SERVICE MANUAL /EPA3. File DGO-293_DGK150D/EPA3

Transcription

1 SERVICE MANUAL /EPA3 File DGO-293_DGK150D/EPA3

2 WARNING This equipment is designed and built with safety in mind. However, your overall safety can be increased by fully understanding and following the content in this manual. Read this manual and familiarize yourself with its contents for your safety. This equipment should only be operated and maintained by trained and qualified personnel. This equipment is designed for generating a power source for electric tools, home appliances and lights. Do not install, operate or service this equipment without reading this manual and clearly understanding this information. This service manual is edited for authorized personnel to perform repair, maintenance, and trouble-shooting of Shindaiwa Diesel Engine Generator, Model DGK150D/EPA3. Shindaiwa products require necessary maintenance and adjustment to ensure product longevity, safety and desired performance. Fully understand this service manual before operating or performing service. The information contained in this service manual describes equipment available at the time of publication. While every attempt has been made to provide you the very latest information about your product, there may be some differences between your equipment and the equipment described in this manual. We reserve the right to make changes to equipment without prior notice, and without obligation to make alterations to equipment previously manufactured. For servicing the engine, refer to the Workshop Manual provided by the engine manufacturer described below. MANUFACTURER ISUZU MODEL 6HK1 The ISUZU engine 6HK1 is electronically controlled. Read and familiarize the instruction manual and service manual for the engine before servicing.

3 Table of Contents 1. Attention Statements 1 2. General Safety Instructions 2 3. Specifications 4 4. General Appearance Dimension 5 5. General Parts Description Equipment Main Parts and Feature Main Component Component Drain Plug and External Fuel Inlet Service Data Service Data Generator Trouble Shooting Procedure Engine and Generator AVR Test Procedure Check the Output Voltage 480/277V Check the Output Voltage 240/139V Check the Output Voltage 240/120V Check the Main Circuit Breaker Check the Generator Winding Check the Exciter Stator Checking the Adjusting Voltage Regulator Check the Voltmeter Check the Voltmeter Selector Dial Check the Current Transformer (CT) Check the Ammeter Reset the Thermal Relay Test the Thermal Relay Test the Voltage Selector Switch Abnormal Frequency or Voltage Drop Engine Won t Start Engine Stops Suddenly Monitor Lamp Blinking No Output Voltage Maintenance Layout of the Unit Engine Oil Replacement Oil Filter Replacement Clean/Replace the Air Filter Element Replace the Electric Fuel Pump Filter Drain the Water from the Internal Fuel Tank Replace the LLC Anti-freeze (Long Life Coolant) Clean/Replace the Fuel Filter Fuel System Air Blow 68

4 9. Tightening Torque Specific Torque General Torque Wiring Diagram 71

5 1. Attention Statements Only technicians with enough knowledge and experience should perform maintenance and operational checks after maintenance. Before maintenance, always read this service manual as well as the owner s manual and be familiar with the contents thoroughly before starting the service and maintenance of the equipment. Completely understanding the equipment, safety and caution notifications. Throughout this manual are special attention statements. WARNING A statement preceded by the triangular attention symbol and the word WARNING contains information that should be acted upon to prevent serious bodily injury. CAUTION A statement preceded by the triangular attention symbol and the word CAUTION contains information that should be acted upon to prevent mechanical damage. 1

6 2. General Safety Instructions ELECTRIC SHOCK NEVER touch the output terminals during operation NEVER touch the output terminal during operation even though the breaker on the load is being set at OFF position. ALWAYS stop engine and make sure it has fully stopped before you connect the loads to the output terminals. WARNING By Entangled Injuries under Moving Component NEVER reach or touch moving component during operation! ALWAYS stop the engine during inspection to prevent serious bodily injury by entangled accident under moving component. Electric shock/injuries/burns Suffocation by exhaust gas NEVER run the engine indoors! Make sure there is always good ventilation. Fumes from engine exhaust cause serious injury. ALWAYS operate the equipment in a well ventilated area. When the equipment is used in a tunnel, hall or any other indoor area, ventilation equipment must be used to prevent serious injury caused by suffocation. NEVER direct the exhaust fumes to houses nearby. Consider the wind flow direction. Exhaust gas contains many harmful elements that can cause effect to humans. Prevent suffocation when the equipment is used in poorly ventilated area such as inside of the building. 2 NEVER inspect equipment during use. NEVER service or inspect equipment while it is being operated. It may cause electric shock, injuries or burns. WARNING-Use good judgment 1 NEVER run the engine when transporting the equipment. 2 ALWAYS stop the equipment immediately if it suddenly begins to vibrate or an abnormal noise is heard. Inspect for broken, missing or improperly installed parts. 3 ALWAYS keep the equipment as clean as practical. Keep it free of loose vegetation, mud, etc. DO NOT makes unauthorized modifications or alterations to this equipment or any of its components. YAMABIKO must authorize alterations and modifications in writing. Unauthorized modifications or alterations may alter the equipment operation and could jeopardize personal safety during operation.

