No. A28453 001043 INSTRUCTION MANUAL Soundproof Engine Generator MODEL: DA-3000SS8S He Denyo Co,Ltd. HEAD OFFICE 4-2-2, KAMITAKADA, NAKANO-KU TOKYO 164-8510, JAPAN TEL. (03) 3228 1111 FAX. (03) 5380 7171 Printed in JapanPREFACE Thank you very much for your purchase of DENYO POWER S$ Model DA-3000SS This manual contains the items necessary for operation of the engine generator purchased. So carefully read explanation of each item and use the generator for a longer time by the correct method of operation. This generator minimizes sound generation owing to the original soundproof system It is an innovative engine generator featuring a small size, lightweight and soundproof design. This generator is extensibly usable as 2 power supply for illumination, for diverse machinery such as a power tool and submersible pump, and for civil engineering and agriculture besides @ usage as an emergent power supply in the event of 2 disaster. Since this generator is a soundproof type, it can be used freely with no need for worrying about noise generation at locations, where noise level is restricted, as exemplified by nighttime work in a city area This generator employs the highly evaluated Robin engine. Ltd generator section has a revolving-field structure and features a high product qual ity. Thanks to installation through vibration-resisting rubber, this engine generator ensures as table operation. For details of engine operation, refer to the “engine instruction manual” seoarately prepared. The contents of this manual may not coincide perfectly with the actual generator due to change of specification. etc.TABLE OF CONTENTS For using generator safely ——--—— Specifications ~ 3. Preparations for operation ------~ stop ----— . Routine check and maintenance —~ Measure to taken before long storage ~ 10 " " 12 14Md wld 12 1.3 1.2 2.1 2.2 22.3 « FOR USING GENERATOR SAFELY ( Be sure to On electricity Do not connect this generator to an indoor cebling. This not only infringes law,but mi ght cause shock hazard or machine trouble. Do not use the generator in rein. Also avoid splashing water on the generator for washing, etc. Otherwise, the generator,or its electrical circuit wight becoue faulty. There is e danger of shock hezard if the poner receptacle or other electrical connection is touched with e wet hand, Never touch the electrically charged part during operation. On exheust gas Exhaust gas contains harmful constituents. Do not use the generator in a roon, werehouse, tunnel, hold or locations vhere ventilation is poor. Do not use the generator at @ location where ventilation is poor or exheust gas does not flow adequately because of a building or eny shielding structure. Then using the generator’on a roed or outdoors, evoid directing the exhaust port tonard a passerby, house, barn, etc. observe the preceutions below )1.3 On fire prevention 1.3.1 ° ° °° 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 Before replenishing fuel,be sure to stop the engine. Pey attention not to spill fuel. If spilled, wipe it off completely end start the engine efter confirming that the generator is dry. Never handle fuel with a cigarette in your zouth. Gerefully confirm that there Is no fire source like a bonfire in the vicinity. Do not bring easy-to~burn substances ( paper, straw, mood, etc.) and dengerous substances (such ss gunpowder, oi]/fat and celluloid) close to the generator or put them near the generator. Do not enclose the generator or put sheet, box, etc. on the generator when operating It. Before use, secure @ distance of 1 m or longer from an adjacent building and other facility. Refrain from using the generator indoors. On indoor use; restrictions are imposed by lew. Follow the regulations and lars on labor safety and hygiene, fire, electric utility industry, ete., which ere stipulated in your country. Avoid inclining or moving the generator while it is operated. hen handing over machine control to other person, explain the operating nethod adequately and instruct the person to reed this nenval carefully in advance. -4-2. SPECIFICATIONS (100V CLASS) SPEC / MODEL DA30008S fo New brushless, revolving-field solid-state statically excited system Rated output (xva) 27 30 0 Number of shases Single phase e Rated vol tage wm | too | 110 | 115 | 120 | 100 } 110 | 115 | 120 th | Rated current ww | 27.0 | 245 | 235 | 225} 300} 27.3 | 261 | 250 5 Frequency tH) 50 60 Sneed (nin) 3000 3600 Power factor 10 Duty Continuous Mode! Fuji industry DY-27-208 Type Air-cooled, 4-cycle, Vertical style reed Soest (aa) Meee ee Z| Total disolacenent — 0. 