Denyo DCA-150ESK Instruction Manual

M A N U A L D E N Y O D I E S E L G E N E R A T I N G S E T S Before using, be sure to read this manual for the sake of safety. Be sure to observe the items under symbol marks W/K WARNING" and " A CAUTION" for the sake of safety. Always keep this manual at your machine for the sake of safety. D C A - 1 5 0 E S K По вопросам продаж и поддержки обращайтесь: Эл. почта: [email protected] || Сайт: https://denyo.nt-rt.ru/ Архангельск (8182)63-90-72 Астана +7(7172)727-132 Астрахань (8512)99-46-04 Барнаул (3852)73-04-60 Белгород (4722)40-23-64 Брянск (4832)59-03-52 Владивосток (423)249-28-31 Волгоград (844)278-03-48 Вологда (8172)26-41-59 Воронеж (473)204-51-73 Екатеринбург (343)384-55-89 Иваново (4932)77-34-06 Ижевск (3412)26-03-58 Иркутск (395) 279-98-46 Киргизия (996)312-96-26-47 Казань (843)206-01-48 Калининград (4012)72-03-81 Калуга (4842)92-23-67 Кемерово (3842)65-04-62 Киров (8332)68-02-04 Краснодар (861)203-40-90 Красноярск (391)204-63-61 Курск (4712)77-13-04 Липецк (4742)52-20-81 Магнитогорск (3519)55-03-13 Москва (495)268-04-70 Мурманск (8152)59-64-93 Набережные Челны (8552)20-53-41 Нижний Новгород (831)429-08-12 Казахстан (772)734-952-31 Новокузнецк (3843)20-46-81 Новосибирск (383)227-86-73 Омск (3812)21-46-40 Орел (4862)44-53-42 Оренбург (3532)37-68-04 Пенза (8412)22-31-16 Пермь (342)205-81-47 Ростов-на-Дону (863)308-18-15 Рязань (4912)46-61-64 Самара (846)206-03-16 Санкт-Петербург (812)309-46-40 Саратов (845)249-38-78 Севастополь (8692)22-31-93 Симферополь (3652)67-13-56 Таджикистан (992)427-82-92-69 Смоленск (4812)29-41-54 Сочи (862)225-72-31 Ставрополь (8652)20-65-13 Сургут (3462)77-98-35 Тверь (4822)63-31-35 Томск (3822)98-41-53 Тула (4872)74-02-29 Тюмень (3452)66-21-18 Ульяновск (8422)24-23-59 Уфа (347)229-48-12 Хабаровск (4212)92-98-04 Челябинск (351)202-03-61 Череповец (8202)49-02-64 Ярославль (4852)69-52-93

In order to ensure safe operation, the following symbols are used for explanation of the machine operation. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment A WARNING: This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. A CAUTION: This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. [Note] : This symbols show handling precautions for effective operation and many years of satisfactory operation. Some of the items shown by "/f\ 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.

* Keep these safety labels clean at all times. * When safety labels are spoiled or lost, contact distributor or our office specifying the nameplate No. shown below and ask for new ones. No. Parts name Parts number No. Parts name Parts number 1 Safety instruction B9211 0140 5 Warning: Hot surfaces B9052 0020 2 Warning : moving parts B9050 0050 6 Warning : diesel fuel B9055 0070A 3 Warning : hot coolant B9051 0030 7 Warning : electric shock B9211 0150 4 Caution : exhaust gas B9052 0000

I Insufficient ventilation may lead to death due to lack of oxygen or poisoning by exhaust gases. * Do not use the machine in a place of poor ventilation or in a place where exhaust gases stays. * Do not use the machine indoors or in storehouse, tunnel, ship hold, tank, etc. of poor ventilation. * If it becomes necessary to use the machine in the above places, the 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. - 3 -

■ 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.

■ Improper grounding may lead to death due to electric shock. * Be sure to execute the grounding of the machine and the load according to the local rule. A WARNING MOVING PARTS can cause severe injury. ■ 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, he sure to stop the machine in advance. - 5 -

I 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. Ж WARNING HOT COOLANT can cause severe scalds. I 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 °C or less as measured with the water temperature gauge). - 6 -

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. Ш Do not operate the machines in the state of stacking to prevent falling or dropping accidents. A CAUTION \ %F=f 5 R V / / V 7 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 bums. * 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. - 1 ~

Improper handling may lead to explosion or serious injury. * Battery should be charged in a well ventilated location. Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and - ) . Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. * For maintenance of the machine, disconnect the ground cable on the ground side. I The battery acid is dilute sulfuric acid. Improper handling will cause unexpected bums. * 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 -

alcohol or take some drugs. * Otherwise, it may cause unexpected accidents or injury. Ш 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. A 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. A CAUTION Connection to house wiring ■ Before connecting this machine to any building's electrical system, a licensed electrician must install an isolation(transfer) switch. * Serious injury or death may result without this transfer switch. - 9 -

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. I 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. - 1 0 -

1. output terminal 2. control panel 3. operating panel 4. engine indicator 5. fuel in 6. hanger rod 7. support hook 8. coolant in 9. fuel drain plug 10. oil drain plug 11. exhaust gas outlet - 11 -

2. diesel engine 3. battery 4. radiator 5. reserve tank 6. fuel filter 7. oil filter 8. AC generator 9. air cleaner 10. dipstic 11. engine oil in - 1 2 -

