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Denyo DCA-150LSKE, Instruction Manual

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Denyo DCA-150LSKE Instruction Manual Download Page 85

-  81  - 

 

Phenomenon

 

Assumed  cause

 

Action

 

Engine  will

 

  not  start  u

p

 

  Cell  motor

 

  will  not  run

 

  or  revolution

 

  speed  is  low

 

Discharged  battery

 

Charge  or

 

replace

 

Detached  or  loosened  or  corroded

 

battery  terminal

 

Repair

 

Fuse  blow

 

Replace

 

Improper  starter  switch

 

Replace

 

Improper  starter

 

Replace

 

Broken  lead  wire

 

Repair

 

Cell  motor  run

s

 

Fuel  shortage

 

Supply

 

Blinded  fuel  filter

 

Replace  cartridge

 

Air  in  fuel  system

 

Remove

 

Speed  will  not  rise

 

Air  in  fuel  system

 

Remove

 

Blinded  fuel  filter

 

Replace  cartridge

 

Compression  failure

 

Repair  engine

 

Blinded  air  cleaner

 

Replace  element

 

  Engine  stop  by  oil  failure

 

Oil  shortage

 

Supply

 

Oil  pressure  switch  failure

 

Replace

 

Blinded  oil  filter

 

Replace  cartridge

 

  Over  heat

 

 

(

water  temperature

)

 

Cooling  water  shortage

 

Supply

 

Fan  belt  looseness

 

Adjust

 

Blinded  core  of  radiator

 

Clean

 

Engine  thermostat  failure

 

Repair

 

  Voltmeter  will  not  operate

 

Voltmeter  failure

 

Replace

 

AVR  failure

 

Contact

 

distributor  or

 

our  office

 

Burned  ZNR

 

Quenched  residual  magnetism 

Burned  rotary  rectifier

 

Disconnected  rotor  wiring

 

Burned  generator  wiring

 

  Rated  voltage  will  not  be

 

  reached

 

Voltmeter  failure

 

Replace

 

AVR  failure

 

Contact

 

distributor  or

 

our  office

 

VR  failure

 

Burned  rotary  rectifier

 

Burned  ZNR

 

Burned  generator  wiring

 

Low  speed

 

Increase

 

 

Summary of Contents for DCA-150LSKE

Page 1: ...d this manual for the sake of safety Be sure to observe the items under symbol marks WARNING and CAUTION for the sake of safety Always keep this manual at your machine for the sake of safety 2 8 5 Nih...

Page 2: ...Japan...

Page 3: ...rrect operation and maintenance of the machine to ensure its performance Incorrect handling of the machine may lead to a serious injury or decease Before using be sure to read this manual carefully Pa...

Page 4: ...ns 53 6 4 Shut down 53 7 Lubrication cooling water and fuel 54 7 1 Engine oil 54 7 2 Cooling water 56 7 3 Fuel 56 8 Handling of battery 57 8 1 Caution on battery charge 58 8 2 Connection of booster ca...

Page 5: ...duct or property damage Note This symbols show handling precautions for effective operation and many years of satisfactory operation Some of the items shown by CAUTION may also cause death or serious...

Page 6: ...pecifying the nameplate No shown below and ask for new ones No Parts name Parts number Safety instruction B9211 0140 Warning moving parts B9040 0100 Warning hot coolant B9041 0030 Warning exhaust gas...

Page 7: ...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...

Page 8: ...al 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...

Page 9: ...njury 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 o...

Page 10: ...d chips etc and hazardous objects oil powder etc near the machine Wipe off spilt fuel and oil WARNING HOT COOLANT can cause severe scalds If the radiator cap is opened while the water temperature is h...

Page 11: ...chine Using square timbers as shown right 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 WARNING HOT...

Page 12: ...ted from the battery may be ignited and exploded by sparks For maintenance of the machine disconnect the ground cable on the ground side The battery acid is dilute sulfuric acid Improper handling will...

Page 13: ...ht by projections which may cause injuries 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 oper...

Page 14: ...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 da...

Page 15: ...utline and part names 1 oil drain plug 2 exhaust gas outlet 3 hanger rod 4 support hook 5 coolant in 6 output terminal 7 fuel in 8 fuel drain plug 9 control and operating panel 10 fuel level gauge 11...

