Power

DCX3000 3.0kW, 36/48VDC Portable Generator Quick Guide

The following instructions are intended to supplement the DCX3000 Operator’s Manual. Read and adhere to all safety instructions listed in the Operator’s Manual (Alpha P/N 041-028-B0) and this document. If you have any questions regarding safe operation of the generator, consult the Operator’s Manual or contact Alpha Technical Support.

WARNING!

Do not make or break any connections between the power supply battery pack and generator while the generator is running. Turn the generator off before disconnecting any cables or equipment.

CAUTION!

Always check the engine oil level prior to operating the generator. Failure to do so could lead to irreparable damage to the engine.

CAUTION!

DC Voltage

Selector

Switch

Only use 86 octane fuel or higher and no more than 10% Ethanol or 5% Methanol by volume.

1.0 Connecting Generator

1. Open the maintenance cover (see Figure 1-1).

2. Using the DC voltage selector switch, select either 36V or 48V (see Figure 1-1).

3. Close the maintenance cover.

Maintenance

Cover

4. Connect the power cord of the UPS to the DC output coupler, ensuring there is no gap (see Figure 1-2).

Fuel Valve

Lever

ON

Choke

Knob

OFF

O

CLOSED

DC Voltage

Selector

Switch

DC Output Coupler

Voltmeter Choke

Knob

ON

O F F

O N

Maintenance

Cover

Fuel Valve

Lever Power

Coupler

OFF

O

CLOSED

No gap

Figure 1-1, DC Voltage Selector Switch location.

Figure 1-2, Connecting the UPS to the DC Output Coupler.

Note: When the UPS battery string is connected to the generator, the backlight in the Voltmeter is turned on and indicates the battery string voltage.

Selector

Switch

2.0 Operating Generator Starter Grip

1. Turn the Fuel Valve Lever to the ON position (see

Figure 2-1).

O F F ON

Choke

Knob

2. Adjust Choke Knob (see Figure 2-1).

No gap

– Pull the Choke Knob to the CLOSED position to start a cold engine.

Maintenance

– Leave the Choke Knob in the OPEN position to restart a warm engine.

O N

Fuel Valve

Lever

Engine

OFF

O

CLOSED

Figure 2-1, Fuel Valve Lever and Choke Knob operation.

Direction to pull

041-028-B1-001 Rev. B (09/2012)

DC Output Coupler

1

Voltmeter

Choke

Knob

Choke

Knob

Starter Grip

Engine

Switch

Choke

Knob

OPEN

O F F

O N No gap

Direction to pull Power

Coupler

O P E N

Engine

Switch

Choke

Knob

Choke

Knob

Starter Grip

Direction to pull

CLOSED

O P E N

Choke

Knob

OPEN

CLOSED

O P E N

DC Voltage

Selector

Switch

Choke

Knob

ON

Maintenance

Cover

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Fuel Valve

Lever

OFF

O

CLOSED

DC Output Coupler

3. Turn the Engine Switch to the ON position (see Figure 2-2).

4. Pull the Starter Grip until you feel resistance, then pull strongly in a straight line (see Figure 2-2).

Note: Pulling the Starter Grip at sharp angle to the engine will prematurely wear out the cord. Do NOT let O F F

Starter Grip

O N

5. If the choke was CLOSED to start the engine, gradually push the choke in to the OPEN position as the engine warms up.

Power

Coupler

Direction to pull

Note: When the engine starts, DC output will begin charging the UPS battery string automatically and the output indicator (green) will go ON. If the UPS battery string voltage is too low, the DC output will turn off. At this time, the output indicator (green) will go OFF and the overload indicator (red) will go ON (see Table 2-1).

Engine

Switch

Figure 2-2, Engine Switch and Starter Grip operation.

Choke

Knob

Battery Voltage 1

0V to 2V

2V to 27V

27V to 42V

42V to 55V

>56V

36V

48V

36V

48V

36V

Battery Voltage Alarm Indicators

Voltage Select

Switch Position

36V

48V

36V

48V

48V

Output Indicator

(Green LED)

OFF

OFF

OFF

OFF

ON

OFF

OFF

ON

OFF

OFF

Overload Alarm

(Red LED)

OFF

OFF

FLASHING

FLASHING

OFF

FLASHING

FLASHING

OFF

FLASHING

FLASHING

Forced Output 2

Choke

Knob and power output begins. The operator may then release the output button.

(3)–Engine shuts down after 1 second.

Table 2-1, Battery Voltage alarm indicators.

Not Available

Not Available

ENABLED

ENABLED

Not Available

ENABLED

Not Available

Not Available

Not Available 3

Not Available 3

OPEN

Run Time Table

Load

25%

80%

100%

Run Time (Hours)

20

10

7.2

Table 2-2, Load to approximate run time.

3.0 Maintenance Schedule

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD

Note: Perform at every indicated month or operating hour interval, whichever comes first.