265 = Rated outout —(ki/nin™') 3.3,/ 3000 3.7 / 3600 a Fuel Diesel fuel ASTH No. 2 or Ea Starting method Cell start Fuel tank capacity (U Approx. 15 Lube oi! capacity = Approx. 0.9 Dimension LXWX# (on) 700 Handle + 120) x 570 x 710 Dry Weight Ke) Approx. 145SPECIFICATIONS (200V CLASS) SPEC / MODEL DA3000SS Type New brushless, revolving-field solid-state statically excited systen Rated output (kv) 27 40 7 Nunber of phases Single phase e Rated voltage w | 200 | 220 | 230 | 240 | 200 | 220 | 230 | 240 th | Rated current w | 135 | 123] m7] 13] 15.0] 126 | 130) 125 i Freauency 2) 50 60 Speed nin") 3000 3600 Power factor 1.0 Duty Continuous Model Fuji industry DY-27-205 Type Air-cooled, 4-cycle, Vertical style bore Ste ton eaten Z| Total displacement 0. 265 : Rated outout — (kW/min"') 33/3000 3.7 / 3600 7 Fuel Diesel fuel ASTM No. 2 or Ea Starting method Cell start Fuel tank capacity (U) Approx. 15 Lube oi! capacity = (U) Approx. 0.9 Dimension LxWxH (om) 700 (Handle + 120) x 570 x 710 Ory Weight (Ke) Approx. 1483. PREPARATIONS FOR OPERATION, Place the generator horizontally. Place the generator on firm and flet ground. Besides, make sure that there is no obstecle within 1 m of the genereter. 3.1 Replenishment of fuel Inject ASTM NO. 2 Diesel fuel or equivalent into the fuel tank. Excessive injection of fuel might cause danger. So stop injection slightly before the tank is filled up. Since this generator is equipped with an ‘automatic air bleeding unit, tedious sir bleeding from fuel is unnecessary. Secure 1m or core. 3.2 Replenishment of engine oil selection of engine oll is very inportent. If improper engine oil is used or replacenent is neglected, sticking of the piston ring, seizure of the piston or early veer of the cylinder liner night be caused. Further, veer of the beering and other moveble perts will be sccelerated to degrade durebility of the engine. Use the engine oil having the quelity siven below. Class CC or higher (CC,CD) of heavy duty oil (HO) Clessification of engine of) (service classification) CA, B,C, CD 3.2.1 ith the generator kept horizontel, inject fuel up to the upper limit of sauce. Note: With the leg face of generator kept horizontel, check oil level with the oil level gauge.3.2.2 If oil is injected with the generator inclined,oil may be injected excessively or inadequately. In case oil is injected excessively, oi! consumption ney incres or oi] temperature nay rise to adversely-a{fect the rachine. Inadequete oi] night invite seizure. 3.2.3 Oil pressure alarm If the pressure of engine of] drops below the specified level, the alarm lamp lights and the engine automatically stops. when attempting to restart the engine, the lamp turns on and the engine stops. In this cese, add oil end restert the engine. 3.3 Charge elerm The charge alerm laxp comes on when turning the key switch to ” OPERATION” With the engine stopped. Once the engine has started, this lamp goes out. If charge becomes poor, the lamp Jights up and the engine automatically stps. Fhen attempting to restart the engine, the lamp turn on end the engine stops. Check each section end repair defective point, then restert the engine. 