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9. Troubleshooting

/К

WARNING

MOVING PARTS can cause severe injury.

■ Rotary unit which 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.

The motor fan for cooling radiator will keep on

running for a while even after engine stops.

--------

Before beginning a repair/maintenance work,

moake sure that th e motor fan has stopped

completely.

W ARNING

ELECTRIC SHOCK can kill.

■ High voltage units are located in the machine.

Care should be taken

When the machine ne

be sure to stop it in ac

Содержание DCA-25USI

Страница 1: ...8 03 48 8172 26 41 59 473 204 51 73 343 384 55 89 4932 77 34 06 3412 26 03 58 395 279 98 46 996 312 96 26 47 843 206 01 48 4012 72 03 81 4842 92 23 67 3842 65 04 62 8332 68 02 04 861 203 40 90 391 204...

Страница 2: ...oduct 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...

Страница 3: ...stributor or our office specifying the nameplate No shown below and ask for new ones No Parts name Parts number No Parts name Parts number 1 Safety instruction B9221 0100 5 Warning hot surfaces B9052...

Страница 4: ...r 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...

Страница 5: ...osed 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 not touch t...

Страница 6: ...ngerous if you touch it Be sure to close the door and lock it during operation When the door needs to be opened during operation do not get your hands and head in the machine to prevent them from bein...

Страница 7: ...chips etc and hazardous objects oil powder etc near the machine Wipe off spilt fuel and oil A WARNING HOT COOLANT can cause severe scalds If the radiator cap is opened while the water temperature is h...

Страница 8: ...s shown right put each machine making sure that the weight is even 1 C l 1 0 9 1 ___1 D 1 I i 7777777777777777 77 7777777 Do not operate the machines in the state of stacking to prevent falling or dro...

Страница 9: ...Otherwise the flammable gases generated from the battery may be ignited and exploded by sparks For maintenance of the machine disconnect the ground cable on the ground side HI The battery acid is dilu...

Страница 10: ...by projections which may cause injuries A 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 opera...

Страница 11: ...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 damage to the...

Страница 12: ...nstruction 2 1 Outline and part names 1 control panel 2 output terminal 3 fuel in A fuel drain plug 5 oil drain plug 6 hanger rod 7 support hook 8 coolant in 9 exhaust gas outlet 10 coolant drain pulg...

Страница 13: ...11 diesel engine 12 AC generator 13 battery 14 radiator 15 electric fan 16 reserve tank D C A 4 5 U S IJ 17 engine oil in 18 dipstick 19 fuel filter 20 control box 21 air cleaner 22 oil filter 12...

Страница 14: ...r 4 voltage regulator 5 circuit breaker 3 phase 6 circuit breaker 1 phase 7 pilot lamp 8 panel light 9 panel light switch 10 engine indicator 11 starter switch 12 preheat lamp 13 emergency stop button...

Страница 15: ...rging voltage or engine coolant temperature Each indication is selectable by pushing the SELECT button Unit Indicated Items min 1 engine speed X engine oil pressure hour run hours V battery charging v...

Страница 16: ...engine running 5 Engine Coolant Temperature That should indicate a temperature between 75 to 90 tC at engine running Note If that would indicate higher temperature disconnect all loads decrease the sp...

Страница 17: ...attery charging voltage or engine coolant temperature the indication will change as the followings 1 The indication changes to AUTO and the abnormal value and unit will be indicated lighting on and of...

Страница 18: ...s together this meter indicates total current of them When running either the three phase or single phase load this meter indicates the current flowing into the load The current of each phase can be c...

Страница 19: ...t preheating is completed 2 Warning Lamps This monitor indicates the following failures if any one of them occurs High jacket water temperature WATER TEMP WATER TEMP lamP Soes on when the water temper...

Страница 20: ...ER This lamp turns on when the water level in the fuel filter would rise WATER LEVEL Drain the water in the strainer soon after the lamp would turn on Only for 25USI USI2 45USLUSI2 Method of Draining...

Страница 21: ...n 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 position of RUN Preheat This is the position to start the engine...

Страница 22: ...e generator against trouble Note Do not use this circuit breaker to turn ON OFF the load to prevent damage to the circuit breaker When it trips with overcurrent the handle of the breaker stops between...