7 CAUTION Work Safely Generators and welders operate at very high speeds and can do serious damage or injury if they are misused or abused. Never allow a person without training or instruction to operate or service this equipment! Attention to CAUTION LABEL! Caution labels are placed on this equipment and require special attention for operation. Make sure to locate the labels and understand the content of the caution. Check that caution labels are legible. Always keep the labels clean or replace them when worn or damaged Clean the labels by cloth, water or detergent and never use organic solvent or gasoline which may cause label to peel off. Make sure to replace the labels when damaged or illegible. Before replacing the label(s), make sure to place the new label(s) in the same position. STOP the equipment immediately when abnormal circumstances are noticed! S STOP the equipment immediately whenever abnormal circumstances are noticed such as unusual noise, smell vibration and etc. It may lead to a serious accident or fatal damage of the equipment or properties. Inflammables! Keep the equipment far away from fire such as cigarettes when filling fuel, oil or battery fluid. NEVER operate or service the equipment nearby fire as the equipment may catch fire. No Modification! NEVER modify the equipment without manufacturer s advanced approval.. It may lead to serious safety issues and damage the equipment. Inspect the equipment before engine start for operation and periodical inspection without fail! Make sure inspect before starting engine and periodically inspect for safety and longer life of the equipment. 3

8 3. Specifications Alternator Engine Unit Model Unit DGK150D/EPA3 Generating Type - Rotating Filed, Brushless 3-Phase Synchronous Alternator Rated Output kva 150 kw 120 Voltage Three Phase V 208/480 Voltage Single Phase V 120/240/277 Three Phase 480V A 180 Amps Three Phase 208V A 416 Single Phase 240V A 361 (zigzag) Single Phase 120V A 361 x 2 (zigzag) Rated Frequency Hz 60 Winding - 3-Phase, 4-Wire Star with neutral/zig-zag Power Factor % 80 Insulation Class - F Excitation - Self-Excitation (Brushless) No. of Pole - 4 Type - Vertical Water-Cooled 4-cycle Diesel Engine Model (Manufacturer) - 6HK1 (ISUZU) No. of Cylinder (Bore x Stroke) (in. /mm) 6 (4.53x4.92/115x125) Rated Output (Continuous) kw 142 HP 190 Rated Speed rpm 1800 Displacement cu.in. /liter 475.4/7.790 Combustion System - Direct Fuel Injection with Turbo Charger Cooling - Radiator Lubricating - Forced Lubrication Starting - Electric Start Fuel - Diesel Lubricant Oil - CD Class Fuel Tank Capacity gal. /liter 74/280 Lubricant Capacity gal. /liter 10/38 Cooling Water Capacity gal. /liter 6.3/23.8 Starting Motor Capacity V-kW Charging Dynamo Capacity V-A Battery - 105E41R x 2 Battery Capacity V-AH 12(V)-100AH Length in. /mm 135.8/3450 Width in. /mm 48.8/1240 Height in. /mm 72.8/1850 Dry Weight lbs. /kg 6504/2950 Installed Weight lbs. /kg 7187/3260 *Specifications subject to change without notice. 4

9 4. General 4.1 Appearance 4.2 Dimension Unit in the drawings below is shows by mm. 5

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11 5. General Parts Description 5.1 Equipment 7

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14 5.2 Main Parts and Feature (1) Unit Serial Number (2) Engine Serial Number Provide both serial number of unit and engine to your local service shop for update parts and warranty information. 5.3 Main Component Ampere Meter Selector Dial Feature: Dial to select the output current. Volt Meter Selector Dial Feature: Dial to change voltage. Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Circuit Breaker Feature: Protect electrical circuit from damage by overload or short circuit. Water Temp. Meter Feature: Display water temp. in the radiator. Oil Pressure Meter Feature: Display oil pressure. Fuel Meter Feature: Display volume of the fuel left in the fuel tank. Voltage Adjusting Dial Feature: A dial to adjust a voltage. Emergency Stop Button Feature: Engine stops when emergency by pressing it. Turn it to clockwise to release the button. 10

15 Control Panel (Internal View) 11

16 Engine Operation Switch Table (refer to No. 3 on page 11) Nomenclature Function Remarks LOAD ADVANCE REGULATION MODE THROTTLE SPEED SPEED INC. SPEED DEC. SPEED MANUAL MEMORY CLEAR Decrease rpm in accordance with the load to be put when the switch turns to ON. Change idle mode. Change engine rpm. to 1500 or 1800 min -1. Increase rpm. per 10 sec/hz. Decrease rpm. per 10 sec/hz. A switch for Speed Inc. and Speed Dec. Clear record of the engine fault. This function is not available in this equipment. Start: low idle mode Run: high idle mode Increase up to 110% of rated rpm. Speed Manual switch ON. Decrease down to 1000rpm. Speed Manual switch ON. Always Speed Manual switch ON to operate Speed Increase/decrease switch. 1. Starter Switch ON. 2. Push Memory Clear switch for 3 sec. 3. Memory Clear switch ON. 4. Turn Starter Switch STOP and, after10 sec., turn the switch RUN. Refer to How to clear Trouble Code in Engine Troubleshooting Manual prepared by Isuzu for details. 12

17 Right Side Door Fuel Drain Plug Feature: Drain the old fuel from the fuel tank. Oil Drain Plug Feature: Drain the old oil from the oil tank. Left Side Door Terminal Rest Feature: Relay terminal block of the power output from the alternator. External Fuel Inlet Feature: Inlet to refuel from the external tank. External Fuel Return Feature: Outlet to return fuel from external tank. 13

18 3-Way Valve Feature: Valve to change fuel supply from a built-in or external tank. NOTE: Do not remove the plugs when fuel is supplied from a built-in tank. (when the 3-way valve positions at position A.) Position A 3-Way Valve Position A (to use a built-in fuel tank) Position the 3-way valve lever to UPWARD to use fuel from the external fuel tank. Position B 3-Way Valve Lever Position B (to use an external fuel tank) Position the 3-way valve lever to DOWNWARD to use fuel from a built-in fuel tank. NOTE: The 3-way valve lever is set at position A at delivery from a factory. 14