O P E R A T I N G P A N E L C O N T R O L P A N E L CONTROL PANEL OPERATING PANEL No. N A M E No. N A M E 1 FREQUENCY METER 3 1 ENGINE IN DICATOR 2 AC AMMETER (INCLUDE AMMETER CHANGE-OVER SWITCH) In< er i i i i с a t o i : l g i n e speed, o i l p r e s s , it egr a t i ng t ime, b a t t e r y l a r g i n g v o l t a g e , wa t e r mp. m n Lamps I T Duel ТпЯт ро + лг 3 AC VOLTMETER (INCLUDE VOLTMETER CHANGE-OVER SWITCH) с I t e A1 k P I L O T LAMP 5 C I R C U I T BREAKER 6 VOLTAGE REGULATOR 7 PANEL LIG H T 3 2 ST A R T E R SWITCH 8 PANEL L IG H T SWITCH m nn PREHEAT LAMP 9 SYNCHRONIZING LAMP 3 i EMERGENCY STOP BUTTON 1 0 SINGLE-PAR CHANGE-OVER SWITCH i_n m THROTTLE HANDLE 1 1 EARTH LEAKAGE RELAY 3 6 A F TE R GLOW LAMP - 13 -

Engine indicators N u m b e r I n d i c a t o r (1) Number Indicator That indicates the numerical values of engine speed, engine oil pressure, run hours, battery charging voltage, or engine coolant temperature, Each indication is selectable by pushing the " SELECT " button. Unit Indicated Items min'’ engine speed X ЮОкРа engine oil pressure hour run hours V battery charging voltage V engine coolant temperature AUTO automatic indication change Unless " SELECT " switch is pushed, " Engine Speed " is always indicated immediately after engine starts - 14 -

indication is automatically changed every three (3) seconds. - 1 - Engine Speed Revolutions per minute is indicated. XSOOmin -1 is indicated at 50Hz and 1800 min -1 is indicated at 60Hz. - 2 - Engine Oil Pressure 2 to б X 100 kPa ( 2 to 6 kg / cm1 ) should be indicated at normal engine operation. Higher value would be indicated in cold condition immediately after engine starts. Conduct a wanning - up operation until it indicates normal value. - 3 - Run Hours That indicated total running hours. - 4 - Battery Charging Voltage That should indicate more than 26V at engine running. - 5 - Engine Coolant Temperature That should indicate a temperature between 75 to 90 °C at engine running. Note ; If that would indicate higher temperature, disconnect all loads, decrease the speed for cool - down operation, and wait until the temperature comes down to normal value. - 6 - Automatic Indication Change Each of the above - started indications from the - 1 - to - 5 - changes by turns every 3 seconds. (2) Fuel Level Indicator That Indicates a fuel level in the fuel tank. Green lamps will turn on with full tank. As the fuel level drops, the numbers of the turn - on lamps decrease and at the sametime the color of lamps changes from green to red. Replenish the tank when there becomes only one lamp turned on. The table below shows the relation between numbers of turn - on lamps and feul level. - 15 -

Fuel level (L) 6 all green 230 to full 5 all green 195 to 230 4 all green 160 to 195 3 red on 1st lamp frombottom green on 2nd & 3rd lamps 120 to 160 2 all red 85 to 120 1 red 0 to 85 (3) Alarm and Memory at Abnomal Condition When any abnormal condition occurs in engine oil pressure, battery charging voltage, or engine coolant temperature, the indication will change as the followings ; - 1 - The indication changes to "AUTO", and the abnormal value and unit will be indicated lighting on and off. - 2 - When the abnormal condition is corrected, the on - and - off indication will stop. - 3 - If engine would stop urgently and automatically or stop manuslly 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 "AUTO" for more than 5 seconds, and the abnormal indication will be reset to normal. Generator indicators (1) Frequency meter This meter indicates frequency of the output voltage. Make sure that it indicates 50Hz or 60Hz during operation. 60Hz - 16 -

connected load. Make sure that it is always pointing below the rated current. When miming the three phase and single phase loads together, this meter indicates total current of them. Ammeter change-over switch When running either the three phase or single phase load, this meter indicates the current flowing into the load. The current of each phase can be checked using the ammeter change-over switch. (3) AC voltmeter This meter indicates AC output voltage. Make sure that it indicates rated voltage. Line-to-line voltages can be checked using the voltmeter change-over switch. Voltmeter change-over switch - 17 -

It will automatically preheating device. If turn the starter switch to "Run" position, it will according to cooling water (coolant) temperature with the preheat lamp goes on. 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. Ф 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) OIL PRESS If this lamp goes on during operation, the emergency stop device immediately operates to shut down the engine automatically. WATER TEMP AIR FILTER ® filter blockage (AIR FILTER) When the air element is blockage, this lamp goes on. Indicating that the element should be cleaned or replaced. (3) After Glow Lamp The After Glow Lamp will be indicated and the engine will be heated automatically when the water temperature remains less than 30°C. This procedure will be carried unless it reaches more than 30X) or glowing maximum for 3 minutes, and then automatically stop glowing at the same time of stop indicating. - 18 -

Switches Functions: (D 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. © Run This switch should be set in this position when the machine is in operation. © Start This is the position to start the engine. When your hand is released from the key after starting, it is automatically set in the position of "RUN”. © Preheat This is the position to start the engine when the air temperature is low. Set the switch in this position until the preheat lamp becomes red heated, and then set it in the start position. (2)ThrottIe handle {Speed Control Handle) Turn the handle toward the "HIGH" side to increase the speed and toward the "LOW" side to decrease it. - 19 - (l)Starter switch

