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Dynamo Power DP7100 Owner's Manual

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Diesel Generator
Owner's Manual
DP7100
This manual provides information regarding the operation and maintenance of these products.
We have made every effort to ensure the accuracy of the information in this manual.
We reserve the right to change this product at any time without prior notice.

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Summary of Contents for Dynamo Power DP7100

  • Page 1 Diesel Generator Owner’s Manual DP7100 This manual provides information regarding the operation and maintenance of these products. We have made every effort to ensure the accuracy of the information in this manual. We reserve the right to change this product at any time without prior notice.
  • Page 2 Some of the pictures in this manual may differ slightly from the actual product as well. DYNAMO POWER CORP. reserves the right to make changes at any time without notice and without incurring any obligation.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS Chapter 1 Technical Specifications and Data 1-1 Overview of the generator 1-2 Technical specifications and data 1-3 Standard features 1-4 Basic operating parameters 1-5 General dimensions and overview of the generators Chapter 2 Operating the Diesel Generator 2-1 Main points of safety during operation of the generator 2-2 Preparation before operation 2-3 Checking the operation of the diesel engine...

  • Page 4: Chapter 1 Technical Specifications And Data

    TECHNICAL SPECIFICATIONS AND DATA CHAPTER 1 TECHNICAL SPECIFICATIONS AND DATA 1-1 Overview of the generator set Fuel Filler Cap Stationary Rings _„ Air Cleaner (inside) Control Panel 4"Solid Wheel Lock Remote Starter (inside) Muffler / ( i n s i d e )

  • Page 5: Technical Specifications And Data

    TECHNICAL SPECIFICATIONS AND DATA 1-2 Technical specifications and data Table 1 The Single-cylinder diesel generator Item Model DP7100 Frequency (HZ) 60 60 Rated power (kW) Peak power (kW) Generator Voltage (VAC) 120/240 technical Single phase Phase type data (AC) Power factor (cos)

  • Page 6: Standard Features

    TECHNICAL SPECIFICATIONS AND DATA 1-3 Standard features  Electric start, recoil start and remote control with preheater (cold start)  Large fuel tank with 12 hours continuous operating capability  Automatic shutdown for low oil pressure  Vibration isolation mounting between engine/alternator base align ...

  • Page 7: General Dimensions And Overview Of The Generators

    TECHNICAL SPECIFICATIONS AND DATA 1-5 General dimensions and overview of the generators 1-5.1 DP7100 dimensions of the series generator. Fig 1 929mm (36.6inch) 1-5.2 Generator model number code Remote start Silent Model Diesel engine Engine set DYNAMO...

  • Page 8: Chapter 2 Operating The Diesel Generator 2

    OPERATING THE DIESEL GENERATOR CHAPTER 2 OPERATING THE DIESEL GENERATOR 2- 1 General main points of safety during operation of the generator set. In order to operate the generator set safely, please follow all the instructions provided in this manual carefully. Doing so otherwise may lead to accidents or equipment damage.
  • Page 9 OPERATING THE DIESEL GENERATOR 2-1.4 Electric shock and short circuits Never touch the generator if the generator is wet. Also never touch the generator if your hand is wet. Never operate your generator if the weather conditions call for any type of precipitation such as rain, snow, or fog . To prevent electrical shocks, the generator should be grounded.

  • Page 10: Preparation Before Operation

    Table 3 Specifications of recommended accumulators for electric start MODEL Amps-hours DP7100 Your generator cones with either a maintenance free or dry cell battery (see fig Ensure the battery is fully charged before installation to prevent damage to electrical circuits. Use trickle charge for 8 hrs.
  • Page 11 OPERATING THE DIESEL GENERATOR Fig 4 Maintenance free battery (left) and dry battery(right) If it is dry battery, the battery must be filled with battery acid to required level. Acid can be purchased at a local automotive supply store. To properly maintain your dry battery, check the height of the battery acid once a month.
  • Page 12 OPERATING THE DIESEL GENERATOR Engine oil is the most important factor in determining the life of your generator engine. If you use poor engine oil or if you don't change the oil regularly, the piston and cylinder will wear easily or seize up. Also, the life of the other parts in your engine such as bearings, and other rotating parts will shorten considerably.
  • Page 13 OPERATING THE DIESEL GENERATOR cold weather; if your remote control unit has remote preheater fun ction, please see refer to operating procedures for remote start for your reference(for electric start) 12. Turn electronic key to ON position and then press the “ ”...

  • Page 14: Checking The Operation Of The Diesel Engine

    2-3 Checking the operation of the diesel engine 2-3.1 Low-pressure alarm system. Dynamo Power diesel engines have a low-pressure sensor system where if the oil pressure drops too low, the sensor will shut the engine off. The purpose of having this system is to ensure that the engine does not seize up. If there is not enough oil in the engine, the temperature of the oil will be raised too high.