3.4 Kaintenance of sir cleaner The air clesner eliminates dust frome sir end delivers clean air into the engine. fhen its element is heavily contaminated, the engine will cause unsnooth start, poor output and abnormal operation. Moreover, the service life of engine might be extrenely sdhortened. Make it a rule to always keep the sir cleaner elexent cl © Disessemble’ the eir cleaner-every 100 hours. Hash the primary end secondary elene adequately with soopy water. After drying, remount the elezents. © fhen using the generator at e dusty locetion in particular, cleening should be perforned every 30 to 50 hours as required. condary elerent3.5 LOAD CONNECTION For ensuring safety + Before connection to the output receptacle, the engine must be stopped. + Avoid connection to indoor cebling. Othervise, shock hazerd night occur or the generator might nalfunction. +k Use 2 new electric cable here possible. Peeling of cable costing and demege wight lead to short-circuit or shock hezerd. 3.5.1 Turn OFF the circuit bresker. 3.5.2 Select an adequate cable teking the load capecity end distance to load into account. Be sure to use a plug et each connection, 3.5.3 Never insert a bere wire directly into the output receptecle. Because of incomplete connection, the wire nay slip off or overheat to ceuse burning. 3.5.4 A single output receptecle has a current cerring capecity of 15 A. If nultiple cables are connected to only one receptecle, it will overheat to cause burnig, To prevent this, distribute load among the receptacles available. 9.5.5 If loed is turned ON/OFF by inserting /renoving the plug during operetion. the receptacle will be broken earlier. Besides,there is @ risk of shock hezerd. 3.5.6 This generator is equipped with a grounding terminal. Be sure to connect this terminel to the ground.4. START For ensuring sefety k Be sure to turn OFF the circuit breaker for srart. % Also turn OFF each switch of electricel equipment. 4.1 Check befor start 4.1.1 Check for fuel/oil leakage and for inadequate oil level. 4.1.2 Check bolts end nuts for loosening. 4.1.3 Check for a dangerous substance or obstacle around the generator. 4.2 For stert, implement the following procedure. 4.2.1 Hake sure thet the circuit breaker is turned OFF (cut off) 4.2.2 Insert the Key into the starter switch and turn it to the ” Operation”position. 4.2.8 Check if the oil pressure elers laxp or cherge alara lanp is lit. 4.2.4 Turn the key fully clockwise to the "Stert” position. The starter will rotate to start the engine. As soon es the engine sterts, the key should be released, The key autonaticelly returns to the “Operation” position. Caution: 1, Do not turn the starter switch to "Start" while the engine runs. 2. If the engine does not start at 10 seconds after turning the starter switch to the “start” position, Fait for half e minute or longer, and then repeat the procedure in 4.2.4. 3. This machine incorporates a safety circuit for preventing’ the self-sterting notor frou overrunning. If the motor is rotated beyond 20 seconds, it autonatically stops. At this time, turn OFF the key switch, end then retry start. 4.2.5 After start of the engine, nake sure that the oil pressure alarm lasp and charge alerm lamp are extinguished: If not extinguished, the engine will stop emergently. localize the cause of this trouble with reference to section 9 and the instruction manual of engine. 4.2.6 Under the current condition, perfors warn-vp for § uinutes or longer. ‘% Automatic sir bleeding unit Since this generator is provided with an automatic air bleeding unit. troublesone air bleeding fron fuel is not required. You have only to add fuel into the fuel tank, and eir will automatically be bled from fuel. -10-* 5.1 Bld 5.2 5.3 5.3.1 ) 2) 3) Emergency stop unit This unit is equipped for protecting the engine if an engine trouble occurs. In case oi! pressure drops abnormally or charge becoze poor, the corresponding alarn laxp lights up end the engine evtoratically stops owing to activation of this unit. Phen the engine hes been stopped by this unit, the cause of trouble should be detected with reference to section 9 end the instruction menval of engine: After elininating the trouble, the machine should be resterted. OPERATION After warm-up