(4) Emergency stop button 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. This is a pushbutton to stop the engine urgently on emergency case. Do not push the button without emergency case. - 20 -

(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) 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. - 21 -

3 -1 Transportation of machine A CAUTION Transportation ■ Do not lift the machine at the support hook or the ladder because it is not strong enough for lifting and may cause a falling accident. * When lifting the machine, use the hanger located at the roof center. * Keep out under the lifted machine. ■ Do not lift or do not transport the machine during operation, as it may cause damage to the fan or serious trouble. * When loading the machine on the truck or the like, fix the machine firmly by support hooks on the both side. The detail as machine size is referred to Г12-1. Specifications See p. 72 J - 22 -

A WARNING ENGINE EXHAUST can kffl. ■ 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. ф Install the machine horizontally on a solid foundation. Operation on an uneven place will generate unusual vibration. © The machine should be installed on a substantial base to prevent claims from nearby living people. For details of the vibration level of the machine and foundation work, contact distributor or our office. [Note] noise: The engine is running during operation of the machine. If the door is open, much noise will be generated. But some noise will stay, when door is closed. When installing the machine, be sure to observe the following points. * Close and lock the door after installation. * We recomend to execute the measure for sound level to prevent claims from nearby living people. - 23 -

* Provide a space of more than about lm 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. - 24 -

4 - 1 Method for selecting output voltage A WARNING ELECTRIC SHOCK can kill. ■ Do not touch the circuit inside the machine during operation to prevent decease due to electric shock. * When open the control panel or the like for changing the output voltage, turn OFF the breaker and stop the machine in advance. In the parallel operation, be sure to shut down the other machine. Load Connection (l)Method For Selecting Output Voltage Select voltagwe according to the voltage of the load to be used. tri_U2 a zd Ы > 2 ffi w? CCX> 400/440V (380V) {415V} [480V] 200/220V (190V) [240V] * Method For Selecting Output Voltage The output voltage of 200/220V or 400/440V can be selected with the voltage change over plates. These generators are shipped from the plant with their output voltage set at 200/220V unless otherwise specified. Change over to the desired output voltage according to the following procedure, if necessary. Ф The voltage change over panel is located on the right-hand side of the control box. Remove the protecting cover of the voltage change over panel first. Ф Change over to the desired output voltage by setting the change over plates. Note that insecure tightening of the locking bolts results in burning. - 25 -

over plates by, for example, setting them together with the actually used ones, ® Mount the protecting cover of the voltage selecting panel again. [Note] Incorrect reconnection of the change— over plates may cause a burning accident 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. in the generator. For reconnection, be sure to tighten the plates to prevent the burning accident. Be sure to mount the protection cover before starting engine again. 4 - 2 Cables to be used Selection of cables: Use cables having sufficient size in consideration of the allowable current of the cables and e where e: voltage drop (V) L: length (m) S: cable thickness(mm 2) I: load current (A) Cable length L Cm) - 26 -

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. A CAUTION Connection to house wiring ■ Before connecting this machine to any building’s electrical system, a licensed electrician must install an isolation(transfer) switch. * Serious injury or death may result without this transfer switch. - 27 -

[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 (190V) (380V) {415V} [240V] [480V] u V w о (O о О) О и V w о (9 о 9) о U V w о Ш Use 0/U,0/V,0/W for single phase load 115/12 7V or 231/254V (110V) (219V) {240V} [139V] [277V] и V W о ft) с ?) о * ' \ • ' 1 Use U/V,V/W,W/U for single phase load 200/220V or 400/440V (190V) (380V) {415V} [240V] [480V] i - 28 -

(D Be sure to provide a switch for turning the load ON and OFF between the output terminal block and the load. Note that the use of the breaker of the machine for turning the load ON and OFF may result in breaker failure. © In connecting the load, be sure to stop the engine and turn OFF the breakers on the control panel. © Don't contact the connecting cable to the output terminal of other phase on the output terminal block. @ When the load connection is finished, close the cover of output terminal and tighten by the bolts. - 29 -

A 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) 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. EARTH LEAKAGE RELAY 3-phase ( ^ ) • PILOT LAMP 1—phase О О RESET BUTTON TEST BUTTON _____ • - 30 -

■ Grounding of the machine Ground the grounding terminal for earth leakage relay and case grounding terminal according to the below. (D 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 5.5mm 2 or larger. Usually it is possible that using attached grounding rod. But if grounding resistance is over 100 Q, provide the grounding rod which surface area contacted the ground is large. © Grounding of the case grounding of the machine Use the grounding wire which sectional area conforms to the local rule. Provide the grounding rod to satisfy the grounding resistance which conforms to the local rule. grounding terminal for earth leakage relay о~~ну case grounding / terminal grounding wire ■ 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. - 31 -

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 Ф 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. Ф If burying the grounding rod on the place that many pedestrians walk on, clamp the lead wire to prevent catching on it. © If the lead wire is not long enough for the connection, connect it as directed below: (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. © Avoid the places within 2m of lightning conductor grounding location for burying of grounding rod. © Do not use a telephone set grounding conductor. - 32 -

For safety reasons, check on the operation of the leakage relay at the startup of the machine according to the procedure described below: Ф Start up the machine according to Г5- 2 Startup J © Make sure that all breakers of the load side are "OFF'. © Set the breaker of three phase and single phase to "ON". © Press the TEST button on the leakage relay. If this causes the LEAK lamp (red) on the leakage relay to go on and the breakers to be activated, the leakage relay can be regarded as operating normally. (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. ©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. EARTH LEAKAGE RELAY 3 - phase ' ф : • PILOT LAMP l-phsse О О RESET BUTTON TEST BUTTON - 33 -