19 5.4 Component Clog Indicator Feature: Display clog in the air filter element. When Red appears in the indicator window, clean element or replace it regardless operating hour. Then, press the reset button so red in the indicator window should disappear. CAUTION NEVER run engine without air filter to prevent mechanical damage of the engine. 15

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26 5.5 Drain Plug and External Fuel Inlet Standard Accessory 1 Owner s Manual 2 Engine Instruction Manual 3 Starter Key 1 copy 1 copy 1 set 22

27 WARNING DANGER OF ELECTRIC SHOCK NEVER TOUCH THE OUTPUT TERMINALS DURING OPERATION! NEVER touch the output terminals during operation even if the breaker on the load is being set at OFF position. ALWAYS stop engine and make sure it has fully stopped before you connect the loads to the output terminals. DANGER OF EXHAUST GAS POISONING NEVER OPERATE THE GENERATOR UNIT IN INDOOR AREA! ALWAYS operate the equipment in a well ventilated area. Exhaust gas contains many harmful elements that can cause effects to humans. Prevent suffocation when the equipment is used in poorly ventilated area such as inside of the building. DDANGER OF INJURY CAUSED BY MOVING PARTS NEVER TOUCH MOVING PARTS DURING ENGINE OPERATING! NEVER reach or touch moving components during operation such as belt, pulley and fan during the engine operating. Moving component can catch your hands, other parts of your body or strike your body with greater force and it can cause serious injury. ALWAYS stop the engine during inspection to prevent serious injury by moving component. ALWAYS stop engine and make sure it has fully stopped before service. DANGER OF ELECTRIC SHOCK, INJURIES AND BURNS PRECAUTION FOR MAINTENANCE, INSPECTION AND REPAIR! Before inspection, maintenance or repair works starts, remove the starter key from the equipment and display the sign DO NOT OPERATE EQUIPMENT NOW or equivalent caution notification on the starter switch. Engine operation during inspection, maintenance or repair can cause a serious injury. Stop engine before you start service, maintenance or repair! 23

28 6. Service Data 6.1 Service Data Insulation Preheat time Items Reference Value Note Armature winding Exciter field 3MΩ or more Approx. 20 sec. with coolant temperature -15 (5 F) and approx. 1 sec. with coolant temperature 30 (86 F) Min. rpm at no load 1000±25 min -1 Max. rpm at no load 60Hz: 1800±25 min -1 Lubricant oil pressure 0.2~0.6MPa{2.0~6.1kgf/cm²} DC500V Megger Tester Automatic preheating system Coolant temperature 75~90 (167~194 F) Frame temperature limit within 115 (239 F) Sealed bearing temperature limit within 70 (158 F) Speed regulation Momentary within 10% Steady-state deviation within 5% Momentary within 20% Voltage regulation Steady-state deviation within 1.0% Frequency Idle: 33.3 Hz, Rated: 60 Hz Variable voltage (60Hz) 400~505V at 60±0.1Hz Protective device 1 Low oil pressure Working Pressure 0.1MPa{1.02kgf/cm²} Engine Stop 2 High water temp. Working Temperature 105 (221 F) Engine Stop 3 Diagnosis Engine Malfunction - - Insufficient Battery 4 Charge - Battery voltage: below 8V - 5 Over Speed - above 2070 min -1 Engine Stop 6 Boost Intake Temperature 85 (185 F) - 24

29 6.2 Generator Bolt Exciter armature Main bearing Rotor Bolt Exciter field Thermo label Bearing cover Thermo label Rear bracket Bolt Exciter stator Bolt Armature Main stator Fan cover Stator Rotor 25

30 (1) Exciting Amperage Amperage fluctuates based upon the winding temperature. Following is for reference only. (Refer to page 39 in this service manual) Frequency/Rated Output Load Exciting Amperage (Measured) 3-Phase 60Hz: 120 kw No load 0.57A Full load( power factor=1.0) 1.04A (2) Resistance Value Nominal resistance of the winding is tolerated within ± 10% at 32 F( 220 ) of the ambient temperature. The resistance must be measured by low resistance tester. It can not be measured by multi-purpose tester cause of index error. (Refer to page 38) Generator Exciter (Measured) Stator Rotor Stator Rotor Armature Exciter Winding J-K Armature Between T1-T4, T7-T10 T2-T5, T8-T11 T3-T6, T9-T Ω 1.574Ω 14.96Ω 0.185Ω (3) Technical Specifications Items Article Method Condition to verify Criteria Check before operation Shape, Dent, Blot Coating Joint Oil, Coolant Wiring Visual Inspection No cracks, stiffness and deformation No looseness Check for cracked or damaged wires Meet the required level Lead wires to be securely fastened against abrasion and damage to bring by vibration Grounding Continuity Tester GROUNDING is connected; -with Engine (bolt for grounding) -with Bed (bolt for grounding) -with grounding for Receptacle Continuity is to be confirmed Insulation Check Insulation Resistance Dielectric Voltage DC500V Mega Tester Tester Main Breaker ON. 1-phase breaker (50A) ON 1-phase breaker (20A) OFF Disconnect one coupler from the stator. Voltage Selector: 480V (3-phase) - Remove all output lines connecting to T10 & T11 in terminal rest. - Remove the output line T12 from the terminal rest. -Open a pc terminal in the output line U2 from the stator. *Insulate all terminals after removal Over 3MΩ AC2400V (1 sec) Electric Current: 10mA (Refer to page 38) 26

