesel engine 7. radiator・inter-cooler 8. oil level gauge 9. control box 10. fuel tank 11. battery 12. muffler 13. fuel pre filter 14. engine oil in 15. blowby drain 16. environmental base 17. voltage selector switch

2-2 Operating panel, control panel and part names No. NAME No. NAME 1 frequency meter 31 engine indicator 2 AC ammeter indicator: engine speed, oil pressure, water temp, battery charging voltage, integrating time warning lamps high water temp, low lubricating oil pressure, air element blinding, fuel filter water level, over speed, fuel level failure fuel level indicator 3 AC voltmeter 4 output voltage indication lam p 5 frequency change-over switch 6 speed regulator 7 voltage regulator 8 circuit breaker (3-phase) 9 circuit breaker (1-phase) (opti on) 10 earth leakage relay (option) 32 starter switch 11 pilot lamp 33 emergency stop button 12 panel light 34 preheat lamp 13 panel light switch 35 speed change-over switch 14 single-parallel change-over sw itch 15 synchronizing lamp

2-3 Meters Engine indicators (1) Engine indicator That indicates the numerical values of engine speed, engine oil pressure, run hours, battery charging voltage, or engine coolant temperature. Indicated Items Unit engine speed min-1 engine oil pressure ×100kPa battery charging voltage V engine coolant temperature ℃

- 1 - Engine Speed Revolutions per minute is indicated. 1500min-1 is indicated at 50Hz and 1800 min-1 is indicated at 60Hz. - 2 - Engine Oil Pressure 2 to 6 × 100 kPa should be indicated at normal engine operation. Higher value would be indicated in cold condition immediately after engine starts. Conduct a warning - up operation until it indicates normal value. - 3 - Battery Charging Voltage That should indicate more than 26V at engine running. - 4 - Engine Coolant Temperature That should indicate a temperature between 75 to 95 ℃ 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. (2) Fuel Level Indicator That Indicates a fuel level in the fuel tank. All the lights are indicated green when the fuel is full. The green lights stop indicating one by one as the fuel level decrease, finally the red light will be indicated when it is only one green light is left. Replenish the tank when there becomes only one lamp turned on. The table below shows the relation between numbers of turn - on lamps and fuel level. Numbers of lamps turned-on Fuel level (L) 9 215 to full 8 190 to 215 7 160 to 190 6 135 to 160 5 105 to 135 4 80 to 105 3 65 to 80 2 40 to 65 1 0 to 40

(3) Alarm and Memory at Abnormal Condition When any abnormal condition occurs in engine oil pressure, battery charging voltage, or engine coolant temperature, the indication will change as the following ; - 1 - The Indicator shows its defect with blinking numbers. - 2 - When the abnormal condition is corrected, the on - and - off indication will stop. - 3 - If engine would stop urgently and automatically or stop manually with the abnormal condition, the abnormal value will be memorized, and then indicated even after engine is started again. In this case, keep on pushing the button "RESET" for more than 5 seconds, and the abnormal indication will be reset to normal. (4) Hour Meter ① When you turn the starter switch to "RUN" position, and push the selector button located on the right side of the Hour Meter, you can see the numbers mentioned below ; ･ "ODO" Total running hour ･ "TRIP A " Running hours "A" on a certain period ･ "TRIP B " Running hours "B" on a certain period ② If you want to reset the Trip Meters, push the selector button for more than 1 second, after selecting each meters.

(5) The hour meter has an internal battery The engine monitor incorporates both a rechargeable internal battery as well as a charging circuit. While the generator is not in operation, the engine monitor will still indicate the hours operated via its internal battery. While the generator is in operation, the internal battery recharges. When the generator remains unused for a long period of time, the battery will continue to lose its charge. Once the charge is exhausted, the hour meter will not indicate hours, and the battery will need to be recharged. From a completely exhausted state, recharging the battery for 30 minutes will only result in a 30 minute charge to the battery. However, if charged for 3 hours, the hour meter will in dicate hours for more than 10 days without another charge. Please refer to the table below to see the relationship between battery time charging versus length of indication by the hour meter.

Generator indicators (1) Frequency meter This meter indicates frequency of the output voltage. Make sure that it indicates 50Hz or 60Hz during operation. (2) AC ammeter 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. 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. A Ｗ Ｕ Ｖ OFF Ammeter change-over switch

Indication/alarm lamp (1) Preheat lamp It has automatically preheating device. If turn the starter switch to "PREHEAT・RUN" position, the preheat lamp will go on according to cooling water (coolant) temperature. When the preheat lamp goes off, it indicates that preheating is completed. (2) Warning Lamps This monitor indicates the following failures, if any one of them occurs. ① High jacket water temperature (WATER TEMP.) This lamp goes on when the water temperature rises abnormally. If the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. The engine control unit will sometimes cause a temporal indication of the light when operating the starter switch, but it is not related to any of the warming. ② Oil pressure failure (OIL PRESS.) If this lamp goes on during operation, the emergency stop device immediately operates to shutdown the engine automatically. ③ Air filter blinding (AIR FILTER) When the air element is blinded, this lamp goes on. Indicating that the element should be immediately cleaned or replaced. ④ Over speed of engine (OVER SPEED) This lamp goes on when the engine speed rises abnormally. If the lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically.

⑤ High fuel pre filter water level (FUEL FILTER WATER LEVEL) This lamp goes on when the water level in the fuel pre filter would rise. Drain the water in the fuel pre filter soon after the lamp would goes on. (3) Synchronizing lamp When operating in parallel, the synchronizing lamp is used. (4) Output voltage indication lamp Indicates the selected voltage output when the engine is running. (5) Environmental base fluid level warning lamp The liquid measure collected in an environmental base is displayed. Drain an environmental base promptly when the lamp lights in the start-up inspection. [Note] There is a possibility that water and some liquids will overflow from an environmental base until the warning lamp of environmental base liquid measure when the unit is used in the sloping land or is kept.

2-4 Use of switches and controllers Switches (1)Starter switch Functions: ① STOP This switch should be set in this position unless the machine is in operation. The key can be inserted or pulled out in this position. ② PREHEAT / RUN Set the switch in this position until the preheat lamp goes off. This switch should be set in this position when the machine is in operation. ③ START This is the position to start the engine. When your hand is released from the key after starting, it is automatically set in the position of " PREHEAT / RUN ". (2) Speed control device · Speed change-over switch This switch is used to control the engine speed. Set the switch at the "START/IDLING" position for startup or warm up/cooling operation of the engine and at the "RUN" position for constant speed operation of the machine (at 50Hz or 60Hz).