Страница 23: ...he 45USI USI2 air vent can also be performed with the priming pump located at the top of the fdter If air cannot be vented completely with this button press the priming pump several times The 25USI US...

Страница 24: ...the regulator to clockwise to increase the voltage and counter clockwise to decrease it Adjust the voltage to the rated voltage with this regulator 2 Overcurrent relay This relay is used to trip the...

Страница 25: ...may cause 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...

Страница 26: ...ine 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 on...

Страница 27: ...ir 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 prevent cl...

Страница 28: ...f 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...

Страница 29: ...re 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 connecting make...

Страница 30: ...tput 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 190V 380V 415V 240V 480V Use O U O V 0 W for sing...

Страница 31: ...turning the load ON and OFF may result in breaker failure D In connecting the load be sure to stop the engine and turn OFF the breakers on the control panel and the out put terminal block Don t conta...

Страница 32: ...unding 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 the g...

Страница 33: ...ad 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 sec...

Страница 34: ...prevention of noise Note If the warning lamp lights stop the engine and check the cause of it Note Check for leaks of oil water exhaust gases and for unusual noise 5 Shut down 5 1 Checking prior to o...

Страница 35: ...er 8 Checking for loose parts 9 Removal of foreign objects in machine Inspection 1 Checking on engine oil Read the instruction manual for the engine D Checking the level of engine oil by the dipstick...

Страница 36: ...cooling water in the reserve tank is within the range of FULL LOW 2 When it is below the low limit supply additional water immediately 3 Normally only the water level of the reserve tank needs to be c...

Страница 37: ...h your thumb The bend should be within the range of 10 15mm Parts number of fan b elt Model name Parts number manufacture Parts number of manufacture DCA 25USI USI2 06020 11430 ISUZU 897224 9990 DCA 4...

Страница 38: ...ets on your clothes or skin wash it out with a large volume of water immediately If it gets in your eyes wash with a large volume of water immediately and consult your doctor In the worst case it will...

Страница 39: ...eck for loose parts Check for loose bolts and nuts Loose parts should be tightened firmly Particularly make check on the fitting of air cleaner muffler turbo charger etc disconnection of electric wiri...

Страница 40: ...preheat lamp red heated V starter switch START starter switch RUN engine startup When it is cold V 1 warm up operation about 5 minutes warm up operation sufficiently throttle lever RUN adjustment of s...

Страница 41: ...START IDLING position 4 Set the starter switch in Preheat position This switch must be ON until the preheat lamp becomes red heated Turn the starter switch to START position until engine starts Note I...

Страница 42: ...ne adjust the revolution frequency to the values listed below by adjusting the throttle handle and monitoring the revolution counter Commercial frequency Idling speed 50Hz drive 52 5Hz 1575mm1 6GHz dr...

Страница 43: ...normal normal warning lamp is all off Make sure that the color of exhaust gases from the engine is normal Check for unusual noise and vibration Color of exhaust gases Colorless or light blue Normal B...

Страница 44: ...engine speed drops once the generator voltage is built up Note The water temperature would rise abnomally when engine idles for a long time just after starting or re starting If a long time idling is...

Страница 45: ...ly 5 Remove the key from the starter switch and keep it at hand 6 Check the pannel light goes out 7 The 25USI unit has a fuel cock at the bottom of the fuel tank After engine is shut down turn the coc...

Страница 46: ...58 8kPa high jacket water temperature WATER TEMP 38 set point S T t stop set point 25USI USI2 0 45USLUSI2 105 C 60USH 102 Battery charging failure stop set point 26 OV only for GOUSH overcurrent of g...

Страница 47: ...y is SAE 10W 30 all season type Use oil according to ambient temperature referring to the table below Ambient temperature 3 0 2 0 1 0 0 10 20 30 S A E 2 0 S A E 3 0 S A E 5 W 2 0 S A E 1 0 W 3 0 S A E...

Страница 48: ...or each ambient temperature 30 1 0 1 40 2 0 1 50 3 0 C In case of replenishment use LLC of the same brand and the same density Normally LLC should be replaced every 2 year 2 Total quantity of cooling...

Страница 49: ...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 handling will cause une...

Страница 50: ...le last Whilethe 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 prevent electri...