31 Items Article Method Condition to verify Criterion Insulation Check Monitor Dielectric Voltage Glow & Monitor Lamp (OIL PRESS, WATER TEMP, ENGINE, AIR FILTER & FUEL) Tester Connect grounding terminal - with output terminal L1. - with output terminal L2 - with output terminal L3. - with initial excitation winding. (Coupler marked with J or K.) Starter Switch RUN position Engine is running. Coolant Temp:-15~50 (5~122 F ) AC2400V (1 sec) Electric Current: 10mA (Refer to page 36) Glow Lamp & Charge Lamp ON. DIAG (diagnosis) lamp OFF after it turns on for a while. Hour Meter is activated. All monitor lamp OFF. Pilot lamp ON. Hour meter is activated. Protection Circuit Operational Check Emergency Stop Water Temp. Thermal Relay Terminal Cover Safety Feature Phase rotation AVR Adjustment 3-Phase Output (Comprehensive Voltage Regulation) 3-Phase Output (Transient Load Change Excursions) Visual Inspection Phase Rotation Indicator AC Volt Meter Load Tester Frequency Meter Wattmeter Stop Watch Engine is running Engine Stop Engine is running Output selector switch is set at 2080V (3-phase) No Load Voltage Adj. Dial: Max Emergency stop switch ON and engine stops. Short-circuit red/black and black/yellow lines connecting to a water temp. sensor. Overheat lamp ON and engine stops. Thermal relay is set at 3.6A. Breaker ON and thermal relay RESET. Turn test trip lever to TRIP. Main breaker lever trips between ON and OFF position. Open 3-Phase output terminal cover. Main breaker lever trips between ON and OFF position. Phase rotation should spin clockwise direction Frequency (Hz) 60±0.1 Engine Speed 1800 min -1, Engine Control Switch Setting: - Load Advance: OFF - Regulation Mode: OFF: Output selector switch is set at 480V. (3-phase) Output: 120±1.2kW Voltage: 480+/-1V Frequency: 60±0.1Hz Power Factor: 1.0 Throttle Switch: RUN /-0.9 Output selector switch is set at 280V. (3-phase) Output: 120±1.2kW Voltage: 240+/-1V Power Factor: 1.0 Throttle Switch: RUN Output (V) 253±1 *Adjust the Volt Adjusting Volume in AVR. (Refer to #1, page 28) % kw V A Hz / ±1 (1.04) 60±0.1 (0.88) /-0.6 (0.72) / ±6 (0.60) 60±0.2 0 no load (0.57) Refer to #2 (page 28) 1-Phase Output 3-Phase Output Voltage Adjustment AC Volt Meter Output selector switch is set at 240/120V. (3-phase) Voltage: 240+/-1V Frequency: 60±0.1Hz Output selector switch is set at 480V. (3-Phase) No Load Voltage Max. (V) Receptacle Voltage (50A) X-Y GFCI Receptacle Output 240±3V 120±2V Voltage Min. (V) over 504 below 408 Engine Speed Adjustment Digital Tachometer Adjust the engine control switch at no load. Idle Speed (min-1) Engine Speed Adjustment (Hz) 27

32 #1: VRE VOLT ADJ. Use the screw locking glue (recommended ThreeBond 1401C) over the VRD and VRE after adjusted. #2: Mode Output Voltage (V) Setting Time Frequency (Hz) Setting Time Loaded No Load (Transient Max.) below 288 below 2 sec. below 66 below 8 sec. No Load 240+/-3-60+/ No Load Loaded (Transient Min.) over 192 below 2 sec. over 54 below 8 Loaded 240+/-3-60+/

33 7. Trouble Shooting Procedures 7.1 Engine and Generator Engine does not start Problem Suspected Cause Action Starter motor does not work or speed is low. Starter motor works but engine does not start <Ambient temperature falls below zero> 1. Battery output is weak 2. Battery has deteriorated 3. Battery terminal is OFF or loose 4. Battery terminal is corroded 5. Starter switch or relay is defective 6. Starter motor is defective 7. ECU(Engine Controller) is defective 1. Fuel is insufficient 2. Fuel filter is clogged 3. Gauze filter is clogged 4. Water is interfused in fuel line 5. Air is in fuel line 6. Poor fuel line connection to external fuel tank 7. Fuel tank selector lever (3-way valve) position is wrong 8. Fuel cut solenoid (motor) does not work 9. Emergency operation/fault detection 1. Fuel is frozen 2. Water in fuel line is frozen 3. Pre-heater is defective 1. Check battery for cracks or leaks/battery liquid/or Charge 2. Change battery 3. Fix/Tighten terminal 4. Clean terminal 5. Check starter and wire connection 6. Contact distributor (Refer to page 19) 1. Add fuel 2. Change fuel filter 3. Clean/Change gauze filter 4. Drain water in water sedimenter, fuel filter or fuel tank 5. Purge line of the air 6. Check fuel line connections 7. Check lever (3-way valve) 8-1. Check/Change fuse 8-2. Check/Change fuel cutoff solenoid 9. Contact distributor to repair (Refer to page 19) 1. Use fuel additive for winterizing 2. Drain water in fuel line 3. Contact distributor to repair Engine starts but stalls immediately Engine oil pressure is low Black smoke comes out from muffler 1. Fuel filter is clogged 2. Gauze filter is clogged 3. Water is interfused in fuel line 4. Air is interfused in fuel line 5. Poor piping connection to external fuel tank 6. Air filter element is clogged 7. Engine oil is insufficient 8. Emergency operation/fault detection 1. Engine oil is insufficient 2. Oil filter is clogged 3. Oil Pressure switch is defective 4. Oil pressure meter is defective 5. Wrong weight of oil is used 1. Air filter element is clogged 2. Fuel injection nozzle is defective 3. Improper fuel is used 1. Clean/Change fuel filter 2. Clean/Change gauze filter 3. Drain water in water sedimenter, fuel filter or fuel tank 4. Extract the air 5. Check piping connection 6. Check/Change air filter element 7. Add engine oil 8. Contact distributor to repair (Refer to pages 14 and 19) 1. Add engine oil 2. Change oil filter 3. Change to proper kind and viscosity oil (Refer to page 8) 1. Check/Change air filter element 2. Contact distributor 3. Change to clean fuel (Refer to page 15) 29