(3) Emergency stop button Push this button for emergency stop only. The control circuit will be de-energized and the engine will stop immediately. [Note] Use this button only for emergency stop. After the engine stops, reset the lock by rotating the button to clockwise direction. The engine will not start if the button is still locked. (4) Single-parallel change-over switch In case of operation of single unit, turn this switch to the 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 changeover switch Use this switch to change the utility frequency. [Note] Do not switch during operation.

(6) Panel light switch This is the switch to turn on the panel light. (7) Circuit breaker · 3-phase circuit breaker This is a main switch to supply power to a load. When the load is shorted or in the state of overload, it trips to protect the generator against trouble. [Note] 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. · 1-phase circuit breaker (Option) It is a circuit breaker for 1-phase output terminal. This machine is protected by this circuit breaker from over-current and leakage. · 1-phase receptacle’s Circuit protector (Option) Every receptacle on this machine is protected by the circuit protector from over-current. When the circuit protector tripped, the white button will extend and push it back in to reset the circuit protector.

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. (2) Speed regulator This regulator is used to adjust the frequency. Turn the regulator to clockwise to increase the speed and counter clockwise to decrease it. (3) Overcurrent relay 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 the electronic governor. The governor is set to Droop Control when it is shipped. For a detailed explanation of how this works, refer to "5. Operation". (2) Droop Adjustment Trimmer This device is used to adjust the Droop (Speed Regulation Ratio).

(3) Defect identify display This is a function that displays engine troubles, and is equipped on the surface of the controller. When the engine starts and the controller turns on, this indicator checks various parameters within about 10 seconds, and if finds normal operation, the digits "00" are displayed. If the indicator finds some parameter abnormality, "E-" is displayed, followed by the error code and type of problem. (4) Reset button This is the reset button for the defect identify display. The display will keep on showing the trouble even after it is corrected and engine is started again. To cancel such condition and recover the normal indication, press this push button for one second. (5) Pre. Lube. Switch It enables non-injection cranking by turning the switch "ON". Use this switch when starting the engine after long term storage or after replacing the oil filter cartridge. The engine will stop if the switch is turned "ON" while the engine is running. At normal operation, make sure the switch is in "OFF" position. [Operation Procedure] ① Turn the starter switch to "RUN" position. ② Turn the Pre,Lube. Mode Switch to "ON" position. ③ Turn the starter switch to "START" position to crank up. (Do not run the starter motor for more than 15 seconds.) ④ Stop the cranking when the oil pressure is increased. ⑤ Turn the Pre.Lube. Mode Switch "OFF". ⑥ Turn the starter switch to "STOP" position .

3. Transportation and installation 3-1 Transportation of machine 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 「12-1. Specifications See p.85」

3-2 Installation of machine WARNING ENGINE EXHAUST can kill. ■ Insufficient ventilation may lead to death due to lack of oxygen or poisoning by exhaust gases. * Do not use the machine in a place of poor ventilation or in a place where exhaust gases stays. * Do not use the machine indoors or in storehouse, tunnel, ship hold, tank, etc. of poor ventilation. * If it becomes necessary to use the machine in the above places, the exhaust pipe should be extended to a well ventilated place. In this case, use a ventilator to ensure proper ventilation. * Do not direct the exhaust outlet to nearby pedestrians and houses. [Note] vibration: The engine, running, generates vibration during operation of the machine. When installing the machine, be sure to observe the following points. ① Install the machine horizontally on a solid foundation. Operation on an uneven place will generate unusual vibration. ② 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 recommend to execute the measure for sound level to prevent claims from nearby living people.

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 air) 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 Voltage selector switch CAUTION VOLTAGE SELECTOR SWITCH ■ Make sure the Load Circuit System and the Output Terminal Connection are matched. Unmatched connection will cause damage to the load side and the generator. ■ Never change the position of the Voltage Selector Switch while the engine is running. Always switch OFF the circuit breaker and stop the engine before selecting voltage. The Voltage Selector Switch is located at the right side of the control box. Use this switch to set the output voltage to 200V or 400V. Check the Voltage Selector Switch position or the Voltage Selector Indicator Lamp to confirm the output voltage. Note that the indicator lamp can only turn ON when the starter switch is in "PREHEAT・RUN" position. Switching the output voltage: (1) Turn "OFF" all the circuit breaker/protector and turn the starter switch to the "STOP" position and the engine will stop. (2) Move the handle cover by removing the screw on the handle cover. (3) Switch the handle to the appropriate output voltage. (4) Move the starter switch to the "PREHEAT・RUN" position, check if the voltage selector indicator lamp is showing the selected output voltage and then turn the starter switch back to "STOP" position. (5) Put back the handle cover and fast the screw on it. (6) Refer to 4-3 Connecting the load for proper connection instruction. 200V class 400V class Voltage selector switch Output voltage indication lamp

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 failure in operation. Select the length and size of cable so that the voltage drop "e" obtained by the following equation is within 5% of the rated voltage. * Equation to obtain 3-phase, 3-wire system voltage drop "e" from the length and size of cable and operating current is as follows. 3 58 1 × × × = Ｉ Ｓ Ｌ ｅ where e: voltage drop (V) L: length (m) S: cable thickness(mm 2 ) I: load current (A)

4-3 Connecting the load WARNING ELECTRIC SHOCK can kill. ■ Do not touch the output terminals during operation to prevent decease due to electric shock. * When a wiring work is required, be sure to turn OFF the circuit breaker and stop the machine. * When operating the engine, close the output terminal cover. Tighten the fixing bolts before operating the machine. ■ Do not use damaged cables to prevent electric shock. Insufficient tightening of bolts will generate heat at connections which may result in fire accidents. * When connecting, make sure the connecting cables are normal and connected firmly to the output terminals. CAUTION Connection to house wiring ■ Before connecting this machine to any building's electrical system, a licensed electrician must install an isolation(transfer) switch. * Serious injury or death may result without this transfer switch.

(1) 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. Use U/V/W for three phase load 200/220V or 400/440V Use O/U,O/V,O/W for single phase load 115/127V or 231/254V Use U/V,V/W,W/U for single phase load 200/220V or 400/440V Ｕ Ｖ Ｗ Ｏ ＵＶ Ｗ Ｏ Ｕ Ｖ Ｗ Ｏ Ｕ Ｖ Ｗ Ｏ

(3) Precaution in load connection ① 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. ② In connecting the load, be sure to stop the engine and turn OFF the breakers on the control panel. ③ Don't contact the connecting cable to the output terminal of other phase on the output terminal block. ④ When the load connection is finished, close the cover of output terminal and tighten by the bolts.

4-4 Grounding 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. Grounding Execute the grounding certainly to prevent the electric shock by leak. (1) 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. (2) Case grounding of the load Execute the grounding for the load similarly. Provide the grounding rod to satisfy the grounding resistance which conforms to the local rule.