Страница 51: ...clip of the booster cable B connected to the engine block of the machine in trouble Remove the clip of the booster cable B connected to the t e r m i n a l of normal machine Remove the C lip O f the...

Страница 52: ...ion When the machine needs checking or maintenance be sure to stop it in advance The motor fan for cooling radiator will keep on running for a while even after engine stops Before beginning a repair m...

Страница 53: ...tion or maintenance be sure to stop it in advance i Even after the machine stops the inside of the bonnet is still hot Wait until the engine is cooled sufficiently A CAUTION BATTERY Battery generates...

Страница 54: ...protectors Do not put on baggy clothes necklace etc because they are easily caught by projections which may cause injuries A CAUTION Handling of waste liquid Waste liquid from the machine should be r...

Страница 55: ...of engine oil filter element Cleaning of radiator Inspection of injection nozzle Checking for terminal and connection of the circuit Checking every 250 hours is also required 1000 hours Checking ever...

Страница 56: ...al of 500 hours Remove the engine oil drain plug and discharge oil completely It can be discharged easily when the engine is warm After engine oil is discharged tighten the plug firmly Charge new engi...

Страница 57: ...in Then mount the cartridge When mounting tighten the cartridge from 3 4 to 1 turn by using filter wrench after the packing is fitted to the seal of the filter base 3 After the element is replaced run...

Страница 58: ...ld be cleaned regardless of operating time when the warning lamp of Air filter blinding goes on Dry dust clings on element Remove the air cleaner element and clean the element with dry and clean compr...

Страница 59: ...cable from the output terminal as shown at below Turn ON the circuit breaker and measure the insulation resistance between the output terminal bolt and the bonnet If the measured resistance is less t...

Страница 60: ...d The relation between battery charge condition charging rate and specific gravity is as shown below Liquid C h a rg m g temp rate 2 0 0 1 0 1 0 0 1 28 1 29 1 30 9 0 1 26 1 27 1 28 8 0 1 24 1 25 1 26...

Страница 61: ...king is fitted to the seal of the filter base cartridge put the filter wrench DCA 60USH After the cartridge is replaced discharge air in the fuel piping For details refer to the instruction manual for...

Страница 62: ...or tube is blinded it should be cleaned with steam or high pressure water o v e r 1 5m Note When a high pressure washer is used spray water from a place about 1 5m away to prevent damage to the fin or...

Страница 63: ...NALDSON 82 9 DCA 45USI2 06020 46366 DONALDSON P82 7653 DCA 60USH 06020 46365 DONALDSON P82 8889 3 Checking on rubber suspension Check on the rubber suspension whether it is damaged or deformed by the...

Страница 64: ...ir cleaner element 0 Checking on specific gravity of battery Cleaning radiator 0 Replacement of fuel filter Cleaning fuel tank Replacement of air cleaner element 1 Inspection of engine valve clearance...

Страница 65: ...ds checking or maintenance be sure to stop it in advance The motor fan for cooling radiator will keep on running for a while even after engine stops Before beginning a repair maintenance work moake su...

Страница 66: ...ion or maintenance be sure to stop it in advance 1Even after the machine stops the inside of the bonnet is still hot Wait until the engine is cooled sufficiently A CAUTION BATTERY B attery generates f...

Страница 67: ...ngine Blinded air cleaner Replace element Oil shortage Supply Engine stop by oil failure Oil pressure switch failure Replace Blinded oil filter Replace element Cooling water shortage Supply Over heat...

Страница 68: ...ltmeter 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 main...

Страница 69: ...fer to the instruction manual for the engine provided separately A CAUTION Stacking Im proper stacking of machines may cause falling or dropping accidents W hen stacking other machines on this machine...

Страница 70: ...85x96 mm 95 4X 107 mm TOTAL DISPLACEMENT 2 179 L 2 179 L 3 059 L 0 1 N E RATED OUTPUT 19 lkW 1500min 19 lkW 1500min 34 2kW 1500min 23 5kW 1800mm 23 5kW 1800min 41 2kW 1800min BATTERY DOMESTIC STANDAR...

Страница 71: ...PLACEMENT 3 059 L 4 009 L G 1 RATED OUTPUT 34 2kW 500min 41 2kW 866min 1 48 5kW 1500mm 57 4kW j 800mm N BATTERY DOMESTIC STANDARD 95D31R 80D26R X2 11 FUEL DIESEL FUEL ASTM No 2 or equivalent FUEL TANK...