34 Problem Suspected cause Action White smoke comes out from muffler Indicator does not move in voltage meter 1. Too much or too little oil to cylinder (white smoke) 2. Water is interfused in fuel line 3. Fuel injection nozzle is defective 4. Coolant temperature is too low 5. Engine thermostat is defective 1. Voltage meter is defective 2. AVR is defective 3. Disconnected circuit, loose terminal or damaged terminal 4. Initial exciter is defective 5. Alternator is defective 1. Contact distributor to repair 2. Drain water in water sediment, fuel filter or fuel tank 3. Contact distributor to repair 4. Warm-up idle is needed 5. Contact distributor to repair 1. Contact distributor to repair Indicator does not goes up to the rated voltage Indicator exceeds the rated voltage The voltage drops drastically when connecting to load Cannot turn the breaker to ON position 1. Voltage meter is defective 2. AVR is defective 3. Voltage regulator dial is defective 4. Frequency is low 5. Improper load cable connection 6. Voltage selector switch set is wrong 1. Voltage meter is defective 2. AVR is defective 3. Voltage regulator dial is defective 4. Frequency is high 5. Improper load cable connection 6. Voltage selector switch set is wrong 1. AVR is defective 2. Unbalanced loads sharing to each terminal 3. Total loads exceeds the rated current 4. Frequency Speed Switch set is wrong 1. The breaker positions stays between ON and OFF 2. Short circuit on the load 3. Terminal cover opened 4. The thermal relay activates 1. Contact distributor to repair 5. Correctly set the connection location to the output terminal 6. Set the Voltage selector switch correct (Do not change during unit running) (Refer to page 20) 1. Contact distributor to repair 5. Correctly set the connection location to the output terminal 6. Set the Voltage selector switch correct (Refer to page 20) 1. Contact distributor to repair 2. Balance the loads sharing to each terminal 3. Decrease the loads with in the rated output 4. Set the Speed Switch correct (Refer to page 9) 1. Turning the lever to OFF first then turn it to ON position 2. Check the load circuit 3. Close terminal cover 4. Reset the thermal relay (Refer to page 11 for location) 30

35 7.2 AVR Test Procedure Do not adjust the volume while operating the generator unit. It may damage the AVR or affect result of the load. Before testing the resistance of the generator unit, remove the connectors from the AVR and Engine Control Module. 31

36 1. Shut off the engine. AVR 2. Open the control panel and access the automatic voltage regulator (AVR). 3. Check the circuit breaker in AVR and push the circuit breaker button back to reset if it was tripped. NOTE: The circuit breaker in AVR trips due to overcurrent transmitted to the exciter. This is generally caused by overload or the unit is operated below the rated rpm. Circuit Breaker 32

37 4. Shut off the engine and disconnect the CN1 connector. CAUTION DO NOT change the voltage selector during the engine run. 33

38 6. Close the terminal cover and turn the main breaker ON, and measure voltage for L1-L2, L2-L3 and L1-L3 in the three phase terminals while the engine run. Reading of the voltage should be 92V under no load. 7.3 Check the Output Voltage 480/277V 1. Shut off the engine. Set the voltage selector switch to 480/277V position. CAUTION DO NOT change the voltage selector during the engine run. 2. Turn the main circuit breaker OFF. 3. Connect the leads to L1-L2 terminals. 4. Close the terminal cover. 5. Start engine. 6. Turn the main breaker ON and check the output voltage. 7. Repeat the above steps #2 through #6 and check the voltage between L2-L3 and L1-L3. NOTE: If the terminal cover is opened during operation, the main breaker lever would trip. The voltage among each terminal shall be the same under no load. 34

39 7.4 Check the Output Voltage 240/139V 1. Shut off the engine. Set the voltage selector switch to 240/139V position. CAUTION DO NOT change the voltage selector during the engine run. 2. Turn the main circuit breaker OFF. 3. Connect the leads to L1-L2 terminal. 4. Close the terminal cover. 5. Start the engine. 6. Turn the main breaker ON and check the output voltage. 7. Repeat the above steps #2 through #6 and check the voltage between L2-L3 and L1-L3. NOTE: If the terminal cover is opened during operation, the main breaker lever would trip. The voltage among each terminal shall be the same under no load. 35

40 7.5 Check the Output Voltage 240/120V 1. Shut off the engine. Set the voltage selector switch to 240/120V position. CAUTION DO NOT change the voltage selector during the engine run. 2. Turn the main circuit breaker OFF. 3. Connect the leads to L1-L2 terminals. 4. Close the terminal cover. 5. Turn the main breaker ON and check the output voltage. 6. Repeat the above steps #2 through #6 and check the voltage between L2-L3 and L1-L3, NOTE: If the terminal cover is opened during operation, the main breaker lever would trip. The voltage among the L1 and L3 terminal shall be 240V under no load. 36