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: / К 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 A 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. - 34 -

(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 grounding for electric shock protection (7) Checking for leakage of oil and water (8) Checking for loose parts (9) Removal of foreign objects in machine Inspection: (1) Checking on engine oil (Read the instruction manual for the engine furnished separately.) ф 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. (D At the same time, check condition of oil by the dipstick. re $ - H 1 H — H S3 1 2? AA A $ L L A L —L 9 A , Щ О X X [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. - 35 -

■ 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 °C or less as measured with the water temperature gauge). Ф Check (to see) that cooling water in the reserve tank is within the range of FULL- LOW. © When it is below the low limit, supply (additional) water immediately. ® Normally, only the water level of the reserve tank needs to be checked. But, the radiator cap should be opened once a week to check that water is full in the radiator. [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. (2) Check on engine cooling water (Read the instruction manual for the engine furnished separately.) normal - 36 -

(Read the instruction manual for the engine furnished separately.) Ф Check the belt for tension and elongation. Also, check it for damage. Replace if necessary, ф 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 b elt: Parts number manufacture Parts number of manufacture 06020 11465 KOMATSU 6732-81-6170 (4) Check on fuel ф Be sure to check the quantity of fuel prior to operation to prevent lack of fuel during operation. ф Loosen the drain plug of the fuel tank from time to time, and remove sediments and water at the bottom of the tank. - 37 -

Ж CAUTION BATTERY ■ The battery acid is dilute sulfuric acid. Improper handling will cause unexpected * 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. burns. x О x - 38 -

Make sure that the case grounding of the machine and the load are certainly. Do not ground directly Г Oj terminal. Grounding wire Case grounding terminal 5 (7) 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. (8) Check for loose parts Check for loose bolts and nuts. Loose parts should be tightened firmly. Particularly, make check on (the fitting of air cleaner, muffler, turbo- charger, etc.), disconnection of electric wiring, short- circuit and loose terminals. (9) Removal of foreign objects in machine * Check that tools-and cleaning cloth are not left in the machine. Remove if necessary. * Check the surroundings of the muffler and engine for presence of dust and flammable objects. Remove if necessary. * Check that the cooling air inlet and the cooling air outlet of the machine are not clogged with dust or other objects. Remove if necessary. - 39

Following is flow of startup. I circuit breaker : OFF ,JT 4 throttle handle : turn the handle toward the HIGH SPEED (clock wise) two or three times. When engine is already warm. starter switch : PREHEAT preheat lamp : red heated starter switch : START Y starter switch : RUN engine startup When it is cold. Y 4 warm up operation : about 5 minutes warm up operation : sufficiently <________________________________________ I -r ? 6 adjustment of speed V adjustment of voltage Y circuit breaker : ON y supply power to load - 40 -

power is supplied to the load at the start of the engine which causes electric shocks or trouble in the load. Startup procedure: (1) Make sure that the circuit breakers of the machine and the loads are all OFF. (2) Turn the throttle handle toward the HIGH SPEED (clock wise) two or three times. (3) Set the starter in "Preheat" position. This switch must be ON until the preheat lamp becomes red heated. Turn the starter switch to "START" position until engine starts. [Note] If the engine is warm, the preheat operation is not required. SEE П OFF It will indicate the after glowing lamp when turning on the Starter Switch to "GLOW" position. However, this doesn't mean glowing, but you must keep glowing until the Glow Lamp is heated to red color. - 41 -

within the range of 750 to 900mm'1 by adjusting the throttle handle. Drive the machine for warming up for approximately five minutes. (5) After warming up the engine, adjust the revolution frequency to the values listed below by adjusting the throttle handle and monitoring the revolution counter. Commercial frequency Idling speed 50Hz drive 52, 5Hz (1575mm1) 60Hz drive 62. 5Hz (1875mm1) If the idling speed set above speed, frequency becomes nearly 50Hz or 60Hz in the rated load, (6) Set the voltage to the rated by the voltage regulator, and turn the breaker to "ON". The machine starts power transmission state. [Note] The after Glow Lamp will be indicated and the engine will be heated automatically until the water temperature reaches to 30°C or glowing maximum for 3 minutes, and then automatically stop glowing at the same time of stop indicating. This device is not activated when it already reaches to high temperature. / l i a t i \ ( © > «\. J \м - 42 -

(1) Checking after startup ф Make sure that each meter and lamp are normal. normal : warning lamp is all off ф 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 tachometer and frequency meter to the rated by the throttle handle. Set the voltmeter to the rated by the voltage regulator. [Note] * Do not turn the throttle handle to "LOW SPEED" 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. - 43 -

(1) Turn OFF the circuit breaker of the load. (2) Turn OFF the circuit breaker of the machine. (3) Turn the throttle handle to “LOW SPEED" circuit breaker of the load circuit breaker of the machine (counter clockwise) to adjust the revolution frequency within the range of 750 to 900mm'1, and drive the engine for approximately five minutes. (4) Check the panel light goes out. (5) Set the starter switch in "STOP" position. The engine will stop immediately. (6) Remove the key from the starter switch and keep it at hand. (7) Check the amount of fuel. Supply additional fuel if necessary. (8) Check for leakage of oil, fuel and water. [Note] * For emergency stop, keep pushing the "EMERGENCY STOP" button until the engine stops. * Check the panel light goes out. - 44 -