operation Check the engine end generator for abnorsel sound or nalodor. Losd throwing throw load by turning ON the circuit breaker. (Avoid turning ON / OFF lodd by inserting /resoving the plug during operetion. othervise, the receptecle night be broken earlier. Further, shock hazerd wight occur.) Caution during operation under load The circuit breaker nay autonatically turn OFF because overJoed operation has continued for 2 long tine, the generatorbeen hes used for sterting an extrenely lerge cepacity motor or short-circuit has occurred. In this case,check the load side.After elizination of trouble, reclose the circuit breaker STOP After completing operation, turn OFF the circuit breaker. Turn the starter switch to the "STOP" position, and the engine will stop. After the engine hes stopped completely, the key should be pulled out. Emergency stop lever Energency stop lever If the engine cannot be stopped by turning the sterter switch to the “STOP” position, open the side door and push down the red-nerked enargency stop lever provided on the engine side. The engine will stop. This lever must not be manipulated in other than energency. Preparation and cere for operation on next day Replenish fuel to the fuel tenk. If the fuel tenk is left as is though fuel level drops significantly, fuel evaporates and codensation occurs. As 8 result, water is ept to accusulete in the tank.To prevent this, the fuel tank should elvays contsin fuel up to the specified level. “11-2)Clean the elements of air cleaner. 3)Check each fastening bolt and nut. If loose, retightening is necessary. 4)Always keep the machine clean by elininating dust and soisture fron both inside and outside. Perform naintenance and check thoroughly with adequate reference to the instruction manual. 7. ROUTINE CHECK AND MAIRTENANCE Routine maintenance is indispensable for alvays using the machine under good conditions and extending its service life. Perform check and maintenance, referring to the following table which lists the itens and intervals of check and saintenance. @ ‘The black circle weans that it needs sone special tools and technique. Perodical maintenance tyably Dayly | Every] Every | Every | Every| Every] Every ITEM/RUNWING HOURS 20Hrs | 50Hrs | 100Hrs | 300Hrs | 500Hrs | 1000Hrs Tighteings of bolt/ nut Engine of] check Engine oi! replacea- First second ent 25Hrs & after Oil leakage check oO ‘Air cleaner elenent Service more frequently cleaning oO when used industry areas Fuel tank - fuel st- Water Replace rainer cleaning drain ° Oo Valve clearance che- ck + adjustment e Oil filter cleaning oO Nozzle check - clea~ ning e Check and lap intake and exhaust valve seat e Battery liquid check Every month ~12-1) Replacenent of engine oi! while the engine is still hot, the drain plug is provided et the foot of engine. Before injection new engine oi confirm thet it meets the specificaticn. Replacenent of Tine interval engine oi} 1 st replecenent At 26 hours 2nd replecenent Every 100 Hrs onward 2) Washing of oil filter Whenever replecing the oil, wash the oi] filter. Dust will adhere to the inside of oil filter mesh, Fash adequately with diesel fuel. 3) Cleaning of air cleener Clean the elenents.For renoval and setting of the elexents,refer to 3.4 Cleaning | Every 100 hours, or whenever heavy contemination is detected €Cautiond If the elements are contaminated heavily, in consequence, air does not flow adequately throgh the clesner, Output is reduced, and each consusption of fuel end engine oil incresse. Besides, unsmooth start or the like trouble ney occur. Therefore, the elements should be cleened periodicel ly. Never use the cleaner without nounting the elenents or with e bored elenent sounted. 1 4) Retightening of cylinder head fastening bolt Since e speciel tool is needed for tightening this bolt, you should esk our seles or sevice representative for this work. 6)feter dreining form fuel filter Perform draining every 300 operation hours end replace the filter element with new ones every 1000 hours. 