HONDA DCX3000 User Manual
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
Keep this owner’s manual handy, so you can refer to it at any time.
This owner’s manual is considered a permanent part of the generator
and should remain with the generator if resold.
The information and specifications included in this publication were in
effect at the time of approval for printing. Honda Motor Co., Ltd.
reserves the right, however, to discontinue or change specifications or
design at any time without notice and without incurring any obligation
whatever.
2004 Honda Motor Co., Ltd. All Rights Reserve
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INTRODUCTION
Congratulations on your selection of this generator. We are certain
you will be pleased with your purchase of one of the finest generators
on the market.
We want to help you get the best results from your new generator and
to operate it safely. This manual contains all the information on how to
do that; please read it carefully.
As you read this manual, you will find information preceded by a
symbol. That information is intended to help you avoid
damage to your generator, other property, or the environment.
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty policy
is a separate document that should have been given to you by your
dealer.
When your generator needs scheduled maintenance, keep in mind
that your Alphagen servicing dealer is specially trained in servicing
this generator. Please contact your Alphagen dealer to have your
generator serviced. Your servicing dealer is dedicated to your
satisfaction and will be pleased to answer your questions and
concerns.
Best Wishes,
1
A FEW WORDS ABOUT SAFETY
Your safety and the safety of others are very important. And using this
generator safely is an important responsibility.
To help you make informed decisions about safety, we have provided
operating procedures and other information on labels and in this
manual. This information alerts you to potential hazards that could
hurt you or others.
Of course, it is not practical or possible to warn you about all the
hazards associated with operating or maintaining a generator. You
must use your own good judgement.
You will find important safety information in a variety of forms,
including:
on the generator.
Safety Labels
Safety Messages
of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
−
preceded by a safety alert symbol and one
−
You WILL KILLED SERIOUSLY HURT
you don’t follow instructions.
You CAN KILLED SERIOUSLY HURT
you don’t follow instructions.
You CAN HURT
instructions.
such as
Safety Headings
Safety Section
Instructions
This entire book is filled with important safety information please
read it carefully.
−
−
such as
−
how to use this generator correctly and safely.
be or if
be or if
be if you don’t follow
IMPORTANT SAFETY INFORMATION
GENERATOR SAFET Y .
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2
.
CONTENTS
............................................................................................CONTROLS .14
.......................................................................................Choke Knob .15
.............................................................................................FEATURES .17
...........................................................................................Voltmeter .17
TM
Indicator .19
.........................................................................................Fuel Gauge .19
................................................................................GENERATOR SAFETY .6
..................................................IMPORTANT SAFETY INFORMATION .6
......................................................................Operator Responsibility .6
.................................................................Carbon Monoxide Hazards .6
.......................................................................Electric Shock Hazards .7
........................................................................Fire and Burn Hazards .7
.................................................................................Refuel With Care .8
.................................................................SAFETY LABEL LOCATIONS .9
........................................................................CONTROLS & FEATURES .12
...........................................COMPONENT & CONTROL LOCATIONS .12
.............................................................DC Voltage Selector Switch .14
................................................................................Fuel Valve Lever .14
....................................................................................Engine Switch .15
.....................................................................................Recoil Starter .16
....................................................................................Output Switch .16
...............................................................................Ground Terminal .17
............................................................................DC Output Coupler .17
........................................................................EcoThrottle System .17
................................................................................Output Indicator .18
............................................................................Overload Indicator .18
............................................................................Oil Alert
...............................................................................BEFORE OPERATION .20
................................................ARE YOU READY TO GET STARTED ? .20
.........................................................................................Knowledge .20
.............................................IS YOUR GENERATOR READY TO GO ? .20
...............................................................................Check the Engine .21
3
CONTENTS
..............................................................................................OPERATION .22
.....................................................SAFE OPERATING PRECAUTIONS .22
..........................................STARTING THE ENGINE/DC OPERATION .23