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 breaker stop the engine indicate by warning lamp function oil pressure failure (OIL PRESS) — — set point: 130kPa ЖО stop О set point: 49kPa high jacket water temperature (WATER TEMP) — — set point: 97°C Stop о set point: lOl'C Battery charging failure ЯЮ stop : 26. OV overcurrent of generator О — . — When overcurrent flows, the device acts earth leakage о — о When electric leakage, the device acts Current sensitivity: 30mA fuel level failure (FUEL LEVEL) „ — о When fuel supply is necessary because of fuel shortage, the device acts. air filter blinding (AIR FILTER) - - о When replace or cleaning of air filter is necessary because of blinding of filter, the device acts Abnormal value and unit will be indicated lighting on and off. •HO When the single-parallel change-over switch is parallel side, device acts. - 45 -

[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 Г4. Connecting the load J and Г5. Operation J . In the case where the capacity of the load exceeds that of a generator. The parallel operation is useful by paralleling electrically generators of 2 units or more. However, note that the stable parallel operation requires the equality of output voltages, frequencies, engine governor characteristics, etc. For this reason, it is requested for easy paralleling to select the quite same type of the generating sets for manufacturer, model, etc. Study this manual carefully before paralleling the units. 6 -1 Preparation for parallel operation (1) Turn off the main circuit breakers on all the units, and stop the engines. (2) Set the voltage change— over board on each unit to the same voltage. (3) Connect each unit and load as shown below, referring the terminal symbols. Use a phase tester to check the sequence of the phases. [Note] Connect the cables in the correct sequence of the 3 - phases, seeing the terminal symbols. (4) Turn the single-parallel change- over switch on each control panel to "PARALLEL" - 46 -

(1) Turn off the breakers on the load side. (2) Start engine and keep it in warming up. (3) Equalize all the voltages and frequencies on the units by adjusting the throttle handle and voltage regulator. (4) First turn on the circuit breaker on the No.l generating set. (5) Adjust the throttle handle on the No.2 set so that the two synchronizing lamp on the No.2 set turn on and off synchronizing when the two phase sequences are in the same direction, while the two turn and off alternately when the sequences are in the different direction. In case the two lamps turn on and off alternately, recheck the cable connections for correct phase sequence. (6) At the instance when the synchronizing lamps turn off, turn on the breaker on the No.2 set. [Note] The generators can damaged due to shortcircuit current if the breaker is turned on when the lamps turn on. CIRCLHl BREAKER © OFF 1 2 CO WARM UP WARM UP WARMUP WCUff WEAKER ON (7) Upon the above procedure, the No.l and No.2 sets are in parallel operation. The AC ammeters are to indicate zero in this no load condition. If the meters indicate some current, it is an uneffective cross current due to voltage difference. Make it zero by adjusting the voltage regulator. - 47 -

and (7), parallel the generating sets of No.3 and so on if any. (9) Turn on the breakers on the load side. If each AC ammeters show an imbalance in loading, make it in equal loading by adjusting the throttle lever for engine rpm. The set is to undertake more load sharing when the engine rpm. is adjusted higher, while less sharing when adjusted lower. [Note] AC ammeter indicates the current including a cross current. Watt meter (Option) is required to know the correct load sharing. - 48 -

(1) Keep each generating sets in equal load sharing by adjusting the throttle handle 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 positiori’PARALLEL" [Note] If it is turned to "SINGLE", a cross current occurs between the alternators and trips the circuit breakers due to over current. (3) Watch the fuel level during parallel operation. [Note] If fuel runs out during parallel operation, the running set must undertake all loading and may result in an accident in the set or a tripping on the breaker. - 49 -

(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 Г5 -4 . Shut downj CIRCUIT BREAKER DFFl g o t I CIRCUIT BREAKER MACHINE

7 -1 Engine oil Use specified engine oil, otherwise, it greatly affects the startup operation and fife of the engine. (1) Kind of oil Use oil, CD class or higher, classified by API service. (2) Oil viscosity Recommended oil viscosity is SAE 10W— 30, all—season type. Use oil according to ambient temperature referring to the table below. Ambient temperature ( t ) - 3 0 -2 0 - 1 0 0 10 20 30 4-----------------S A E 2 0 -------------- ► 4 S A E 3 0 --------------► 4------------------------S A E 5 W - 2 0 --------------------- ► 4--------------------------S A E 1 0 W - 3 0 ------------------------- ► 4----------------------------S A E 1 5 W - 4 0 --------------------------- [Note]: Do not mix with different kind of oil, or else, it deteriorates the oil quality. (3) Quantity of replacement oil Total oil quantity 2 2 . О L (0. 5) (Value in parentheses is filter capacity.)