  • Page 15: Starting The Generator Set

    OPERATING THE DIESEL GENERATOR Fig 9 Interval of changing engine oil Start: About one month or 20 hours. / Then every 3 months or 100 hours. Starting the generator set 2-4.1 Electric starting Start the engine in accordance with procedures below: (1) Put the switch of fuel filter in the ON position.
  • Page 16 OPERATING THE DIESEL GENERATOR 2-4.2 Remote starting Fig 11 Remote starter and remote jumper Preheat Stop Preheat Remote Starter Remote Jumper Remote Starter Signal Receiver Remote Starter antenna There are ON OFF, Preheat ( ) and Stop Preheat ( ) buttons in Remote Starter Key.

  • Page 17: How To Use Glow Plug

    OPERATING THE DIESEL GENERATOR IMPORTANT NOTE Some of our units come with a dry battery for shipping safety purposes. In order to get your generator started for the first time, the battery must be filled with battery acid which can be purchased at a local automotive supply store and slowly charged (trickle charged) for a day.

  • Page 18: Proper Operation Of The Generator Set

    OPERATING THE DIESEL GENERATOR 2-6 Proper operation of the generator set Fig 13 2-6.1 Operating the diesel engine 1. Pre-heat the diesel engine for 3 minutes under no load conditions. 2. First check the height of the lubricating oil level, if it is low, refill it.
  • Page 19 OPERATING THE DIESEL GENERATOR NOTE: During operation, the generator should be put in a place with good ventilation. Never cover open frame generator using your own cage to solve a noisy problem, as this will cause overheating problem and then damage your generator.
  • Page 20 OPERATING THE DIESEL GENERATOR Fig 18 Wiring diagram of electric output for control panel L1(Red)- R1(Yellow) (GREEN) ,40410{, - (Green) - (Black) 2-7.3 AC application 1. Ensure engine is running properly and is warmed up for 3 minutes. 2. The voltmeter should point to 240V±5%. Turn circuit breaker on. The AC voltage from the socket of the power supply can be output.

  • Page 21: Stopping The Generator

    OPERATING THE DIESEL GENERATOR 2-7.4 DC application Both DC terminals provide output: 12VDC, 7A. The red terminal is "+"(positive) pole of power supply. It can be used as load for rated voltage 12VDC and also used for charging 12V battery. 1.
  • Page 22 OPERATING THE DIESEL GENERATOR warm down. Stopping the diesel engine suddenly may raise the temperature of the engine abnormally and lock the nozzle and damage the diesel engine. 3. Turn electronic key to the OFF position to stop the genset. In the same way, you can press the OFF button in remote starter key to stop the genset.

  • Page 23: Chapter 3 Maintenance

    CHAPTER 3 MAINTENANCE Maintenance schedules Keeping your generator well maintained will prolong the life of your generator. Everything needs to be checked including the diesel engine, generator, control cabinet, and frame. For overhauling procedures, please refer to the instruction manual of the relative subassembly. If you need these manuals, please call our company and we will send you one.
  • Page 24 MAINTENANCE C h a n g i n g t h e e n g i n e o i l Take the oil cover off. Remove the oil drain plug when the diesel engine is still hot. Be careful of hot oil and hot engine as you may get burned.

  • Page 25: Storing For Long Periods Of Time

    MAINTENANCE 3-2 Storing for long periods of time If your generator needs to be stored for long per[ods of time, the following preparations should be made. 1. Start the diesel engine for 3 minutes then stop it. 2. When the engine is still hot, change the engine oil with new engine oil of the proper grade.