....................................................................................Forced Output .26
......................................................................STOPPING THE ENGINE .28
.............................................................SERVICING YOUR GENERATOR .30
.............................................THE IMPORTANCE OF MAINTENANCE .30
......................................................................MAINTENANCE SAFETY .31
............................................................................Safety Precautions .31
................................................................MAINTENANCE SCHEDULE .32
...........................................................................................REFUELING .33
...............................................................FUEL RECOMMENDATIONS .34
..................................................................ENGINE OIL LEVEL CHECK .35
...........................................................................ENGINE OIL CHANGE .36
....................................................ENGINE OIL RECOMMENDATIONS .37
........................................................................AIR CLEANER SERVICE .38
.............................................................FOAM AIR FILTER CLEANING .40
.................................................................SEDIMENT CUP CLEANING .41
.........................................................................SPARK PLUG SERVICE .43
................................................................SPARK ARRESTER SERVICE .45
4
CONTENTS
..................................................................................................STORAGE .48
....................................................................STORAGE PREPARATION .48
.............................................................................................Cleaning .48
.....................................................................................................Fuel .48
...........................................................................Engine Preparation .51
...................................................................STORAGE PRECAUTIONS .52
................................................................REMOVAL FROM STORAGE .52
......................................................................................TRANSPORTING .53
.......................................TAKING CARE OF UNEXPECTED PROBLEMS .54
.............................................................................ENGINE PROBLEMS .54
....................................................................GENERATOR PROBLEMS .56
..........................................TECHNICAL & CONSUMER INFORMATION .58
................................................................TECHNICAL INFORMATION .58
...................................................................Serial Number Location .58
....................Carburetor Modification for High Altitude Operation .59
.............................................................................Oxygenated Fuels .60
............................................Emission Control System Information .61
.............................................................................................Air Index .63
....................................................................................Specifications .64
.................................................................................Wiring Diagram .65
...............................................................CONSUMER INFORMATION .66
.......................................................................................Publications .66
.........................................................Customer Service Information .67
........................................................................................................INDEX .68
.............................QUICK REFERENCE INFORMATION .Inside back cover
5
GENERATOR SAFETY
IMPORTANT SAFETY INFORMATION
This generator is designed for use with CATV/Telecommunications
equipment that has suitable power requirements. Other uses can
result in injury to the operator or damage to the generator and other
property.
Most accidents can be prevented if you follow all instructions in this
manual and on the generator. The most common hazards are
discussed below, along with the best way to protect yourself and
others.
Operator Responsibility
Know how to stop the generator quickly in case of emergency.
Understand the use of all generator controls, output receptacles,
and connections.
Be sure that anyone who operates the generator receives proper
instruction. Do not let children operate the generator without
parental supervision.
Carbon Monoxide Hazards
Exhaust contains poisonous carbon monoxide, a colorless, odorless
gas. Breathing exhaust can cause loss of consciousness and may
lead to death.
If you run the generator in a confined or even partially enclosed area,
the air you breathe could contain dangerous amounts of exhaust
gas. To keep exhaust gas from building up, provide adequate
ventilation.
6
GENERATOR SAFETY
Electric Shock Hazards
The generator produces enough electric power to cause a serious
shock or electrocution if misused.
Do not touch uninsulated portion of output coupler.
Risk of electrical shock.
Using a generator or electrical appliance in wet conditions, such as
rain or snow, or near a pool or sprinkler system, or when your hands
are wet, could result in electrocution. Keep the generator dry.
If the generator is stored outdoors, unprotected from the weather,
check all of the electrical components on the control panel, before
each use. Moisture or ice can cause a malfunction or short circuit in
electrical components which could result in electrocution.
Fire and Burn Hazards
The exhaust system gets hot enough to ignite some materials.
Keep the generator at least 3 feet (1 meter) away from buildings
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and other equipment during operation.
Do not enclose the generator in any structure.
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Keep flammable materials away from the generator.