(3) Precaution in grounding ① 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. ② If burying the grounding rod on the place that many pedestrians walk on, clamp the lead wire to prevent catching on it. ③ If the lead wire is not long enough for the connection, connect it as directed below: 1) 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. ④ Avoid the places within 2m of lighting conductor grounding location for burying of grounding rod. ⑤ Do not use a telephone set grounding conductor.

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 Droop Control when it is shipped. * Use Droop control for normal operation. * 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 ■ Droop Control: (The frequency changes depending on the load size) With Droop control applied, the frequency is controlled to change according to the applied load. The RATED LOAD frequency will be decreasing approximately 2-2.5Hz compared to the NO-LOAD frequency. Operation Method ①After the engine warmed up, set the speed using the Speed Regulator (refer to the right picture) once the machine is running at high speed. ②Set the required voltage using the voltage regulator. ③Turn ON the Circuit Breaker and the unit will be at power transmission state. ■ Isochronous Control: (The frequency is constant regardless of the load size.) With Isochronous Control applied, the frequency set at NO LOAD state is constantly controlled regardless of the applied load. (The last set frequency will be recorded and saved in the controller even after 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 ①After the engine warms up, set the speed using the Speed Regulator (refer to the right pictured) once the machine is running at high speed. ②Set the required voltage using the voltage regulator. ③Turn ON the Circuit Breaker and the unit will be at power transmission state. Installation of the switch Only operate the switch when the engine is stopped. Open the control panel and turn the "Isochronous- Droop Change-Over Switch". After turning the switch, close and tighten the control panel using the fixation bolts. - 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: In 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] If 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 WARNING MOVING PARTS can cause severe injury. ■ Rotary unit which runs at a high speed is located in the machine. (Note that it is very dangerous if you touch it.) * Be sure to close the door and lock it during operation. * When making check or maintenance of the machine, be sure to stop the machine in advance. - To prevent unexpected trouble, be sure to check the following points. (1) 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 environmental base drain (7) Checking on grounding for electric shock protection (8) Checking for leakage of oil and water (9) Checking for loose parts (10) Removal of foreign objects in machine (11) Checking on blowby drain Inspection: (1) Checking on engine oil (Read the instruction manual for the engine furnished separately.) ① Checking the level of engine oil by the dipstick. Make sure the oil level is always between H and L. ② When it is below the low limit, supply oil immediately. ③ At the same time, check condition of oil by the dipstick. [Note] Oil is consumed gradually during operation. When the machine is to be used continuously for a long time, be careful with lack of oil.

(2) Check on engine cooling water (Read the instruction manual for the engine furnished separately.) WARNING HOT COOLANT can cause severe scalds. ■ If 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 (50℃ or less as measured with the water temperature gauge). ① Check (to see) that cooling water in the reserve tank is within the range of FULL-LOW. ② When it is below the low limit, supply (additional) water immediately. ③ Normally, only the water level of the reserve tank needs to be checked. But, the radiator cap should be opened once a week to check that water is full in the radiator. [Note] When closing the radiator cap after water level is checked or water is supplied, turn the cap fully clockwise so that it can be firmly tightened. Otherwise, cooling water is evaporated which results in serious damage to the engine.

(3) Check on fan belt (Read the instruction manual for the engine furnished separately.) ① Check the belt for tension and elongation. Also, check it for damage. Replace if necessary. ② For adjustment or replacement of the belt, refer to the instruction manual for the engine. Press (about 6kg) the position shown by arrow mark (middle of belt) with your thumb. The bend should be within the range of 10-15mm. Parts number of fan belt : Model name Parts number manufacture Parts number of manufactur e DCA-150LSK E Y06020 15229 KOMATSU 6732-82-3550 (4) Check on fuel ① Be sure to check the quantity of fuel prior to operation to prevent lack of fuel during operation. ② Loosen the drain plug of the fuel tank from time to time, and remove sediments and water at the bottom of the tank. [Note] Remove the drain to a container and dispose the drain appropriately as industrial waste.

(5) Check on battery acid CAUTION BATTERY ■ The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. * When the battery acid gets on your 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. (6) Checking on environmental base drain Loosen the drain cock and drain the water or contents collected in environmental base. [Note] Remove the drain to a container and dispose the drain appropriately as industrial waste.

(7) Check grounding for electric shock protection Make sure that the case grounding of the machine and the load are certainly. Do not ground directly 「O」terminal. (8) Check for leak of water and oil Check the machine for the trace of leak of oil or water. If a leak is found, check the location of leak and stop it. When the leak cannot be stopped, contact our service factory. (9) 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. (10) 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. (11) Checking on blowby drain Remove the blowby drain cock and drain the oil. [Note] Remove the drain to a container and dispose the drain appropriately as industrial waste.

5-2 Startup Following is flow of startup. check emergency stop button is reset. circuit breaker：OFF Frequency change-over switch：:50or60Hz Speed change-over switch：START/IDLING Single-parallel change-over switch：SINGLE starter switch：PREHEAT/RUN preheat lamp：check preheat lamp goes off. starter switch：START engine startup starter switch：PREHEAT/RUN When it is cold. warm up operation： about 5 minutes warm up operation：sufficiently Speed change-over switch：RUN adjustment of speed adjustment of voltage circuit breaker：ON supply power to load

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) check it the emergency stop button is reset. (2) Make sure that the circuit breakers of the machine and the loads are all in the "OFF" position. Switch it to the frequency according to the utility frequency of your region or country. (3) Set the frequency chang-eover switch to the 50Hz or 60Hz position. (4) Set the speed change-over switch to the "START/IDLING" position. (5) Turn the single-parallel change-over switch to single side. (6) Turn the starter switch to "PREHEAT/RUN" position. (7) After the preheat lamp goes off, turn the starter switch to "start" position. The engine starts, release the starter switch and allow to return to the "PREHEAT/RUN" position. [Note] If the engine is warm, the preheat operation is not required. The duration of preheating differs according to the temperature of cooling water. And if the temperature of cooling water is high enough, the preheat lamp does not turn on because no preheating is required.