(1) Water for cooling Use the mixture of the good quality soft water like city water and the Long Life Coolant (LLC) of anti-freeze and anti-rust for the aluminum radiator. Percentage of LLC must be 30% to 50%, Under the 30%, the anti-rust effect will decrease, and over the 50%, the anti-freeze effect will decease. The following percentages are recommended for each ambient temperature; 30%: - l o t : 40%: - 2 0 1: 50%: - 3 0 °C In case of replenishment, use LLC of the same brand and the same density. Normally LLC should be replaced every 2 year. (2) Total quantity of cooling water Total cooling water quantity 2 8 . 4 L (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. - 52 -

A CAUTION BATTERY ■ Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * Battery should be charged in a well ventilated location. Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and —). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. * For maintenance of the machine, disconnect the cable on the ground side. ■ The battery acid is dilute sulfuric acid. Improper handling will cause unexpected bums. * 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. - 53 -

Charging of loaded battery * Disconnect the wiring cable from the battery terminals before charging. (Otherwise, the alternator may be damaged due to unusual voltage applied to the alternator) * When disconnecting the wiring cables from the battery terminals, remove the ground cable first. (If a tool touches the space between the terminal and the machine, electric spark will occur which is very dangerous) When connecting the wiring cables to the battery terminals, connect the ground cable last. * While the battery is being charged, open all the liquid plugs to discharge the gas. Keep the battery away from fire to prevent unexpected explosion. Handle the battery carefully to prevent electric sparks. * If the battery is overheated (liquid temperature above 45 °C), stop charging for a while. * At the completion of charging, stop charging immediately. (The relation between battery charge condition and specific gravity See p.p.63) 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.

When the engine is started using booster cables, connect the cables as follows. (1) Connection of booster cable ф Connect the clip of the booster cable "A" to the terminal"+" of the machine in trouble. © Connect the other clip of the booster cable 'A" to the t e r m i n a l o f normal machine. (3) Connect the clip of the booster cable "B" to the terminal "В" to the t e r m i n a l " of normal machine. © Connect the other clip of the booster cable "B" to the engine block of the machine in trouble. battery of normal machine engine block of the machine in trouble battery of the machine in trouble ® _ ® battery of normal machine (2) Removal of booster cable CD Remove the clip of the booster cable'B" connected to the engine block of the machine in trouble. (D Remove the clip of the booster cable "B" connected to the t e r m i n a l " of normal machine. ® Remove the clip of the booster cable " A " engine block of the machine in trouble connected to the terminal"+" of normal machine. © Remove the clip of the booster cable ’A" connected to the terminal"+" of the machine in trouble. © battery of the machine in trouble © _ (D (3) Caution on handling of booster cable ф Use booster cables and clips of the size that matches the size of battery. © The battery used for normal machine should be the same in capacity as the battery of the machine in trouble. © After connection, check that clips are firmly connected. © When connecting booster cables, make sure that the terminal"+" does not touch the t e r m i n a l ". © The engine block should be connected at a place more than 30cm away from the battery. ~ 55 -

(Read the instruction manual for the engine furnished separately) A 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. A 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. - 56 -

■ High temperature parts are located in the machine. Care should be taken during operation. * When the machine needs inspection or maintenance, be sure to stop it in advance. * Even after the machine stops, the inside of the bonnet is still hot. Wait until the engine is cooled sufficiently. A CAUTION BATTERY ■ 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. - 57 -

* During checking or maintenance, be sure to put up a sign "Under maintenance" at a conspicuous place such as the starter switch to prevent the machine from being operated by other persons. A\ CAUTION Safety clothes * During checking or maintenance, be sure to put on suitable clothes and protectors. * Do not put on baggy clothes, necklace, etc., because they are easily caught by projections which may cause injuries. /К 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. - 58 -

50 hours: Checking/first 50hours * Replacement of engine oil * Replacement of engine oil filter element 250 hours: Checking/every 250 hours * Replacement of engine oil * Replacement of engine oil filter element * Cleaning of air cleaner element * Measurement of generator insulation resistance (once a month) * Checking on battery specific gravity 500 hours: Checking/every 500 hours * Replacement of fuel filter cartridge * Cleaning of radiator and intercooler * Checking for terminal and connection of the circuit * Checking/every 250 hours is also required. 1000 hours: Checking/every 1000 hours * Cleaning inside fuel tank * Replacement of air cleaner element * Inspection of injection nozzle * Adjustment of fuel injection timing * Checking on rubber suspension * Checking on nylon and rubber hose * Checking on lining * Checking/every 250 and 500 hours are also required. On the engine system, main checking items only are shown in this manual. For details, refer to the instruction manual for the engine furnished separately. - Б9 -

(1) Replacement of engine oil Replace the engine oil at 50 hours only first time and every 250 hours after second time. Ф Remove the engine oil drain plug and discharge oil completely. It can be discharged easily when the engine is warm. © After engine oil is discharged, tighten the plug firmly. © Charge new engine oil from the oil filler until it reaches the notched line of the "H" on the dipstick. © After engine oil is supplied, run the engine for a few minutes. Check that oil is supplied to the level between H and L . (2) Replacement of engine oil filter element Replace the engine oil filter at 50 hours only first time and every 250 hours after second time. Cartridge type (Cartridge type is unit of filter case and element) ф Remove the cartridge type element (cartridge) using filter wrench. cartridge © 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. © 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. □ ГШГП . put the filter wrench Parts number of oil filter cartridge : Parts number manufacture Parts number of manufacture 06020 41205 KOMATSU 6736-51-5142 - 60 -

(1) Replacement of engine oil Replacement is refer to Г9-2.(1) Replacement of engine oil J , (2) Replacement of engine oil filter element Replacement is refer to Г9-2,(2) Replacement of engine oil filter element J (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 dean 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.