41 7.6 Check the Main Circuit Breaker 7.6 Check the Main Circuit Breaker 1. Shut off the engine. Turn the main circuit breaker OFF. 2. Check the resistance with the ohmmeter between the upper and lower terminal as follows.; Upper Terminal T1 T2 T3 Lower Terminal T1 T2 T3 The ohmmeter shall display the symbol of infinity,, or similar wording per the ohmmeter. 1. Shut off the engine. Turn the main circuit breaker ON. 2. Check the resistance with the ohmmeter between the upper terminal and lower terminal as follows.; Upper Terminal T1 T2 T3 Lower Terminal T1 T2 T3 The ohmmeter shall display approx ohms. 37

42 7.7 Check the Generator Winding NOTE: Use a mill-ohmmeter with the Kevin four wire probes. 1. Shut off the engine. Disconnect the lower wires from the terminal rest. 2. Check the resistance in the windings as per the table below. NOTE: Use a mill-ohmmeter with the Kevin four wire probes. Terminal T1-T4 T7-N10 T2-T5 T8-N11 T3-T6 T9-T12 The mill-ohmmeter should display ohms ±10% at 70 in the Fahrenheit. 38

43 7.8 Check the Exciter Stator 1. Shut off the engine. Disconnect the CN1 connector in the AVR. 2. Check the resistance between the terminals J and K. CN1 Connector The ohmmeter should display 15.0 ohms ±10% at 70 in the Fahrenheit. NOTE: Use the ohmmeter. 39

44 7.9 Check the Adjusting Voltage Regulator 1. Shut off the engine. Disconnect the CN3 connector in the adjusting voltage regulator. 2. Turn the adjusting voltage regulator knob fully counter-clockwise. 3. Connect the lead to the terminal #1 and #2 (white/blue wire) in the CN3 connector as shown in the picture below. Reading Resistance: 2kΩ NOTE: Use the ohmmeter. 4. Turn the adjusting voltage knob slowly clockwise while reading the voltage in display of the ohmmeter. 5. Turn the knob fully clockwise and check the resistance. Reading Resistance: approx. 0.3Ω 40

45 7.10 Check the Voltmeter 1. Access the back of the control panel. 2. Start the engine. 3. Turn the main breaker ON. 4. Turn the voltmeter selector dial to L1-L2. 5. Check the output voltage of the VS1 and VS2 located the back of the voltmeter. (ref: photo) 6. Check the output voltage of L1-L2 in the main terminal rest. Ref. Checking output voltage (section 7.4 & 7.5) Output voltage in the voltmeter and main terminal should be the same. 41

46 7.11 Check the Voltmeter Selector Dial 1. Set the voltmeter selector dial to L1-L2. 2. Check the output voltage of the T1-T2 located in the volume of the voltmeter selector dial 3. Check the output voltage of L1-L2 in the main terminal rest. Ref. Checking output voltage (section 7.4 & 7.5) 4. Set the voltmeter selector dial to L2-L3. 5. Check the output voltage of T2-T3 in the back of the voltmeter selector dial. 6. Check the output voltage of L1-L2 in the main terminal rest. Ref. Checking output voltage (section 7.4 & 7.5) 7. Check the output voltage of T1-T3 in the back of the voltmeter selector dial. 8. Check the output voltage of L1-L2 in the main terminal rest. Ref. Checking output voltage (section 7.4 & 7.5) Output voltage in the voltmeter and main terminal should be the same. 42

47 7.12 Check the Current Transformer (CT) 1. Shut off the engine. Connect the load (3-phase) to the unit. (cf. motor) 2. Start the engine. 3. Turn the main breaker ON. 4. Check the current of the wires TT, TR and CTE in the ammeter selector dial. Replace the CT1 if no amps were confirmed in TR and CTE Replace the CT2 if no amps were confirmed in TT and CTE. CAUTION DO NOT disconnect the current transformer (CT) during operation. 43

48 7.13 Check the Ammeter NOTE: Check the following after Check the Current Transformer (CT) in the previous section, 7.12 with a satisfactory result confirmed. 1. Shut off the engine. Connect the load (3-phase) to the unit. (cf. motor) 2. Start the engine. 3. Turn the main circuit breaker ON, that functions a supply of output to the 3-phase load. NOTE: The ammeter selector should not turn OFF. Current shall be confirmed either the lead A1 or A2 in the ammeter selector dial or ammeter. 44

49 7.14 Reset the Thermal Relay If there would be no voltage output and the main breaker would not reset, check the thermal relay in the inside of the control panel. How to determine if the thermal relay has tripped. 45

50 7.15 Test the Thermal Relay 46

51 7.16 Check the Voltage Selector Switch 1. Shut off 1. engine. Stop the engine. 2. Remove all leads from the voltage selector switch. 3. Check continuity of terminals in the voltage selector switch. Use ohmmeter. There should be continuity between the terminals as shown in the table below. 47

52 7.17 Abnormal Frequency or Voltage Drop 1. Check the engine rpm with the tachometer. The engine should run at 1800±80 rpm. 2. Confirm all the switches in the engine control switch panel direct correct as shown in the picture below. RPM should run higher or lower if all the toggle switches turn to correct direction. Refer to the engine manufacturer s workshop manual for further diagnosis. 48

53 7.17 Abnormal Frequency or Voltage Drop (cont.) 3 Check the current in each phase. 4 Lower the load if current exceeds the rated output shown in the specifications. 49