Page 16: ...ter 4 reserve tank 5 AC generator 6 diesel engine 7 radiator inter cooler 8 oil level gauge 9 control box 10 fuel tank 11 battery 12 muffler 13 fuel pre filter 14 engine oil in 15 blowby drain 16 envi...

Page 17: ...ing fuel filter water level over speed fuel level failure fuel level indicator 3 AC voltmeter 4 output voltage indication lam p 5 frequency change over switch 6 speed regulator 7 voltage regulator 8 c...

Page 18: ...14 16 environmental base fluid level warning lamp...

Page 19: ...t indicates the numerical values of engine speed engine oil pressure run hours battery charging voltage or engine coolant temperature Indicated Items Unit engine speed min 1 engine oil pressure 100kPa...

Page 20: ...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 2 Fuel Level Indicator That Indicate...

Page 21: ...condition the abnormal value will be memorized and then indicated even after engine is started again In this case keep on pushing the button RESET for more than 5 seconds and the abnormal indication...

Page 22: ...s unused for a long period of time the battery will continue to lose its charge Once the charge is exhausted the hour meter will not indicate hours and the battery will need to be recharged From a com...

Page 23: ...pointing below the rated current When running the three phase and single phase loads together this meter indicates total current of them When running either the three phase or single phase load this m...

Page 24: ...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 a...

Page 25: ...oltage indication lamp Indicates the selected voltage output when the engine is running 5 Environmental base fluid level warning lamp The liquid measure collected in an environmental base is displayed...

Page 26: ...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 po...

Page 27: ...s switch to the side of SINGLE In case of parallel operation turn the switch to the side of PARALLEL In the parallel mode the synchronizing lamp and the cross current compensation circuit function to...

Page 28: ...f 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 1 p...

Page 29: ...o decrease it Adjust the voltage to the rated voltage with this regulator 2 Speed regulator This regulator is used to adjust the frequency Turn the regulator to clockwise to increase the speed and cou...

Page 30: ...o adjust the electronic controller for it has already been set in the factory 1 Isochronous Droop Change Over Switch This switch is used to select the control characteristic of the electronic governor...

Page 31: ...tarted again To cancel such condition and recover the normal indication press this push button for one second 5 Pre Lube Switch It enables non injection cranking by turning the switch ON Use this swit...

Page 32: ...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 damag...

Page 33: ...ngine running generates vibration during operation of the machine When installing the machine be sure to observe the following points Install the machine horizontally on a solid foundation Operation o...

Page 34: ...st 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 preven...

Page 35: ...tor Indicator Lamp to confirm the output voltage Note that the indicator lamp can only turn ON when the starter switch is in PREHEAT RUN position Switching the output voltage 1 Turn OFF all the circui...

Page 36: ...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...

Page 37: ...olts 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 connect...

Page 38: ...ike 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...

Page 39: ...r 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 connec...

Page 40: ...e grounding certainly to prevent the electric shock by leak 1 Case grounding of the machine Use the grounding wire which sectional area conforms to the local rule Provide the grounding rod to satisfy...

Page 41: ...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...

Page 42: ...g on the load size With Droop control applied the frequency is controlled to change according to the applied load The RATED LOAD frequency will be decreasing approximately 2 2 5Hz compared to the NO L...

Page 43: ...panel using the fixation bolts From pre start check to shut down 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 p...

Page 44: ...n fuel 5 Checking on battery acid 6 Checking on environmental base drain 7 Checking on grounding for electric shock protection 8 Checking for leakage of oil and water 9 Checking for loose parts 10 Rem...

Page 45: ...il the engine is cooled 50 or less as measured with the water temperature gauge Check to see that cooling water in the reserve tank is within the range of FULL LOW When it is below the low limit suppl...

Page 46: ...elt with your thumb The bend should be within the range of 10 15mm Parts number of fan belt Model name Parts number manufacture Parts number of manufactur e DCA 150LSK E Y06020 15229 KOMATSU 6732 82 3...

Page 47: ...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 electro...