Engine Oil CLOSED

Change

Air Cleaner

Canister

Purge tube

Charge tube

Sediment Cup

Spark Plug

Spark Arrester

Valve Clearance

Combustion chamber

Fuel tank and filter

Fuel tube

Check

Clean

Replace

Check

Check

Check

Check

Check-adjust

Replace

Clean

Check-adjust

Clean

Clean

Check

O P E N

O

O

O

O2

O

Every 2 years (Replace if necessary)3

Every 2 years (Replace if necessary)3

Every 2 years (Replace if necessary)3

O

O

O

Every 2 years (Replace if necessary)2

Table 2-3, Battery Voltage alarm indicators.

O1

O

O3

O3

(1)–Replace the paper air filter element only.

(2)–Service more frequently when used in dusty areas.

(3)–These items should be serviced by an authorized

AlphaGen dealer.

For commercial use, log hours of operation to determine proper maintenance intervals. Failure to follow this maintenance schedule could result in nonwarrantable damage.

2 041-028-B1-001 Rev. B (09/2012)

Oil Drain Plug

Oil Maintenance

Cover

Oil Filler Cap

Dipstick

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Upper Limit

4.0 Engine Oil Recommendations

Oil affects performance and service life for the engine. Always use 4-stroke automotive detergent oil. The engine can hold .58 U.S. qt (.55 L) of oil.

SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is with the recommended range (see Figure 4-1).

AMBIENT TEMPERATURE

Figure 4-1, Oil recommendations for ambient temperature.

The SAE oil viscosity and service category are in the API label on the oil container. We recommend that you use

API SERVICE category SJ or later (or equivalent) oil.

5.0 Changing Engine Oil

CAUTION!

Hot engine oil can BURN. The engine should be warm to the touch but not hot when changing the oil.

Draining warm oil assists rapid and complete draining.

2. Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick. Using a 10mm wrench remove the drain plug and sealing washer (see Figure 5-1).

Oil Drain Plug

3. Allow the used oil to drain completely, then reinstall the drain plug and sealing washer. Tighten the plug securely.

Note: Improper disposal of engine oil can be harmful to the environment and may violate local and federal laws. Dispose of the used oil in accordance with all local, state and federal laws.

4. With the generator in a level position, fill to the outer edge of the oil filter hole with the recommended oil (see

Figure 5-2).

Oil Maintenance

Cover

Oil Filler Cap

Dipstick

5. Screw in the oil filler cap/dipstick securely.

6. Reinstall, close, and latch the oil maintenance cover.

Note: Always wash your hands after handling motor oil.

Oil Drain Plug

Upper Limit

Oil Maintenance

Cover

Oil Filler Cap

Figure 5-1, Draining oil.

041-028-B1-001 Rev. B (09/2012)

Dipstick

Figure 5-2, Filling oil limit.

3

Upper Limit

AMBIENT TEMPERATURE

Drain Screw

AMBIENT TEMPERATURE

Drain Screw

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Sediment Cup

Filter

6.0 Draining Fuel Tank and Carburetor

WARNING!

O-Ring

(replace)

Gasoline is highly flammable and explosive. You can be burned or otherwise seriously injured improperly handling fuel. STOP the engine and let it fully cool before adding or draining fuel. Remove all sources of ignition, heat, and spark from the immediate area.

Wipe up spills immediately.

Sediment Cup

1. Open the maintenance cover.

2. Place a suitable gasoline conatiner below the carburetor drain hose.

3. Loosen the carburetor drain screw and drain the gasoline from the carburetor (see Figure 6-1).

4. After all the fuel has drained into the container, tighten the drain screw securely.

5. Place an approved gasoline container below the sediment cup, and use a funnel to avoid spilling fuel (see Figure 6-2).

Note: The engine fuel tank can hold 3.5 U.S. gallons

(13.3L) of fuel.

6. Remove the sediment cup, then move the Fuel Valve Lever to the ON position.

7. Allow the fuel to drain completely, then reinstall the sediment cup.

8. Close the maintenance cover.

Drain Screw

Figure 6-1, Draining carburetor.

Sediment Cup

Filter

O-Ring

(replace)

Sediment Cup

Figure 6-2, Draining/cleaning sediment cup.

7.0 Storing Generator

Proper storage preparation will help prevent corrosion damage and help extend the life of the fuel system. Prior to storage clean the generator entirely with a damp rag. Once dry, touch up damaged paint and lightly coat exposed metal surfaces with a quality rust inhibitor. To prevent fuel oxidizing, entirely drain the fuel system. If this is not possible, fill the fuel tank entirely to reduce the air in the tank (air hastens fuel oxidation) and ensure a quality gasoline stabilizer is used per the manufacturer's recommendations. It is also good practice to change the oil before long term storage.

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Drain Screw

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Alpha is a registered trademark of Alpha Technologies. 041-028-B1-001 Rev B. (09/2012) For more information visit www.alpha.com