(8) Set the speed change-over switch to "START/IDLING" position and let the engine idle for about 5 minutes. The engine speed during idling will be 650 min-1. (9) After warming up the engine, set the speed change-over switch to the "RUN" position. Check if the idling speed and the frequency are similar to the specified value in the following table. If the idling speed is not as specified or change of frequency is required, adjust the idling speed using the speed regulator. If the idling speed set above speed, frequency becomes nearly 50Hz or 60Hz in the rated load. (10) Set the voltage to the rated voltage using the voltage regulator. (11) Turn the circuit breaker to the "ON" position. The machine starts power transmission state. Commercial freque ncy Idling speed Operation at 50Hz 1575min-1(52.5Hz) Operation at 60Hz 1875min-1(62.5Hz)

5-3 Handling during operation (1) Checking after startup ① Make sure that each meter and lamp are normal. normal : warning lamp is all off ② 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 (2) Adjustment during operation Set the engine indicators and frequency meter to the rated by the speed regulator. Set the voltmeter to the rated by the voltage regulator. [Note] * Do not set the speed change-over switch in "START/IDLING" position or do not decrease the speed by the speed change-over switch 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.

5-4 Shut down (1) Turn OFF the circuit breaker of the load. circuit breaker of the load (2) Turn OFF the circuit breaker of the machine. circuit breaker of the machine (3) Set the speed change-over switch in "START/IDLING" position and put the machine in cooling operation for about 5 minutes. cooling operation for about 5 min. (4) Set the starter switch in "STOP" position. The engine will stop immediately. (5) Check the panel light goes off. (6) Remove the key from the starter switch and keep it at hand. stop (7) Check the amount of fuel. Supply additional fuel if necessary. (8) Check for leakage of oil, fuel and water. [Note] * The stop button is a push button to stop the engine in case of an emergency. When the button is pressed, it must be emergency stop button unlocked by turning it clockwise before the engine can be re-started. * Check the panel light goes out.

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 warning turn OFF the circuit break er stop the engine indicate by warning lamp function oil pressure failure (OIL PRESS) － － ※● set point : 150kPa ※○ stop ○ set point : 49kPa high jacket water temperature (WATER TEMP) － － ※● set point : 97℃ ※○ stop ○ set point : 101℃ Battery charging failure － － ※● set point : 26.0V overcurrent of generator ○ － － When overcurrent flows, the device acts earth leakage (option) ○ － ○ When electric leakage, the device acts Current sensitivity : 30mA fuel level failure (FUEL LEVEL) ※○ stop ○ When fuel supply is necessary because of fuel shortage, the device acts Warning lamp : 40L Stop the engine : 20L high fuel pre filter water level (FUEL FILTER WATER LEVEL) － － ○ When the water level in the fuel pre filter would rise air filter blinding (AIR FILTER) － － ○ When replace or cleaning of air filter is necessary because of blinding of filter, the device acts over speed of engine (OVER SPEED) ※○ stop ○ ※● 60Hz set point : 2070 min-1 50Hz set point : 1725 min-1 an environmental liquid measure increase － － ○ When the liquid measure in an environmental base becomes a half level. (Orange Lamp) ※● Abnormal value and unit will be indicated lighting on and off.

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 required load capacity exceeds the generator capacity, 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 same model of the generating sets. 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 selector switch on each unit to the same voltage. (3) Connect each unit and load as shown below, referring the terminal symbols. Use a phase tester to check the sequence of the phases. Generator 1 Generator 2 Generator 3 U V W U V W U V W Circuit breaker No.1 No.2 No.3 Load [Note] Connect the cables in the correct sequence of the 3-phases, check the terminal symbols. (4) Turn the single-parallel change-over switch to "PARALLEL" position on each control panel.

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 voltage regulator and the speed regulator. (4) First turn on the circuit breaker on the No.1 generating set. (5) Adjust the speed regulator on the No.2 set so that the two synchronizing lamp on the No.2 set turn on and off at the same time when the two phase sequences are in the same direction, while the two turn on 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. (6) At the instance when the synchronizing lamps on No.2 set turn off, turn the No.2 set breaker on. [Note] The generators can be damaged due to short circuit current if the breaker is turned on when the synchronizing lamps are still on. (7) Upon the above procedure, the No.1 and No.2 sets are in parallel operation. The AC ammeters are supposed to indicate zero in this no load condition. If the meters indicate some current, it is an uneffective cross current due to voltage difference. Make it zero by adjusting the voltage regulator.

(8) If more than 2 generators (No.3, No.4～) are required, apply the same ⑤⑥⑦ procedures. (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 speed regulator 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. Wattmeter (Option) is required to know the correct load sharing.

6-3 Precautions (1) Keep each generating sets in equal load sharing by adjusting the speed regulator 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-parallel change-over switch in the position "PARALLEL" [Note] If it is turned to "SINGLE", a cross current occurs between the generators 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. (4) Never turn the speed change-over switch to the "START/IDLING" side. [Note] If it is turned to "START/IDLING" 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. 6-4 Shut down (1) Turn off the breakers on the load side. (2) Turn off the main circuit breaker on each generating set. ↓ (3) Shut down each engine referring to 「5-4. Shut down」 MACHINE ↓ ↓

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) Type of engine oil Use API service category class CF-4, CH-4, CI-4 or JASO DH-1. [Note] * For new oil, the Total Base Number (TBN) must be at least 8mgkOH/g. * Do not use the unrecommended combination of fuel and oil stated in the following table. * Refer to the engine instruction manual for further information. The oil replacement interval depends on the grade of engine oil. * For CF-4 Replace the oil after first 125 hours, and afterward in every 250 hours. * For CH-4, CI-4, JASO DH-1 Replace the oil after first 125 hours, and afterward in every 500 hours.
every 250 hours every 500 hours CI-4, CH-4, JASO DH-1

(2) Oil viscosity Recommended oil viscosity is SAE 10W-30, all-season type. Use oil according to ambient temperature referring to the table below. Ambient temperature （℃） -30 -20 -10 0 10 20 30 ＳＡＥ２０ ＳＡＥ３０ ＳＡＥ５Ｗ－２０ ＳＡＥ１０Ｗ－３０ 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 ２４．８Ｌ

7-2 Cooling water (1) Water for cooling Use the mixture of the good quality soft water and the Long Life Coolant (LLC) of anti-freeze and anti-rust for the 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℃ 40%: -20℃ 50%: -30℃ In case of replenishment, use LLC of the same brand and the same density. Normally LLC should be replaced every 2 year. (2) Total quantity of cooling water Total cooling water quantity ２５．４Ｌ（２．４） （Value in parentheses is reserve tank capacity.） 7-3 Fuel (1) 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.

8. Handling of battery WARNING 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. ■ 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. ■ For checking or handling of the battery, be sure to stop the engine in advance.

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℃), 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.