Страница 72: ...0 I DCA 45USI USI2 5GHz 60Hz Rated output kVA 37 37 37 33 3 40 5 45 45 45 kW 29 6 29 6 29 6 26 6 32 4 36 36 36 Rated voltage V 190 380 400 415 220 440 190 380 200 400 440 240 480 Rated current A 112 5...

Страница 73: ...I P H A S E O UT PU T T E R M I N A L C E N T E R OF G R A V I T Y 11 3 Outline drawing DCA 25USI...

Страница 74: ...H E A T E D A I R O U T l p h a s e O U T P U T R E C E P P T A C L E H E A T E D A I R O U T E X H A U S T G A S O U T C E N T E R O F G R A V I T Y DCA 25USI2...

Страница 75: ...1 P H A S E OUTPUT R E CE P T A CL E...

Страница 76: ...H E A T E D A I R O U T H E A T E D A I R O U T E X H A U S T G A S O U T C E N T E R OF G RA VI T Y DCA 45USI2...

Страница 77: ...1 PHASE OUTPUT TERMINAL CENTER OF GRAVITY DCA 60USH...

Страница 78: ...11 4 Generator connection diagram DCA 25USI 11 CONNECTOR...

Страница 79: ...ATURE WINDING I i p l EXCITER FIE LD WINDING CB1 C IR C U IT BBBASER E A C IR C U IT BREAKER p l i P ILO T U K P CTI CURRENT TRANSFORMER 100 5A oc OVER CURRENT RELAY AC VOLTMETER fl JIO AC ALQ6ETER 0...

Страница 80: ...AC O 150A u AC VOLTMETER O 300V F FR E G tfE U n D E T E R iWSHi cei C IR CU IT BREAKER U S A C62 C IR C U IT BREAKER 1 FUA tl 0A F L 1 P ILO T LAMP CONt 7 POWER RECEPTACLE 15 OVER CURRENT RELAY P L...

Страница 81: ...PANEL LIGHT DCA 45USI2 ini 80...

Страница 82: ...ATURE W IN DING e j t c E X C ITE R F IE L D W IN DING Rt R ECTIFIER AVR AUTOMATIC VOLTAGE REGULATOR V VOLTAGE RBGVLATIHG RHEOSTAT C T L 3 CURRENT TR A N S F O R M 200 SA h AC AUBCTER 0 7 0 Q A a AC V...

Страница 83: ...11 5 Engine wiring diagram DCA 25USI USI2 82...

Страница 84: ...O L O R C O D E J 8 1 1 r u t OOI OI v n t c o i o t 5 B L A C K R R E D 7 7 L B I B B w W H F TB B R e a o w w Y Y B L L O W G 0 L B LIGHT G R L G u c r r c a m V V I O L B T 0 O R A N C B O T H E R...

Страница 85: ...Z E so j 60a7 ft s 1 2 1 25a7 O F F 3 PREHEAT RUNNING A START STARTER S W I T C H CCMNECT1CH R i l A C C Rj BR O F F 1 KWHNJMG O K n 2 S T A R T O p K H 3 PREHEAT O o O CONNECTOR v i e w f r o m l e...

Страница 86: ...device for leakage protection does not operate effectively Grounding terminal for the earth leakage relay case grounding terminal and case of the load are grounded 1 Applicable models DCA US SERIES 2...

Страница 87: ...below Grounding of the grounding terminal for 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 sectiona...

Страница 88: ...to the procedure described below Start up the machine according to 5 2 Startup J Make sure that all breakers of the load side are OFF1 Set the breaker of three phase and single phase to ON Press the T...

Страница 89: ...on The machine is designed with double voltage specification which allows the output voltage of 200 V class or 400 V class to be selected with the voltage change over cables 2 Method for selecting out...

Страница 90: ...7172 727 132 8512 99 46 04 3852 73 04 60 4722 40 23 64 4832 59 03 52 423 249 28 31 844 278 03 48 8172 26 41 59 473 204 51 73 343 384 55 89 4932 77 34 06 3412 26 03 58 395 279 98 46 996 312 96 26 47 84...

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