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The muffler becomes very hot during operation and remains hot for
a while after stopping the engine. Be careful not to touch the muffler
while it is hot. Let the engine cool before storing the generator
indoors.
7
GENERATOR SAFETY
Refuel With Care
Gasoline is extremely flammable, and gasoline vapor can explode.
Allow the engine to cool if the generator has been in operation. Refuel
only outdoors in a well-ventilated area with the engine OFF. Do not
overfill the fuel tank. Never smoke near gasoline, and keep other
flames and sparks away. Always store gasoline in an approved
container. Make sure that any spilled fuel has been wiped up before
starting the engine.
8
GENERATOR SAFETY
SAFETY LABEL LOCATIONS
These labels warn you of potential hazards that can cause serious
injury. Read them carefully. If a label comes off or becomes hard to
read, contact your Alphagen servicing dealer for a replacement.
9
GENERATOR SAFETY
10
GENERATOR SAFETY
11
CONTROLS & FEATURES
COMPONENT & CONTROL LOCATIONS
Use the two illustrations on these pages to locate and identify the
most frequently used controls.
OUTPUT
INDICATOR
OVERLOAD
INDICATOR
OIL ALERT
INDICATOR
ENGINE SWITCH
CHOKE KNOB
FUEL VALVE LEVER
VOLTMETER
OUTPUT SWITCH
GROUND
TERMINAL
DC OUTPUT
COUPLER
12
MUFFLER
CONTROL & FEATURES
SPARK PLUG CAP
FRONT HANDLE
OIL FILLER CAP/
DIPSTICK
OIL DRAIN PLUG
OIL MAINTENANCE COVER
MAINTENANCE COVER
FUEL TANK CAP
STARTER GRIP
DC VOLTAGE
SELECTOR SWITCH
FUEL GAUGE
REAR HANDLE
AIR CLEANER
13
CONTROL & FEATURES
CONTROLS
DC Voltage Selector Switch
The DC voltage selector switch is
used to select generator DC
voltage; either 36 V or 48 V.
Select the same voltage as the
battery voltage of the UPS battery
string.
To operate the DC voltage
selector switch, make sure the
engine is off, then open the
maintenance cover.
After selecting the voltage, close
the maintenance cover.
Fuel Valve Lever
The fuel valve lever is located on
the control panel.
DC VOLTAGE SELECTOR SWITCH
MAINTENANCE COVER
The fuel valve lever must be in the
ON position for the engine to run.
After stopping the engine, turn
the fuel valve lever to the OFF
position.
14
OONN
OOFFFF
FUEL VALVE LEVER
CONTROLS
Choke Knob
The choke knob opens and closes
the choke valve in the carburetor.
The CLOSED position enriches
the fuel mixture for starting a cold
engine.
The OPEN position provides the
correct fuel mixture for operation
after starting, and for restarting a
warm engine.
CONTROL & FEATURES
CHOKE KNOB
CCLLOOSSEEDD
OOPPEENN
Engine Switch
The engine switch controls the
ignition system.
OFF Stops the engine. The
−
engine switch key can be
removed/inserted.
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ON Running position, and for
starting with the recoil starter.
OOFFFF
OONN
ENGINE SWITCH
ENGINE SWITCH KEY
15
CONTROL & FEATURES
Recoil Starter
Pulling the starter grip operates
the recoil starter to crank the
engine for starting.
Do not allow the starter grip to
snap back against the engine.
Return it gently to prevent
damage to the starter.
Do not let the starter rope rub
against the generator body or
the rope will wear out
prematurely.
STARTER GRIP
Output Switch
The output switch has two functions.
Stop Output
During the output operation,
press the output switch to
stop output. To reset, stop
and restart the engine.
Forced Output
Following the forced output
procedure, the generator will
provide output to charge the
battery string when the
battery string charge is too
low to activate automatic
charging.
OUTPUT SWITCH
16
FEATURES
Ground Terminal
The ground terminal is connected
to the frame of the generator and
the metal non-current-carrying
parts of the generator.