Page 48: ...make check on the fitting of air cleaner muffler turbo charger etc disconnection of electric wiring short circuit and loose terminals 10 Removal of foreign objects in machine Check that tools and clea...

Page 49: ...IDLING Single parallel change over switch SINGLE starter switch PREHEAT RUN preheat lamp check preheat lamp goes off starter switch START engine startup starter switch PREHEAT RUN When it is cold warm...

Page 50: ...uency chang eover switch to the 50Hz or 60Hz position 4 Set the speed change over switch to the START IDLING position 5 Turn the single parallel change over switch to single side 6 Turn the starter sw...

Page 51: ...d value in the following table If the idling speed is not as specified or change of frequency is required adjust the idling speed using the speed regulator If the idling speed set above speed frequenc...

Page 52: ...ombustion White Abnormal combustion of oil due to failure of oil 2 Adjustment during operation Set the engine indicators and frequency meter to the rated by the speed regulator Set the voltmeter to th...

Page 53: ...4 Set the starter switch in STOP position The engine will stop immediately 5 Check the panel light goes off 6 Remove the key from the starter switch and keep it at hand stop 7 Check the amount of fue...

Page 54: ...When overcurrent flows the device acts earth leakage option When electric leakage the device acts Current sensitivity 30mA fuel level failure FUEL LEVEL stop When fuel supply is necessary because of f...

Page 55: ...51 When the single parallel change over switch is parallel side device acts...

Page 56: ...teristics etc For this reason it is requested for easy paralleling to select the same model of the generating sets Study this manual carefully before paralleling the units 6 1 Preparation for parallel...

Page 57: ...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...

Page 58: ...w an imbalance in loading make it in equal loading by adjusting the speed regulator for engine rpm The set is to undertake more load sharing when the engine rpm is adjusted higher while less sharing w...

Page 59: ...rrent 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...

Page 60: ...r TBN must be at least 8mgkOH g Do not use the unrecommended combination of fuel and oil stated in the following table Refer to the engine instruction manual for further information The oil replacemen...

Page 61: ...all season type Use oil according to ambient temperature referring to the table below Ambient temperature 30 20 10 0 10 20 30 Note Do not mix with different kind of oil or else it deteriorates the oi...

Page 62: ...he following percentages are recommended for each ambient temperature 30 10 40 20 50 30 In case of replenishment use LLC of the same brand and the same density Normally LLC should be replaced every 2...

Page 63: ...le 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 handl...

Page 64: ...ound 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 preven...

Page 65: ...ble B connected to the engine block of the machine in trouble Remove the clip of the booster cable B connected to the terminal of normal machine Remove the clip of the booster cable A connected to the...

Page 66: ...ch 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 WARNING ELECTRIC SHOCK can...

Page 67: ...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 WARNING BATTERY Battery generate...

Page 68: ...and protectors Do not put on baggy clothes necklace etc because they are easily caught by projections which may cause injuries CAUTION Handling of waste liquid Waste liquid from the machine should be...

Page 69: ...ctor switch once a month 500 hours Checking every 500 hours Replacement of engine oil for CH 4 CI 4 JASO DH 1 engine oil Replacement of engine oil filter cartridge for CH 4 CI 4 JASO DH 1 engine oil R...

Page 70: ...ge 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...

Page 71: ...he engine for a while Then check to see that oil is supplied to the level between H and L Parts number of oil filter cartridge Model name Parts number manufacture Parts number of manufact ure DCA 150L...

Page 72: ...DH 1 engine oil is used replace the engine oil filter cartridge every 500 hours 3 Cleaning of air cleaner element This element should be cleaned regardless of operating time when the warning lamp of A...

Page 73: ...the AVR located in the control box before measuring Measurement Disconnect the load side cable from the output terminal as shown at below Turn ON the circuit breaker and measure the insulation resista...

Page 74: ...exhaust pipe line and muffler could cause not only system derates but also could lead to fires To destroy soot and unburned fuel run the unit at rated power until the exhaust gas become mostly colorle...

Page 75: ...CH 4 CI 4 JASO DH 1 engine oil Replacement is refer to 9 4 1 Replacement of engine oil If CF 4 engine oil is used replace the engine oil every 250 hours 2 Replacement of engine oil filter cartridge f...