6) Check of generator Check for oil stain, dust, etc. and for loosening of bolt, nyt or the like, Internal dust, etc. should be purged by blowing compressed air. 7) Rotational speed of this generator under the rated loed has been adjusted to 3000 rpm for S0Hz specificetion, end to 3600 rpm for 60 Hz specification. To maintein this, avoid changing the sopper position of the engine revolution adjustment lever. -13-8, MEASURE 10 BE TAKEN BEFORE LONG STORAGE 1)Discharge of fuel (fire source unallowable in the vicinity) ODischarge fuel from the fuel tank with its drain cook loosened. Also discharge fuel from the fuel filter vith its drain screw removed. 2)Engine oil replacenent. Ofeplace the engine oil with new one. 3)Cleaning and storage. COfurn the engine and stop it when compression is felt. Okipe each section vith oil cloth. Put on cover and store at e dust free location. 4)Charging fhe battery is subject to natural discharge even while it is unused. So it should be charged once month. -14-9. TROUBLE SHOOTING Trouble Cause Reaedy Alternetor feils to generete. Short in wire. Check wiring(U1-V.U2-¥, J-k) with tester end repair. Burnt out arpature or field winding. ¥alfunction of voltmeter. Replace ermature or field winding. Check output voltege with tester. Replace voltmeter if necessery. Voltage too low. Engine speed is too low. Reise engine speed to reting. Overheating. Overload. Reduce the lord. Poor ventilation. Check eir space around the gene~ rating set. Heke sure there is at least In(3.3feet)cleerance on all sides of the generating. Engine does not start. Fuel does not flow. Check the fuel tank and fuel Tilter,and remove water,dust end sediments. All fuel is filtered, end dust or sedinents ere sticked on the filter. Clean the filter. Air or water is in the fuel systen. In cold weether,oil ves~ cosity is too high. Check looseness on the fuel pepe pipe joint bolts or nuts. Bleed air. Select a suiteble oil depending ambient temp. Battery is powerless to start the engine. Charge the bettery. In winter seeson, disconnect the battery,and store in 8 room efter full-cherging. Nount the bettery when use the set. Engine is power less. Engine suddenly stops. Fuel shortege Check the element, Air cleener is clogged. Fuel shortage. Replace the eleaent. Feed the fuel. Cehck the fuel systea. (Teke cere air singling.) Energency stop is actuated. Check the oil level. Colour of exheust gas is bad. Bed fuel. Replece the bed fuel with good one. Air cleaner is clogged. Replace the elesent with new one. -15-10. Outline Drawing ALIOVaWO NYE Tan AUHALVE AHOTIM ANG YOLVEANGD ANTONG Ww a To -16-11. Connection Diagram 11-1. Generator ® @,* Wiring Diagram (100V CLASS) Rel y®| ! Bagine Wiring = Bingen & Tape Lightiee cei — CONNECTOR SYMBOL PARTS NAME View from loserting Wise side NC Output Winding SC Exciting Winding jcc Charging Winding WIRING COLOR CODE Fe-P,N [Field Winding SYMBOL | COLOR [SYMBOL T COLOR cB Cirevit Breaker H piacx Th seo yz AC Voltmeter 3h jeaown TY FELLOW CONT [Receptacle j GREEN [LS Ture 008 [con? [Receptacle or Jenny [uo cere [Rel Rectilier a FINK We11-2. Generator Wiring Diagram (200V CLASS) ELCB ® ¥ Re From Engine Diagram Lighting Coil™ symbol PARTS NAME MC Output Winding SC Exciting Winding Fe-PN [Field Winding Re Rectifier BLOB |farth Leakage Cirewit Breater (OPTION) + Ground Terminal (fer ELCS) (OPTION) Ci7 [Condenser (OPTION) x AC Voltmeter CON] _[Receptacte (J0A) CON? [Receptacle (iSAx2) WIRING COLOR CODE SYMBOL [COLOR [SYMBOL [COLOR 2 Btack | R RED L BLUE Ww [WHITE BR Brown | ¥ yELLow c GREEN [LE LTGRT BLUE GE GRAY LG LIGAT GREEN v violet | 0 ORANGE F PINKWiring Diagram 11-3. Engine AVIRY ALBVS 3 AVITY ONGOUINE «| Reva | tle leds fLeszisy sie ry v | VVY vans € ND! J tno| | 7 zn - lo aed 10) | | aioxatos AKamt was. 12| =] fo) yay antona 7 ND. 205K > 6) 7 7 HOLIAS BaLaVis is vst asng 7 y HOLLMs oN y+ “saad T10 Sw. a - aais:0 2208 any Sagan, emu ain Tor0s [ToaRAS Paso TOURS us ol a YOLOENNOD ‘TdO9_WO10D NINA