8-2 Connection of booster cable, and installation When the engine is started using booster cables, connect the cables as follows. (1) Connection of booster cable ① Connect the clip of the booster cable "A" to the terminal "+" of the machine in trouble. ② Connect the other clip of the booster cable "A" to the terminal "+" of normal machine. ③ Connect the clip of the booster cable "B" to the terminal "B" to the terminal "-" of normal machine. ④ Connect the other clip of the booster cable "B" to the engine block of the machine in trouble. (2) Removal of booster cable ① Remove the clip of the booster cable "B" connected to the engine block of the machine in trouble. ② Remove the clip of the booster cable "B" connected to the terminal "-" of normal machine. ③ Remove the clip of the booster cable "A" connected to the terminal "+" of normal machine. ④ Remove the clip of the booster cable "A" connected to the terminal "+" of the machine in trouble. (3) Caution on handling of booster cable ① Use booster cables and clips of the size that matches the size of battery. ② The battery used for normal machine should be the same in capacity as the battery of the machine in trouble. ③ After connection, check that clips are firmly connected. ④ When connecting booster cables, make sure that the terminal "+" does not touch the terminal "-". ⑤ The engine block should be connected at a place more than 30cm away from the battery.

9. Periodical checking and maintenance (Read the instruction manual for the engine furnished separately) WARNING MOVING PARTS can cause severe injury. ■ 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. 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.

WARNING 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. WARNING BATTERY ■ 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.

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. 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. CAUTION Handling of waste liquid * Waste liquid from the machine should be received in a vessel. * Do not dispose of waste liquid recklessly, as it causes environment pollution. Do not throw it on the ground or in rivers, lakes, sea, etc. * Lubrication, fuel, cooling water (coolant) and other harmful objects such as filter, battery, etc., should be disposed of according to the related regulations.

9-1 Maintenance schedule 50 hours: Checking/First 50 hours * Cleaning on nylon and rubber hose 100 hours: Checking/every 100 hours * Checking on nylon and rubber hose 125 hours: Checking/first 125 hours * Replacement of engine oil * Replacement of engine oil filter cartridge 250 hours: Checking/every 250 hours * Replacement of engine oil (for CF-4 engine oil) * Replacement of engine oil filter cartridge (for CF-4 engine oil) * Cleaning of air cleaner element * Measurement of generator insulation resistance (once a month) * Checking on battery specific gravity * Emission carbon deposition check. * Maintenance of output voltage selector switch. (once a month) 500 hours: Checking/every 500 hours * Replacement of engine oil (for CH-4・CI-4・JASO DH-1 engine oil) * Replacement of engine oil filter cartridge (for CH-4・CI-4・JASO DH-1 engine oil) * Replacement of fuel pre filter cartridge * Cleaning of radiator and intercooler * Checking for terminal and connection of the circuit * Checking/every 100 and 250 hours is also required. 1000 hours: Checking/every 1000 hours * Replacement of fuel filter cartridge * Cleaning inside of environmental base * Cleaning inside of fuel tank * Replacement of air cleaner element * Checking on rubber suspension * Checking on lining * Checking/every 100, 250, and 500 hours is 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) 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. 9-3 Checking/every 100 hours (1) 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. 9-4 Checking/first 125 hours (1) Replacement of engine oil Replace the engine oil at 125 hours only first time and every 250 or 500 hours after second time. ① Remove the engine oil drain plug and discharge oil completely. It can be discharged easily when the engine is warm. ② After engine oil is discharged, tighten the plug firmly. ③ Charge new engine oil from the oil filler until it reaches the notched line of the "H" on the dipstick. ④ After engine oil is supplied, run the engine for a few minutes. Check that oil is supplied to the level between H and L . (2) Replacement of engine oil filter cartridge Replace the engine oil filter at 125 hours only first time and every 250 or 500 hours after second time. Cartridge type (cartridge type is unit of filter case and element) ① Remove the cartridge type element (cartridge) using filter wrench. ② Clean the filter base. Coat the packing of new cartridge with engine oil thin. Then, mount the cartridge. ・When mounting, tighten the cartridge from 3/4 to 1 turn by using filter wrench after the packing is fitted to the seal of the filter base.

③ After the element is replaced, run the engine for a while. Then, check to see that oil is supplied to the level between H and L. Parts number of oil filter cartridge : Model name Parts number manufacture Parts number of manufact ure DCA-150LSK E Y06020 41209 KOMATSU 6736-51-5142

9-5 Checking/every 250 hours (1) Replacement of engine oil (for CF-4 engine oil) Replacement is refer to ｢9-4.(1) Replacement of engine oil｣. * If CH-4・CI-4・JASO DH-1 engine oil is used, replace the engine oil every 500 hours. (2) Replacement of engine oil filter cartridge (for CF-4 engine oil) Replacement is refer to ｢9-4.(2) Replacement of engine oil filter cartridge｣. * If CH-4・CI-4・JASO DH-1 engine oil is used, replace the engine oil filter cartridge every 500 hours. (3) 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 - Remove the air cleaner element and clean the element with dry and clean compressed air. * While it is being cleaned, check the element for any damage. Replace if necessary. * Before installing the air cleaner, wipe off dirt on the element cover. * When insert the element, insert the element completely pressing equal edge of element.

(4) Measurement of insulation resistance. WARNING ELECTRIC SHOCK can kill. * Measurement should be made after the machine stops. - Using a 500V insulation resistance tester, make a check once a month to ensure that the insulation resistance is more than 1MΩ. In case of measuring with an insulation resistance tester over 500 V, disconnect all connectors from the AVR located in the control box before measuring. 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 1MΩ, 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.

(5) 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 temp. Charging (℃) rate(%) ２０ ０ －１０ １００ 1.28 1.29 1.30 ９０ 1.26 1.27 1.28 ８０ 1.24 1.25 1.26 ７５ 1.23 1.24 1.25 Each value has a deviation of ±0.01. When the charging rate is below 75%, the battery needs to be recharged. 「8-1. Caution on battery charge」 (6) Emission carbon deposition check Deposition of carbon (soot, unburned fuel) in the exhaust pipe line and muffler could cause not only system derates but also could lead to fires. To destroy soot and unburned fuel, run the unit at rated power until the exhaust gas become mostly colorless every 250 hours operation time. More carbon will be generated when the unit operates at less then 30% of rated power. In this case, perform the above procedures more frequently. NOTE: ・ Applying a large load suddenly to the unit when the carbon deposition is generated in the exhaust system could produce sparks and will lead to abnormal combustion. Therefore, apply load gradually and observe the exhaust gas color during the process. ・ Sparks may come out of the exhaust gas outlet during load operation. Make sure the unit’s surrounding is free from any flammable material.