  • Page 26: Chapter 4 Troubleshooting

    TROUBLESHOOTING CHAPTER 4 TROUBLESHOOTING 4-1 Inspections before operation and maintenance. 4-1.1 Inspections before operation 4-1.1.1 Check the insulated resistance An insulated resistance usually results in the creepage of the alternator when it is below the regulated value and then brings on the security problems.
  • Page 27 TROUBLESHOOTING If you have used your generator for some time and find you cannot start it or it shuts off automatically, it is usually caused by failure fuel system such as running out of fuel, non-energized solenoid, and burned solenoid or by failed remote control unit.
  • Page 28 TROUBLESHOOTING CAUSES TROUBLESHOOTING Tighten the nuts of cylinder head in Deficiency in pressure of compression. the diagonal sequence; check the Loosened nut of cylinder head. gasket of cylinder as per the standard 1 Damage or leakage in the gasket of requirement.
  • Page 29 TROUBLESHOOTING b. Take off fuel injector and test it: open the cover right on the top of enclosure (silent model) or muffler cover (open frame model), loosen two 10MM nuts, take out fuel injector with high pressure metal fuel pipe hooked up together, reconnect the other end of metal fuel pipe to fuel pump so that make sure you can observe the tip of fuel injector when cranking engine.
  • Page 30 TROUBLESHOOTING You should use two flat head screwdriver to warp up the stator out through two symmetrically distributed notches in the alternator cast case. It usually takes less than 10 seconds to remove stator from alternator. 4. Remove rotor from engine shaft. Completely loosen the long bolt with a 14MM hex head nut that is used to hold rotor to engine shaft so that you can take it out.
  • Page 31 TROUBLESHOOTING 4. Align crank gear(drive shaft) and cam gear(cam shaft): there are TWO NOTS and ONE NOT in crank and cam gears respectively, you must align them at this step; 5. Put case gasket and match two halves of engine together, tighten all bolts. 6.
  • Page 32 TROUBLESHOOTING 4-2.2 Causes and Troubleshooting for Deficient Power of Diesel Engine Table 6 CAUSES TROUBLESHOOTING Malfunction of fuel system Check the fuel switch, they should be Parts obstruction in fuel filter and fuel opened fully. pipe Check the fuel filter and fuel pipe. Inadequate fuel supplying Bad pressing of fuel pump Check or change the damaged parts of...
  • Page 33 TROUBLESHOOTING 4-2.2.2 Causes and Troubleshooting for Engine Stopping Automatically Table 7 CAUSES TROUBLESHOOTING Malfunction of the fuel system Check solenoid, fuel pipe, fuel pump Run out of fuel fuel injector Fill fuel. & Low oil level or oil is too dirty Check oil and change if necessary.
  • Page 34 TROUBLESHOOTING Causes and Troubleshooting for Exhaust with White Smoke 2.2.5 Table10 CAUSES TROUBLESHOOTING Clean the fuel tank and filter and Water mixed in diesel fuel change the diesel fuel. Faulty fuel injection system Incorrect fuel injection and valve timing Improper air/fuel mixture Engine overheating Faulty fuel pump and/or injection pump...
  • Page 35 TROUBLESHOOTING CAUSES TROUBLESHOOTING No or little spray from injection pump Disassemble the nozzle and adjust it on the test table and nozzle The governor speed handle is not on Turn the governor handle to the the position of "RUN" position of "RUN" The standard of lubricating oil is between upper line "H"...
  • Page 36 TROUBLESHOOTING 4-2.4 Damage Cause and Remedy of Brush less Alternator Table l4 PHENOMENA CAUSE REMEDY 1 .Switch 1. Turn the switch to the position "ON". position of "OFF" 2.Adjust the contactor of the plug or the wires 2.Worse connection of the plug or the control panel.
  • Page 37 TROUBLESHOOTING 4-2.5 Damage Cause and Remedy of Brush Alternator Table15 REMEDY PHENOMENA CAUSE 1.Switch is on the position 1.Turn the switch to the of "OFF". position "ON". 2. Adjust the contactor of the 2,Worse connection of the plug or the wires inside the plug or the control panel.

  • Page 38: Questions And Doubts

    TROUBLESHOOTING 4-3 Questions and doubts If you do not understand anything or have any questions, please feel free to contact your local dealer or with our company directly. Below is a list of some information you should have ready before contacting your local dealer or us. 1.

  • Page 39: Chapter 5 Generator Parts Diagrams And Listings

    GENERATOR PARTS DIAGRAMS AND LISTINGS Table 5-1. Please refer to figure 5-1 for illustration Part Description Quantity Part Code Silencer cover 6500S-E-001 Silencer bend 6500S-E-002 Left board of cover 6500S-E-003 Back door of cover 6500S-E-004 Fixing sleeve for observing bore 6500S-E-005 6 Fixing sleeve for input of fuel tank 6500S-E-006...
  • Page 40 G E N E R A TO R P A R TS D I A G R A MS A N D L I S TI N G S Part Description QU.T Part Code clamp of accumulator with bolt and nut 6500S-E-047 cover of clamp of accumulator 6500S-E:048...
  • Page 41 GENERATOR PARTS DIAGRAMS AND LISTINGS Figure 5-2. Electric panel parts drawing...
  • Page 42 GENERATOR PARTS DIAGRAMS AND LISTINGS Table 5-2. Please refer to figure 5-2 Part Description Quantity Part Code[ AED6500XER panel for DYNAMO 6500XER-P-001 Electric start switch (JK426) 6500WF-P-002 Electronic key 6500WF-P-003 Indicating lamp of power supply (12V) 6500WF-P-004 Low-oil protection indicating lamp (12V) 6500WF-P-005 Voltmeter(99T1/300V) 6500WF-P-006...
  • Page 43 GENERATOR PARTS DIAGRAMS AND LISTINGS Figure 5-3. Generator head assembly Table 5-3. Please refer to figure 5-3 Number Part Description Quantity Part Code Front end cover 1000-B-001 Diode 3510 1000-B-002 Bolt M5 x 16 1000-B-003 Fan Blade 1000-B-004 Bearing 6204(GB/T 307) 1000-B-005 Rotor Unit 1000-B-006...

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