A WARNING ELECTRIC SHOCK can kill * Measurement should be made after the machine stops. - Using a 500V megger, make a check once a month to ensure that the insulation resistance is more than 1M £3. Measurement: Disconnect the load side cable from the output terminal as shown at below. Turn ON the circuit breaker and measure the insulation resistance between the output terminal bolt and the bonnet. — If the measured resistance is less than 1M Q, it may cause electric leakage or fire accident. Wipe off dirt and oil on the output terminals, circuit breakers and generator leads (cables) and dry them thoroughly. If the insulation resistance is not recovered after cleaning, contact distributor or our office. - 62 -

If battery is likely to be discharged due to failure in startup of the engine, measure the specific gravity of battery acid. The relation between battery charge condition (charging rate) and specific gravity is as shown below. Liquid Charging temp, rate (%) °C 2 0 0 - 1 0 1 0 0 1. 28 1.29 1. 30 9 0 1. 26 1.27 1.28 8 0 1. 24 1.25 1.26 7 5 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. Г8—1. Caution on battery charge j - 63 -

Checking/every 250 hours is also required. (1) Replacement of fuel filter cartridge. (D Remove the cartridge type element (cartridge) using filter wrench. © Clean the filter base. Coat the packing of new cartridge with engine oil thin. Then, mount the cartridge. — When mounting, tighten the cartridge about from 1/2 to 3/4 turn by hand after the packing is fitted to the seal of the filter base. cartridge put the filter wrench ® 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 : Parts number manufacture Parts number of manufacture 06020 42521 KOMATSU 6732-71-6112 (2) 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 over 1.5m (3) 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. - 64 -

Drain the fuel in the fuel tank completely, and wash out deposits and water collected inside the tank. 9 - 5 Checking/every 1000 hours Checking/every 250 and 500 hours is also required. (2) Replacement of air cleaner element The element should be replaced referring to "Cleaning of air cleaner element" . Parts number of air cleaner element : Parts number manufacture Parts number of manufacture 06020 46603 KOMATSU 600-181-6820 (3) Checking on rubber suspension Check on the rubber suspension, whether it is damaged or deformed by the oil. Contact distributor or our office to replace the rubber suspension, if necessary. (4) Checking on nylon and rubber hose Check on the nylon and rubber hose, whether they are hardened or deteriorate. Contact distributor or our office to replace the nylon hose and rubber hose, if necessary. (5) Checking on lining Check on the lining, whether it deteriorates greatly, or it is stained by clinging of oil or the like, or it is removed. Contact distributor or our office to replace the lining, if necessary. - 65 -

0:Check or Clean 0:Replacement ☆:Only first time List of maintenance and inspection daily first 50h every 250h every 500h every lOOOh Checking on oil level and stain of oil О Checking on cooling water О Checking on fan belt О Checking on fuel and drain О О Checking on battery acid level о Checking on for water and oil leakage о Checking on bolts and nuts for looseness о Checking on exhaust color, sound and vibration о Engine Checking on meters and warning lamps о Replacement of engine oil ☆ о О Replacement of engine oil filter element ☆ о О Clean air cleaner element О Checking on specific gravity of battery О Cleaning radiator О Replacement of fuel filter О Cleaning fuel tank <> Replacement of air cleaner element О SS Inspection of engine valve clearance ☆ о О is Adjust fuel injection nozzle О $ Inspection of timing of fuel injection О Checking on rubber suspension О Checking on nylon and rubber hose О Checking on lining О Checking on generator case grounding о Generator Checking on insulation resistance о Checking on terminal and connected section О Ж 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. - 66 -

■ 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. A 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. * ~ 67 -

■ High temperature parts are located in the machine. Care should be taken during operation. * When the machine needs inspection or maintenance, be sure to stop it in advance. * Even after the machine stops, the inside of the bonnet is still hot. Wait until the engine is cooled sufficiently. A CAUTION BATTERY ■ 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.

Cell motor will not run or revolution speed is low Cell motor runs Discharged battery Detached or loosened or corroded battery terminal Fuse blow Improper starter switch Improper starter Broken lead wire Fuel shortage Blinded fuel filter Air in fuel system Charge or replace Repair Replace Replace Replace Repair Supply Replace element Remove Speed will not rise Air in fuel system Blinded fuel filter Compression failure Blinded air cleaner Remove Replace element Repair engine Replace element Engine stop by oil failure Oil shortage Oil pressure switch failure Blinded oil filter Supply Replace Replace element Over heat (water temperature) Cooling water shortage Fan belt looseness Blinded core of radiator Engine thermostat failure Supply Adjust Clean Repair Voltmeter will not operate Voltmeter failure AVR failure Burned ZNR Quenched residual magnetism Burned rotary rectifier Disconnected rotor wiring Burned generator wiring Replace Contact distributor or our office Rated voltage will not be reached Voltmeter failure AVR failure VR failure Burned rotary rectifier Burned ZNR Burned generator wiring Low speed Replace Contact distributor or our office Increase - 69 -

Voltmeter failure Replace AVR failure Contact distributor or our office VR failure Burned rotary rectifier Contact Applied load causes load AVR failure distributor or voltage drop Burned main field, exciter field wiring our office Unbalanced load Balance - 70 -

When the machine is to be stored for a long period of time, choose a cpol place free from moisture and dust, and observe the following points. (1) Remove dirt dinged 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. A CAUTION 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. Ш ■M / / / / / / - 71 -