Before using the ground terminal,
consult a qualified electrician,
electrical inspector or local
agency having jurisdiction for
local codes or ordinances that
apply to the intended use of the
generator.
DC Output Coupler
The DC output coupler may ONLY
be used for charging UPS 36 V or
48 V battery strings.
When connecting the power cord
to the DC output coupler, always
use the correct coupler and power
cord.
CONTROL & FEATURES
DC OUTPUT COUPLER
Positive
side
Negative
side
Voltmeter
The voltmeter indicates the voltage of the UPS batteries when
connected to the DC output coupler.
EcoThrottle System
The EcoThrottle system automatically reduces engine speed when
TM
TM
the UPS battery string is fully charged.
When the UPS battery string becomes discharged, the engine returns
to the proper speed to recharge the batteries.
17
CONTROL & FEATURES
Output Indicator
The output indicator (green) is illuminated when the generator is
operating normally. It indicates that the generator is producing
electrical power at the DC output coupler.
OUTPUT INDICATOR
(GREEN)
Overload Indicator
The overload indicator (red) will go steady ON if the generator is
overloaded, the converter becomes overheated or there is a short
circuit in the connected UPS battery string. The overload indicator
(red) will stay ON, and after about five seconds, current to the
connected UPS and the output indicator (green) will go OFF. When the
UPS battery voltage is too low or too high, the overload indicator (red)
will flash.
OVERLOAD INDICATOR
(RED)
18
CONTROL & FEATURES
Oil Alert
The Oil Alert
Indicator
system is designed to prevent engine damage caused
by an insufficient amount of oil in the crankcase. Before the oil level in
the crankcase can fall below a safe limit, the Oil Alert
on and the Oil Alert
system automatically will stop the engine (the
indicator comes
engine switch will remain in the ON position).
If the engine stops or the Oil Alert
the starter grip, check the engine oil level (see page ) before
indicator comes on when you pull
35
troubleshooting in other areas.
OIL ALERT
INDICATOR
Fuel Gauge
The fuel gauge is a mechanical device that measures the fuel level in
the tank. The red indicator in the window will reference the level in
relation to full or empty. To provide increased operating time, start
with a full tank before beginning operation. Check the fuel level with
the generator on a level surface. Always refuel with the engine OFF
and cool.
FULL
EMPTY
FUEL TANK CAP
FUEL GAUGE
19
BEFORE OPERATION
ARE YOU READY TO GET STARTED?
Your safety is your responsibility. A little time spent in preparation will
significantly reduce your risk of injury.
Knowledge
Read and understand this manual. Know what the controls do and
how to operate them.
Familiarize yourself with the generator and its operation before you
begin using it. Know how to quickly shut off the generator in case of
an emergency.
When the generator is being used, check the voltage requirement of
the UPS battery strings. This generator is designed to charge 36 V and
48 V battery strings.
IS YOUR GENERATOR READY TO GO?
For your safety, and to maximize the service life of your equipment, it
is very important to take a few moments before you operate the
generator to check its condition. Be sure to take care of any problem
you find, or have your servicing dealer correct it, before you operate
the generator.
Improperly maintaining this
generator, or failing to correct a
problem before operation, could
cause a malfunction in which you
could be seriously injured.
Always perform a preoperation
inspection before each operation,
and correct any problem.
To prevent a possible fire, keep the generator at least 3 feet (1 meter)
away from building walls and other equipment during operation. Do
not place flammable objects close to the engine.
Before beginning your preoperation checks, be sure the generator is
on a level surface and the engine switch is in the OFF position.
20
Check the Engine
BEFORE OPERATION
Check the oil level (see page ). A low oil level will cause the Oil
Alert
Check the air filter (see page ). A dirty air filter will restrict air flow to
the carburetor, reducing engine and generator performance.
Check the fuel level (see page ). Starting with a full tank will help to
eliminate or reduce operating interruptions for refueling.
system to shut down the engine.
35
38
33
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