(7) Maintenance of output voltage selector switch. CAUTION No output change during running * The generator will fail, if the output voltage is changed during running. Stop the engine before changing the output voltage. When the handle of switch hasn`t operated for long term, contact failure of switch terminals may rarely occurs by the dust. To remove the dust from terminals, please switch the handle between 200V class and 400V class and return it for 10 times 『return it for 10 times』 9-6 Checking/every 500 hours Checking/every 100 and 250 hours is also required. (1) Replacement of engine oil (for CH-4,・CI-4・JASO DH-1 engine oil) Replacement is refer to ｢9-4.(1) Replacement of engine oil｣. * If CF-4 engine oil is used, replace the engine oil every 250 hours. (2) Replacement of engine oil filter cartridge (for CH-4,・CI-4・JASO DH-1 engine oil) Replacement is refer to ｢9-4.(2) Replacement of engine oil filter cartridge｣. * If CF-4 engine oil is used, replace the engine oil filter cartridge every 250 hours. (3) Replacement of fuel pre filter cartridge ① Using a filter wrench, remove the clear cap (A) and the cartridge-type element (B) (hereinafter, "cartridge"), in this order. Remove the seal (C) from the clear cap to clean the cap. ② Spread clean fuel or oil lightly on a new seal (C) and fit it in the clear cap (A) and next install it on a new cartridge (B). Tightening torque of the clear cap: 10N･m(1.0kgm) 200V class 400V class

③ Clean the filter housing and, next, pour fuel into the filter with the cap (D) being left installed on the new cartridge (B). After filling the filter with fuel, remove and dispose the cap(D). During the fitting process, spread engine oil lightly on the surface of the cartridge's packing and install it in the filter housing. After confirming that the packing surface contacts the seal surface, tighten a 3/4 turn. ④ After completing the replacement with a new cartridge, release the air out of the fuel piping system (for air releasing method, refer to the instruction manual for the engine or check the name plate installed on the machine.) Get the engine started to check if there is a fuel leakage. [Note] Do not fail to wipe off spilled fuel completely and to ensure there is no fuel leakage. Parts number of fuel pre-filter cartridge : Model name Parts number manufacture Parts number of manufactur e DCA-150LSK E Y06020 42584 KOMATSU 600-319-3610 (4) Cleaning of radiator and intercooler When the fin or tube is blinded, it should be cleaned with steam or high pressure water. [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. (5) 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.

9-7 Checking/every 1000 hours Checking/every 100, 250 and 500 hours is also required. (1) Replacement of fuel filter cartridge. ① Remove the cartridge type element (cartridge) using filter wrench. ② 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 1/2 to 3/4 turn by hand after the packing is fitted to the seal of the filter base. ③ 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 method of discharging air is also attached to the machine. Parts number of fuel filter cartridge : Model name Parts number manufacture Parts number of manufact ure DCA-150LSK E Y06020 42585 KOMATSU 600-319-3750 (2) Internal cleaning of an environmental base ＜Division Procedure＞ ① Drain the water or contents collected in an environmental base. ② Bolt that unites environmental base with upper base is detached with the hook of the crane hung on the hanging metal fittings of this machine. ③ This machine is slowly lifted up, and it separates from an environmental base. ④ Check and clean the internal environmental base.

[Note] Remove the drain to a container and dispose the drain appropriately as Industrial Waste. ・Confirm there is no leakage after it cleans it in an environmental base. Ask the nearest office or service factory when you discover the leakage by any chance. ・Paint after it removes the rust when rust has been found in an environmental base. ＜Assembly procedure＞ ① Set to store this machine from an environmental base internally, and install the bolt for uniting. (3) Cleaning inside of fuel tank Drain the fuel in the fuel tank completely, and wash out deposits and water collected inside the tank. (4) Replacement of air cleaner element The element should be replaced referring to ｢9-5.(3) Cleaning of air cleaner element｣. Parts number of air cleaner element :

Model name Parts number manufacture Parts number of manufactu re DCA-150LSK E Y06020 4665 4 KOMATSU 600-185-4100 (5) 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. (6) Checking on lining Check on the lining, whether it deteriorates greatly, or it is stained by clinging of oilier the like, or it is removed. Contact distributor or our office to replace the lining, if necessary.

9-8 Table of periodical maintenance and checking ◇:Check or Clean ○:Replacement ☆:Only first time List of maintenance and inspection daily first 50h every 100h every 125h every 250h every 500h every 1000h Engine Checking on oil level and stain of oil ◇ Checking on cooling water ◇ Checking on fan belt ◇ Checking on fuel and drain ◇ ◇ Checking on environmental base drain ◇ Checking on battery acid level ◇ Checking on for water and oil leakage ◇ Checking on bolts and nuts for looseness ◇ Checking on blowby drain ◇ Checking on exhaust color, sound and vibration ◇ Checking on meters and warning lamps ◇ Checking on nylon and rubber hose ☆○ ◇ Replacement of engine oil ☆○ ○ ※1 ○ ※2 Replacement of engine oil filter cartridge ☆○ ○ ※1 ○ ※2 Cleaning of air cleaner element ◇ Checking on specific gravity of battery ◇ Emission carbon deposition check ◇ Cleaning radiator and intercooler ◇ Replacement of fuel pre filter cartridge ○ Replacement of fuel filter cartridge ○ Emission carbon deposition check ◇ Cleaning inside environmental base, Cleaning of fuel tank ◇ Replacement of air cleaner element ○ ※3 Checking of alternator ◇ ※3 Checking of engine valve clearance 2000h ※3 inspection of tightening parts of engine intake air piping clamps 2000h ※3 checking of vibration damper 2000h

List of maintenance and inspection daily first 50h every 100h every 125h every 250h every 500h every 1000h Generator Checking on rubber suspension ◇ Checking on lining ◇ Checking on generator case grounding ◇ Checking on insulation resistance ◇ Checking on terminal and connected section ◇ ※1 If CF-4 engine oil is used. ※2 If CH-4・CI-4・JASO DH-1 engine oil is used. ※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.

10. Troubleshooting WARNING MOVING PARTS can cause severe injury. ■ 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. 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.