1 2 -1 Specifications MODEL DCA-150ESK A MODEL DB-1651K С FREQUENCY 50/60 Hz G RATED OUTPUT 125 / 150 kVA E RATED VOLTAGE 200 / 220 V or 400 / 440 V N RATED CURRENT 361 / 394 A or 180 / 197 A E POWER FACTOR 0. 8 (lagging) R NO. OF PHASES Three- phase (four wire) A EXCITATION Bmshless type (with automatic voltage regulator) T NO. OF POLES 4 0 SPEED 1500 / 1800 min "Mrpml R INSULATION class F MANUFACTURE KOMATSU MODEL SAA6D102E-2-D E N TYPE 4-cyde water cooled diesel engine, direct injection, turbocharged with inter-cooler NO. OF CYLINDERS 6 C* I N E BORE x STROKE 102 X 120 mm TOTAL DISPLACEMENT 5.88 L RATED OUTPUT (1500/1800mm _1) 113 /135 kW BATTERY (DOMESTIC STANDARD) 95E41R X 2 FUEL DIESEL FUEL ASTM No. 2 or equivalent FUEL TANK CAP. 250 L ENGINE OIL OVERALL 22. 0 L *1 FILTER 0. 5 L COOLANT OVERALL 28.4 L QUANTITY *2 RESERVE TANK 2.4 L LENGTH OVERALL 3250 mm ь WIDTH OVERALL 1080 mm E HEIGHT 1500 mm DRY WEIGHT 2390 kg 1 TOTAL WEIGHT 2670 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 wight: This weight does not contain the cooling water, engine oil and fuel. Total weight: This weight contains the cooling water, engine oil and fuel. - 72 -

50 Hz 60Hz rated output kVA 125 125 112.5 135 150 150 150 kW 100 100 90 108 120 120 120 rated voltage (V) 190/380 200/400 220/440 190/380 200/400 220/440 240/480 rated current (A) 380/190 361/180 295/148 410/205 433/217 394/197 361/180 auxiliary output voltage (V) 100 100 110 100 100 110 120 current (A) 100 100 90.9 100 100 90.9 83.3 - 73 -

»ш 1 2 - 5 Engine wiring diagram A О ОО E*i ;S 2* я ^ (А О Umiig - 76 -

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. 1 3 - 1 FUEL PIPING SELECTOR (1) Description of the device The "Fuel piping selector" selects the supply of fuel to the engine from the machine loaded fuel tank or directly from the out side machine tank through its change— over valve. (2) Operating procedure Ф The fuel piping and the change— over valve lever are set as shown in Fig.l before the machine is shipped. If the fuel is to be supplied from the machine loaded tank, operate the machine with setting left as such. © If the outside machine tank is to be used for fuel supply, remove the two plugs for connection of the outside machine tank and pipe it as illustrated in Fig.2, then turn the change— over valve in the arrow indicated direction before operating the machine. © If the outside machine tank is not used with the piping removed from it, be sure to return the change-over valve lever to the position as shown in Fig.l and screw in the two plugs. (3) Precaution in piping and operation Ф For the piping, use an oil resistant pipe with an inside diameter of approximately 8 to 10 mm. Ф 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.l until the piping is complete before turning it to the position as shown in Fig.2 . ® Set the suction pipe 15 to 20mm above the tank bottom to prevent it from drawing in water and/or foreign matter present in the tank. (See Section A in Fig.2 .) © Take good care to avoid entry of water and or foreign matter into outside machine tank. - 77 -

To engine To engine Outside of machine Outside fuel tank Fig.2 Use of outside fuel tank Outside of Inside of По вопросам продаж и поддержки обращайтесь: Эл. почта: [email protected] || Сайт: https://denyo.nt-rt.ru/ Архангельск (8182)63-90-72 Астана +7(7172)727-132 Астрахань (8512)99-46-04 Барнаул (3852)73-04-60 Белгород (4722)40-23-64 Брянск (4832)59-03-52 Владивосток (423)249-28-31 Волгоград (844)278-03-48 Вологда (8172)26-41-59 Воронеж (473)204-51-73 Екатеринбург (343)384-55-89 Иваново (4932)77-34-06 Ижевск (3412)26-03-58 Иркутск (395) 279-98-46 Киргизия (996)312-96-26-47 Казань (843)206-01-48 Калининград (4012)72-03-81 Калуга (4842)92-23-67 Кемерово (3842)65-04-62 Киров (8332)68-02-04 Краснодар (861)203-40-90 Красноярск (391)204-63-61 Курск (4712)77-13-04 Липецк (4742)52-20-81 Магнитогорск (3519)55-03-13 Москва (495)268-04-70 Мурманск (8152)59-64-93 Набережные Челны (8552)20-53-41 Нижний Новгород (831)429-08-12 Казахстан (772)734-952-31 Новокузнецк (3843)20-46-81 Новосибирск (383)227-86-73 Омск (3812)21-46-40 Орел (4862)44-53-42 Оренбург (3532)37-68-04 Пенза (8412)22-31-16 Пермь (342)205-81-47 Ростов-на-Дону (863)308-18-15 Рязань (4912)46-61-64 Самара (846)206-03-16 Санкт-Петербург (812)309-46-40 Саратов (845)249-38-78 Севастополь (8692)22-31-93 Симферополь (3652)67-13-56 Таджикистан (992)427-82-92-69 Смоленск (4812)29-41-54 Сочи (862)225-72-31 Ставрополь (8652)20-65-13 Сургут (3462)77-98-35 Тверь (4822)63-31-35 Томск (3822)98-41-53 Тула (4872)74-02-29 Тюмень (3452)66-21-18 Ульяновск (8422)24-23-59 Уфа (347)229-48-12 Хабаровск (4212)92-98-04 Челябинск (351)202-03-61 Череповец (8202)49-02-64 Ярославль (4852)69-52-93