Page 76: ...eleasing method refer to the instruction manual for the engine or check the name plate installed on the machine Get the engine started to check if there is a fuel leakage Note Do not fail to wipe off...

Page 77: ...73 Check for main and sub circuit whether there are no abnormality such as loosening corrosion and burning etc...

Page 78: ...g 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 Model name Parts nu...

Page 79: ...removes the rust when rust has been found in an environmental base Assembly procedure Set to store this machine from an environmental base internally and install the bolt for uniting 3 Cleaning inside...

Page 80: ...n the rubber suspension whether it is damaged or deformed by the oil Contact distributor or our office to replace the rubber suspension if necessary 6 Checking on lining Check on the lining whether it...

Page 81: ...n exhaust color sound and vibration Checking on meters and warning lamps Checking on nylon and rubber hose Replacement of engine oil 1 2 Replacement of engine oil filter cartridge 1 2 Cleaning of air...

Page 82: ...case grounding Checking on insulation resistance Checking on terminal and connected section 1 If CF 4 engine oil is used 2 If CH 4 CI 4 JASO DH 1 engine oil is used 3 Contact distributor or our office...

Page 83: ...d in the machine Care should be taken during operation When the machine needs checking or maintenance be sure to stop it in advance WARNING ELECTRIC SHOCK can kill High voltage units are located in th...

Page 84: ...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 WARNING BATTERY Battery generate...

Page 85: ...engine Blinded air cleaner Replace element Engine stop by oil failure Oil shortage Supply Oil pressure switch failure Replace Blinded oil filter Replace cartridge Over heat water temperature Cooling...

Page 86: ...h Voltmeter failure Replace AVR failure Contact distributor or our office VR failure Applied load causes load voltage drop Burned rotary rectifier Contact distributor or our office AVR failure Burned...

Page 87: ...will appear on the display instead of 00 before the defect contents and defect code appear display example Power ON 88 Engine Master Controller System CA442 CA111 CA689 CA144 CA689 CA144 saved defect...

Page 88: ...heat CA146 Engine stop Oil Press Low CA143 Engine stop Charge Air Temp High Trq Derate CA448 Engine stop Charge Air Temp High Speed Derate CA155 Coolant Temp Sensor High CA144 Bad cold start Performan...

Page 89: ...gine efficiency Sensor Sup 1 Volt High CA386 Sensor Sup 2 Volt Low CA187 Sensor Sup 2 Volt High CA227 Ne NE Speed Sensor Sup Volt Error CA238 Defect of speed regulation Throttle Sensor Sup Volt High C...

Page 90: ...ptime Adj Vol Low bF Vol Speed Adj Vol High Isochronous A8 Unstable engine speed ISO Vol Speed Adj Vol Low Isochronous A9 Vol Droop Rate Adj Vol High b6 Unstable droop rate Vol Droop Rate Adj Vol Low...

Page 91: ...gine refer to the instruction manual for the engine provided separately WARNING Stacking Improper stacking of machines may cause falling or dropping accidents When stacking other machines on this mach...

Page 92: ...TROKE 107 124 mm TOTAL DISPLACEMENT 6 69 L RATED OUTPUT 113 kW 1500 min 135 kW 1800 min BATTERY DOMESTIC STANDARD 95E41R 2 FUEL DIESEL FUEL ASTM No 2 or equivalent FUEL TANK CAP 250 L ENGINE OIL 1 OVE...

Page 93: ...89 12 2 Outline drawing...

Page 94: ...90 12 3 Generator connection diagram...

Page 95: ...91 12 4 Engine wiring diagram...

Page 96: ...92 12 5 Controller wiring diagram...

Page 97: ...eath 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 ground...

Page 98: ...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 5mm2 or larger Usually it is possi...

Page 99: ...at the startup of the machine according to the procedure described below Start up the machine according to 5 2 Startup Make sure that all breakers of the load side are OFF Set the breaker of three pha...

Page 100: ...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 1...

Page 101: ...97...

Page 102: ...0V the single phase output voltage stands at 100 110V Note receptacle can be used up to 1 5 1 65kVA When using the single phase and 3 phase output simultaneously the output of the 3 phase side will de...

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