WARNING 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. WARNING BATTERY ■ 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 Engine will not start u p Cell motor will not run or revolution speed is low Discharged battery Charge or replace Detached or loosened or corroded battery terminal Repair Fuse blow Replace Improper starter switch Replace Improper starter Replace Broken lead wire Repair Cell motor run s Fuel shortage Supply Blinded fuel filter Replace cartridge Air in fuel system Remove Speed will not rise Air in fuel system Remove Blinded fuel filter Replace cartridge Compression failure Repair engine Blinded air cleaner Replace element Engine stop by oil failure Oil shortage Supply Oil pressure switch failure Replace Blinded oil filter Replace cartridge Over heat (water temperature) Cooling water shortage Supply Fan belt looseness Adjust Blinded core of radiator Clean Engine thermostat failure Repair Voltmeter will not operate Voltmeter failure Replace AVR failure Contact distributor or our office Burned ZNR Quenched residual magnetism Burned rotary rectifier Disconnected rotor wiring Burned generator wiring Rated voltage will not be reached Voltmeter failure Replace AVR failure Contact distributor or our office VR failure Burned rotary rectifier Burned ZNR Burned generator wiring Low speed Increase

Phenomenon Assumed cause Action Voltage goes too high Voltmeter failure Replace AVR failure Contact distributor or our office VR failure Applied load causes load voltage drop Burned rotary rectifier Contact distributor or our office AVR failure Burned main field, exciter field wiring Unbalanced load Balance

Engine Diagnostic Users can check the engine defect with defect identify display inside the control box. In normal condition When the switch is on, the program number will appear on the display, follows by saved defect code with it’s contents and after a few seconds, if there is no defect, [00] will appear. display example Power ON → 88 → Engine Master Controller System → ― ― → CA442 → CA111 → 00 （saved defect codes） (OK) In defect condition If any defect occurred, the [E.] will appear on the display instead of [00] before the defect contents and defect code appear. display example Power ON → 88 → Engine Master Controller System → ― ― → CA442 → CA111 → CA689 → CA144 → CA689 → CA144 （saved defect codes） ※（current defect codes） → ※ is repeated ・ The program number and defect code stated above are only for examples. ・ Refer to the defect code table in the next page for the defect contents. ・ Even if the engine doesn’t stop, check and repair the machine immediately after any defect code are indicated. ・ After occurred defect is repaired, switch the starter switch to "PREHEAT/RUN" position, push reset button for more then one second to delete the saved defect code.

Defect code list Defect content Defect code Open circuit error Machine condition System responce 電源電圧高異常 (Battery Voltage High) CA442 Engine stop 電源電圧低異常 (Battery Voltage Low) CA441 エンジンコントローラ内部異常 (ECM Critical Internal Failure) CA111 Engine stop エンジンコントローラデータ整合異常 (Calibration Code Incompatibility) CA342 エンジンコントローラ全データ損失異常 (All Date Lost) CA757 エンジンNe回転センサ異常 (NE Speed Sensor Error) CA689 ● Engine stop エンジンBkup回転センサ異常 (Bkup Speed Sensor Error) CA778 ● Drive normally with bad start-up performance Normal drive エンジンBkup回転センサ位相異常 (Bkup Speed Sensor Phase) CA731 Normal drive エンジンNE,Bkup回転センサ異常 (NE,Bkup Speed Sensor Error) CA115 Engine stop エンジンオーバースピード(Eng. OverSpeed) CA234 Engine stop エンジンオーバースピード(Eng. OverSpeed) CA2341 Engine stop エンジンオーバーヒート(Eng. Overheat) CA146 Engine stop エンジン油圧低下トルクディレート (Oil Press. Low) CA143 Engine stop チャージ温度高異常トルクディレート (Charge Air Temp. High (Trq. Derate)) CA448 Engine stop チャージ温度高異常回転ディレート (Charge Air Temp. High (Speed Derate)) CA155 水温センサ高異常 (Coolant Temp. Sensor High) CA144 ● Bad cold-start Performance. Bad exhaust gas color in cold ambient. 水温センサ低異常 (Coolant Temp. Sensor Low) CA145 エンジン油圧スイッチ異常 (Oil Press. SW Error) CA435 Engine stop チャージ圧センサ高異常 (Charge Air Press Sensor High) CA122 Black exhaust gas when loading チャージ圧センサ低異常 (Charge Air Press Sensor Low) CA123 ● KOMNET異常(KOMNET Error) CA1633 Engine stop PCV1短絡異常(IMV PCV1 Short) CA271 Engine stop PCV1断線異常(IMV PCV1 Open) CA272 ● Engine stop コモンレール圧センサ高異常 (Rail Press. Sensor High) CA451 ● Engine stop コモンレール圧センサ低異常 (Rail Press. Sensor Low) CA452 コモンレール圧高圧異常２ (Rail Press. Very High) CA449 Engine stop コモンレール圧高圧異常１ (Rail Press. High) CA553 Drive normally with bad engine efficiency Normal drive サプライポンプ無圧送異常１ (Rail Press. Low) CA559 Drive normally with bad engine efficiency Normal drive

Defect content Defect code Open circuit error Machine condition System responce サプライポンプ無圧送異常２ (Rail Press. Very Low) CA2249 Engine stop IMVソレノイド異常(IMV Solenoid Error) CA2311 Engine stop インジェクタ駆動回路異常 (INJ. Drive Circuit Error) CA351 Engine stop インジェクタ#1(L/B #1)系統 断線、短絡異常 (Injector #1 Open/Short) CA322 Engine stop インジェクタ#2(L/B #2)系統 断線、短絡異常 (Injector #2 Open/Short) CA331 インジェクタ#3(L/B #3)系統 断線、短絡異常 (Injector #3 Open/Short) CA324 インジェクタ#4(L/B #4)系統 断線、短絡異常 (Injector #4 Open/Short) CA332 インジェクタ#5(L/B #5)系統 断線、短絡異常 (Injector #5 Open/Short) CA323 インジェクタ#6(L/B #6)系統 断線、短絡異常 (Injector #6 Open/Short) CA325 センサ電源１低異常 (Sensor Sup.1 Volt. Low) CA352 Drive normally with bad engine efficiency センサ電源１高異常 (Sensor Sup.1 Volt. High) CA386 センサ電源２低異常 (Sensor Sup.2 Volt. Low) CA187 センサ電源２高異常 (Sensor Sup.2 Volt. High) CA227 Ne回転センサ電源異常 (NE Speed Sensor Sup. Volt Error) CA238 Defect of speed regulation スロットルセンサ電源高異常 (Throttle Sensor Sup. Volt. High) CA2185 Drive normally スロットルセンサ電源低異常 (Throttle Sensor Sup. Volt. Low) CA2186 チャージ温度センサ高異常 (Charge Air Temp. Sensor High) CA153 ● Bad cold performance チャージ温度センサ低異常 (Charge Air Temp. Sensor Low) CA154 大気圧センサ高異常 (Ambient Air Press Sensor High) CA221 Out-put power reduction 大気圧センサ低異常 (Ambient Air Press Sensor Low) CA222 ● 燃料中水混入異常(Water in Fuel) CA418 Normal drive 水検知センサ高異常 (Water in Fuel Sensor High) CA428 ● Normal drive 水検知センサ低異常 (Water in Fuel Sensor Low) CA429 吸気ヒータリレー短絡異常 (Heater Relay Volt. High) CA2556 Bad cold-start performance Normal drive (incapable of driving a glid heater relay) 吸気ヒータリレー断線異常 (Heater Relay Volt. Low) CA2555 ●