54 7.18 Engine Won t Start 1. Check the fuel level. 2. Inspect the fuel filter if it is dirty. 3. Inspect the air filter if it is plugged with dirt. 4. Disconnect the terminal from the battery and check voltage of each battery. Voltage should be 12 ~ 14 volts. 5. Check the specific gravity of electrolyte and its level. Specific Gravity: 1.28 or higher WARNING Battery Removal 1. Disconnect the clamp and terminal from negative (-) post from the battery. 2. Disconnect the clamp and terminal from positive (+) post from the battery. Always disconnect the negative (-) terminal first. It might be short-circuited when a tool contacts the bonnet as the negative (-) terminal is grounded with the bonnet. There might be a risk of scalds when it is disconnected from the positive (+) terminal. Battery Installation 1. Connect the clamp and terminal from positive (+) post to the battery. 2. Connect the clamp and terminal from negative (-) post to the battery. 50

55 7.18 Engine Won t Start (cont.) 6. Access the starter relay located in the back of the control panel. 7. Disconnect CN4 connector from the starter relay. 8. Turn the ignition switch to START and check the output voltage between the red/white and blue/white terminals in the CN4 connector. Voltage should be DC 24C2V. 9. Check the current of starter switch terminal. Current should be 15.0Ω±10% at 70 the Fahrenheit. 51

56 7.19 Engine Stops Suddenly Upper Limit Lower Limit 1. Check the engine oil and refill if the level is below the low level. Oil should be leveled between LOW and HIGH in the oil gauge. Oil Gauge 2. Check coolant and refill if the level is below LOW in the sub tank. 3. Check and clean the fuel filter and pre-filter. Replace the filters if necessary. 4. Check and clean the air filter. Replace it if necessary. 5. Check the fuel and intake system if there is leak. 6. Refer to the engine manufacturer s workshop manual for further diagnosis. HIGH LOW 52

57 7.20 Monitor Lamp Blinking This unit is equipped with monitoring function and the monitoring lamp flashes when defect is detected. The EMPS III diagnostic equipment would be necessary if the engine control module and etc. in the electronic fuel injection system may be caused. Contact your local Isuzu dealer if the monitor lamp may flush and did not cure the problem. Source: Isuzu Tier 3 training material 53

58 54

59 ECM * - Tier 3 Engine by Isuzu *ECM: Emission Control Module 55

60 7.21 No Output Voltage If the output voltage has dropped to zero, the rectifier might be malfunctioned when an abnormal voltage or excessive current might be applied or flowed to the rectifier, as one of the possible causes. Follow to the procedure below to check the rectifier. 1) Unfasten the 6 pcs. of the bolt and remove the rear bracket. Rear Bracket After the rear bracket removed 56

61 Exciter Armature Front View of the Exciter Armature Group A Group B CAUTION The rectifier in the group A & B are not interchangeable as the current flows at different direction. 2) Remove the varnish with a file or sand paper that the probe of the tester would contact. 3) Remove the nut that fastens the rectifier. Nut Remove the varnish. 57

62 4) Set the dial to the diode mode in the tester. IMPORTANT! The tester shall display 2.6V. If not, refer to the owner s manual of the tester that you use. 5) Directly make contact the two probes (red & black) to the electrodes. The tester shall show 0.46V. Probe 6) Again, make contact the two probes (red & black) to the electrodes by reversing the red and black position. The tester shall show 0.46V. Probe IMPORTANT! 1. The tester shall show 2.6V when the probes and electrodes are not in contact. 2. The tester shall show 0.46V when the probes and electrodes are contacted.. Judgement: The rectifier works fine when the both test confirms 2.6V and 0.46V. 58

63 8. Maintenance Description Engine Side Daily check Every 250hrs Every 500hrs Every 1000hrs Clean each parts / tightening Engine oil checks / add oil Engine oil and Oil Filter change PCV Filter change Coolant level check / add coolant (1 st time at 50 hrs) (1 st time at 50 hrs) Exhaust color check Coolant change / bleeding EGR Drain excess water and sediments in the fuel filter and water sedimenter Clean or 1 yr. Clean or replace fuel filter element and water sedimenter element Clean Replace Drain water from fuel tank Clean gauze filter in engine feed pump Change filter in the electromagnetic pump for air extraction in fuel line Clean inside fuel tank Clean Clean Leak check (fuel, oil, and coolant) Replacing fuel hose Clean or replace air cleaner element Clean Replace or 1yr. Battery fluid level check Battery hydrometer check Fan belt check Radiator Flush Cleaning Check and adjust engine valve clearance Compression check Alternator side Various meter and alarm lamps check 59

64 8.1 Layout of the Unit Radiator Air Cleaner Generator Intercooler Fuel Drain Valve Left Oil Drain Valve - Right Pre-Fuel Filter Oil Filter Electromagnetic Fuel Pump Main Fuel Filter 60

65 8.2 Engine Oil Replacement CAUTION Use only the engine oil recommended API category CD or higher with an equivalent viscosity. Refer to the instruction manual by the engine manufacturer for the recommended engine oil for details. 61

66 8.3 Oil Filter Replacement Oil Gauge Lower Limit Upper Limit CAUTION Use the engine oil only recommended API category CD or higher with an equivalent viscosity. Refer to the instruction manual by the engine manufacturer for the recommended engine oil for details. 62

67 8.4 Clean/Replace the Air Filter Element CAUTION Only use the engine oil recommended API category CD or higher with an equivalent viscosity. Refer to the instruction manual by the engine manufacturer for the recommended engine oil for details. 63

68 8.5 Replace the Electric Fuel Pump Filter 8.6 Drain the water from the Internal Fuel Tank 64