Defect content Defect code Open circuit error Machine condition System responce 定格回転調整 Vol（中央値調整）高異常 (Speed Adj. Vol. High(Default))) bc Unstable rated speed 定格回転調整 Vol（中央値調整）低異常 (Speed Adj. Vol. Low(Default))) bd ランプタイム Vol 高異常 (Ramptime Adj. Vol. High) bE Unstable ramp time ランプタイム Vol 低異常 (Ramptime Adj. Vol. Low) bF 定格回転調整 Vol（ｱｲｿ）高異常 (Speed Adj. Vol. High(Isochronous)) A8 Unstable engine speed (ISO) 定格回転調整 Vol（ｱｲｿ）低異常 (Speed Adj. Vol. Low(Isochronous)) A9 ドループ率調整 Vol 高異常 (Droop Rate Adj. Vol. High) b6 Unstable droop rate ドループ率調整 Vol 低異常 (Droop Rate Adj. Vol. Low) b7 定格回転調整 Vol（ﾄﾞﾙｰﾌﾟ）高異常 (Speed Adj. Vol. High(Droop)) AA Unstable engine speed (Droop) 定格回転調整 Vol（ﾄﾞﾙｰﾌﾟ）低異常 (Speed Adj. Vol. Low(Droop)) AB Li 回転調整 Vol 高異常 (Low Idle Speed Adj. Vol. High) b8 Unstable low idle speed Li 回転調整 Vol 低異常 (Low Idle Speed Adj. Vol. Low) b9 KOMNET異常（CR710異常認識） (KOMNET Error(CR710) AF

11. Long-term storage When the machine is to be stored for a long period of time, choose a cool place free from moisture and dust, and observe the following points. (1) Remove dirt clinged the machine and clean it thoroughly. If painting is peeled off, it should be repaired. (2) Remove the battery from the machine. The battery should be charged completely before it is stored. - Battery is discharged of itself. Recharge it once a month. (3) If any defects are found, check and repair the machine so that it can be used for future operation. (4) For details of handling the engine, refer to the instruction manual for the engine provided separately. WARNING Stacking ■ 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 stacked machines. * Machines can be stacked up to 2 stages. The weight and size of stacked machines should be less than those of this machine. * Using square timbers as shown below, put each machine making sure that the weight is even. ■ Do not operate the machines in the state of stacking to prevent falling or dropping accidents.

12. Service data 12-1 Specifications MODEL ＤＣＡ-１５０ＬＳＫE Ａ Ｃ Ｇ Ｅ Ｎ Ｅ Ｒ Ａ Ｔ Ｏ Ｒ MODEL DB-1651K FREQUENCY 50 / 60 Hz RATED OUTPUT 125 /150 kVA RATED VOLTAGE 200 /220 V ・ 400 / 440 V RATED CURRENT 361 /394 A ・ 180 /197 A POWER FACTOR 0.8 (lagging) NO.OF PHASES Three-phase (four wire) EXCITATION Brushless type (with automatic voltage regulator) NO.OF POLES 4 SPEED 1500 / 1800 min-１ INSULATION class F Ｅ Ｎ Ｇ Ｉ Ｎ Ｅ MANUFACTURE KOMATSU MODEL ＳＡＡ６ＤＩ０７Ｅ－１－Ｃ TYPE 4-cycle water cooled diesel engine, direct injection turbocharged with inter-cooler NO.OF CYLINDERS 6 BORE×STROKE 107×124 mm TOTAL DISPLACEMENT 6.69 L RATED OUTPUT 113 kW / 1500 min-１ 135 kW / 1800 min-１ BATTERY (DOMESTIC STANDARD) 95E41R×2 FUEL DIESEL FUEL ASTM No.2 or equivalent FUEL TANK CAP. 250 L ENGINE OIL *1 OVERALL 24.8 L FILTER 1.0 L COOLANT QUANTITY *2 OVERALL 25.4 L RESERVE TANK 2.4 L Ｓ Ｅ Ｔ LENGTH OVERALL 3250 mm WIDTH OVERALL 1150 mm HEIGHT 1650 mm DRY WEIGHT 2550 kg TOTAL WEIGHT 2820 kg The above specifications and set dimensions are subject to change. *1 Overall of engine oil contains filter. *2 Overall of coolant quantity contains reserve tank. Dry weight : This weight does not contain the cooling water, engine oil and fuel. Total weight : This weight contains the cooling water, engine oil and fuel.

13. Options instruction manual If equipment the option device to the machine after the purchase is required, contact distributor or our office. If the machine is modified on your own, the warranty of manufacturer will become invalid. 13-1 Earth leakage relay WARNING ELECTRIC SHOCK by leak can kill. ■ Improper grounding may lead to death due to electric shock. Because the device for leakage protection does not operate effectively. * Grounding terminal for the earth leakage relay, case grounding terminal and case of the load are grounded. (1) Applicable models DCA-LS SERIES (2) Description of the device The machine is provided with an earth leakage relay to detect any leakage 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.

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. (3) Grounding Ground as following to operate the earth leakage relay certainly. ■ Grounding of the machine Ground the grounding terminal for earth leakage relay and case grounding terminal according to the below. ① Grounding of the grounding terminal for earth leakage relay. If grounding described below does not comply with the local rule, stricter of the two shall apply. Use the grounding wire which sectional area is 5.5mm2 or larger. Usually it is possible that using attached grounding rod. But if grounding resistance is over 100 Ω, provide the grounding rod which surface area contacted the ground is large. ② Grounding of the case grounding of the machine Grounding the case grounding of the machine is refer to「4-4 (1) Case grounding of the machine 」. ■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.

[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 such 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. ■ Precaution in grounding Precaution in grounding is refer to「4-4 (3) Precaution in grounding 」. ■ 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: ① Start up the machine according to 「5-2 Startup 」 ② Make sure that all breakers of the load side are "OFF". ③ Set the breaker of three phase and single phase to "ON". ④ 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. ⑤ 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. (4) 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.

13-2 Instruction for fuel source changeover device (Three-way valve) (1) Description of the device The "Fuel piping selector device" selects the supply of fuel to the engine from the machine loaded fuel tank or directly from the outside machine tank through its change-over valve. (2) Operating procedure ① 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. ② 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. ③ 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. (3) Precaution in piping and operation ① For the piping, use an oil resistant pipe with an inside diameter of approximately 8 to 10 mm. ② 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. ③ 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 . ④ 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 Fig.2 .) ⑤ Take good care to avoid entry of water and or foreign matter into outside machine tank.