69 8.7 Replace the LLC Anti-freeze (Long Life Coolant) 65

70 8.8 Clean/Replace the Fuel Filter 66

71 8.8 Clean/Replace the Fuel Filter (cont.) Wrench for Fuel Filter: 67

72 8.9 Fuel System Air Blow The air intake into the fuel system may lead hard starting of the engine. After drain the fuel from the tank and water from the sediment, blow the air as per the following. NOTE: Blow the air to the air filter when the filter element was maintained and served. NOTE: Air blow to the air filter when the filter element was serviced or maintained. The Air Blow Procedure 1. Loosen the air blow screw located in the top of the main fuel filter housing. 2. Turn the starter switch to RUN or ON. DO NOT position the switch to START as the engine will start. 3. Operate the priming pump in the fuel filter to blow the air. 4. Tighten the air blow plug of the fuel filter. 5. Operate the priming pump until cogging the resistance. 6. Fasten the priming pump securely and start the engine. Repeat the procedure described in the above if the engine will not start. Air Blow Screw 68

73 9. Tightening Torque 9.1 Specific Torque No Nomenclature 1 Drain Plug~Socket Part to be tighten Drain Plug Size M24 (fine pitch) 2 Socket~Oil Pan Nipple ditto 1 3 Cushion~Bonnet Screw M4x Panel~Front Door Nut M5 8 5 Stay~Engine Bolt M10x Rotor~Engine (flywheel side) Qty Bolt M10x Stator~Engine Bolt M10x Bolt~Plate Nut M Terminal Cover~Bonnet Bolt M10x Radiator~Frame Bolt M12x Exhaust Pipe~Engine Flex. Tube~Exhaust Pipe Fuel Tank~Frame (bed) Nut M10 (fine pitch) Bolt M16x Torque Allowance Nm(kgf/cm) ( ) ( ) (11-14) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ) Bolt M8x Elbow~Valve Elbow Valve~Frame (bed) Pipe~Fuel Strainer Eye Bolt M16x ( ) Reference Put a lubricant to O-ring and align it into a groove. ditto Uniformly tighten the bolts. There should be no rattles in fuel tank. Attention to the direction for installation of the elbow. Attention to the direction for installation of the elbow. Attention to the direction for installation of the pipe. Insert the packing into both side of the pipe. Put a lubricant. 17 Fuel pomp~frame Put a lubricant. 18 Fuel Pomp~Frame Attention to the direction of the fuel pomp. 19 Joint~Oil Strainer Joint G3/ ( ) Attention to the direction of the joint. Put a lubricant. 69

74 No Nomenclature Part to be tighten Size 20 Joint~Engine Joint G3/ Hose,14~Joint Hose, 14 G3/ Air Cleaner Cleaner Band 23 Plug~Engine Plug M10 1 Qty Torque Allowance Nm(kgf/cm) ( ) ( ) ( ) Reference ditto Attention to piping for inlet & outlet. Attention to the direction of the air cleaner intake. 9.2 General Torque Unit: N m {kgf cm} Intensity 4.6, 4.8, 5.6, 5.8, 6.3 (4T, 5T, 6T) 8.8, 9.8, 10.9, 12.9 (7T) Nominal Designation M3 0.5 Nominal 0.6 {6} Tightening Torque Allowance Limit 0.5 ~ 0.8 {5 ~ 8} Tightening Strength N{kgf} 845 {86} Nominal 1.2 {12} Tightening Torque Allowance Limit 1.0 ~ 1.5 {11 ~ 15} Tightening Strength N{kgf} 1610 {164} M {15} 1.3 ~ 1.9 {14 ~ 19} 1475 {150} 2.8 {29} 2.8 ~ 4.8 {29 ~ 49} 2810 {287} M {30} 2.6 ~ 3.8 {27 ~ 39} 2386 {243} 5.7 {58} 4.8 ~ 7.1 {49 ~ 72} 4544 {463} M {52} 4.3 ~ 6.4 {44 ~ 65} 3377 {344} 9.6 {98} 8.6 ~ 14.4 {88 ~ 147} 6432 {656} M {125} 11 ~ 16 {112 ~ 163} 6149 {627} 23 {239} 20 ~ 30 {204 ~ 306} {1194} M {248} 21 ~ 31 {214 ~ 316} 9744 {994} 46 {473} 40 ~ 60 {408 ~ 612} {1893} M {433} 37 ~ 54 {377 ~ 551} {1444} 81 {825} 70 ~ 100 {714 ~ 1020} {2751} M {690} 60 ~ 85 {612 ~ 867} {1970} 129 {1313} 110 ~ 160 {1122 ~ 1632} {3753} M {1076} 90 ~ 130 {918 ~ 1326} {2690} 201 {2049} 170 ~ 250 {1734 ~ 2549} {5123} M {1480} 125 ~ 180 {1275 ~ 1835} {3289} 276 {2819} 235 ~ 345 {2396 ~ 3518} {6265} M {2099} 175 ~ 260 {1785 ~ 2651} {4197} 392 {3997} 335 ~ 490 {3416 ~ 4997} {7995} M {2855} 240 ~ 350 {2447 ~ 3569} {5191} 533 {5438} 455 ~ 665 {4640 ~ 6781} {9887} M {3628} 305 ~ 445 {3110 ~ 4538} {6047} 678 {6911} 575 ~ 845 {5863 ~ 8617} {11519} Material SS, S C, SWRM, SWCH NC, SNCM, SCM (hardening & tempering treated) 70

75 10. Wiring Diagram 71

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77 YAMABIKO CORPORATION 35 SHIN-UJIGAMI, KITA-HIROSHIMA-CHO, YAMAGATA-GUN, HIROSHIMA JAPAN Telephone: (81) Fax: (81)