SERVICE MANUAL. File DGO-650_DGK14F

Transcription

1 SERVICE MANUAL File DGO-650_DGK14F

2 WARNING This equipment is designed and built with safety in mind. However, your overall safety can be increased by your full understand followed by 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 power source of electric tools, home appliances and lights. Do not install, operate or service this equipment without reading this manual and unless you clearly understand this manual. Specifications subject to change without notice. This service manual is edited for authorized person to perform repair, maintenance, and trouble-shooting to Shindaiwa Diesel Engine Generator, Model Designation DGK14F. It is inevitably necessary to maintain and adjust Shindaiwa products periodically in order to use fully and safely for long time. Therefore, understand this service manual fully enough before use and proper maintenance. The information contained in this service manual describes equipment available at the time of publication. While every attempt has been made to give 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 service of the engine, refer to Workshop (Service) Manual provided by the engine manufacturer described below. (Ref: KUBOTA Diesel Engine 03-M-E3B SERIES WORKSHOP MANUAL #9Y ) MANUFACTURER KUBOTA MODEL D1503

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 Operation Panel Configuration Main Parts and Feature Main Component Service Data Technical Specification Generator Inspection & Adjustment Trouble Shooting Engine Generator Periodical Check Tightening Torque Specific Tightening Torque General Tightening Torque Print Circuit Board Wiring Diagram 48

4 1. Attention Statements Technicians only who own enough knowledge and experience should work for maintenance and operational check after maintenance. Before maintenance, always read this service manual as well as owner s manual and familiarize contents thoroughly before starting the service and maintenance of the equipment for understanding of the equipment, safety instructions and cautions. 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 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

5 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 stopped before you will connect the loads to the output terminals. WARNING Entangled Injuries under Moving Component NEVER reach and touch the 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 the ventilated area. When the equipment is used in a tunnel, hall or any other indoor, the equipment for ventilation must be used to prevent serious accident caused by suffocation. NEVER direct the exhaust fume to houses nearby while considering the wind flow direction. Exhaust gas contains many harmful elements that would cause affect to human. Be free from suffocation when the equipment is used in poorly ventilated area such as inside of the building. NEVER inspect equipment during use. Never serve and inspect when equipment 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 violate or abnormal noise. 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 of 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. 2

6 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 and serve this equipment! Attention to CAUTION LABEL! Caution labels are placed on this equipment and it would request special attention for operation. Make sure to locate the labels and understand the content of the caution. Check the caution labels is 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 peel off due to adhesive solvent. Make sure to replace the labels when damaged and 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! STOP the equipment immediately whenever abnormal circumstances are noticed such as unusual noise, smell vibration and etc. It may lead serious accident or fatal damage of the equipment or properties. Inflammables! Keep the equipment far away from fire such as cigarettes when Refueling fuel, oil or battery fluid. NEVER operate or service the equipment nearby fire as the equipment may catch fire. Modification! NEVER modify the equipment without manufacturer s advanced approval. It may lead serious safety issue and damage the equipment. Inspect the equipment before engine start for operation and periodical inspection without fail! Make sure to serve initial check before start engine and periodical inspection for safety and longer life of the equipment. 3

7 3. Specifications Alternator Engine Unit Model Unit DGK14F Generator Type - Revolving Field Brushless Armature Connection - ZigZag-W Rated Frequency Hz 60 Rated Output(Prime) kva 14 kw 14 Standby Output kva 14.7 kw 14.7 Rated Voltage V 240/120 Rated Current A 58.3 Phase Single phase Power Factor Insulation class - F Excitation - Self Excitation (brushless). of Poles - 4 Type - Vertical Water-Cooled 4-Cycle Diesel Model(Manufacturer) - Kubota D1503. of Cylinders (bore stroke) (in./mm) 3( / ) Continuous Rated Output hp 19.5 Rated Speed rpm 1800 Displacement cu.in./liters 91.5/1.499 Combustion System - Indirect Injection Cooling Method - Radiator Lubricating Method - Forced Lubrication Starting Method - Electric Fuel -.2-D,S15 EPA regulation Lubricating Oil - CF class Fuel Tank Capacity gal./liters 34.3/130 Lubricant Volume gal./liters 1.9/7.3 (including filter 0.1/0.3) Cooling Water Volume gal./liters 2.3/8.8 (including sub-tank 0.3/1.1) Starting Motor Capacity V-kW Charging Alternator Capacity V-A Battery Capacity V-Ah Length in./mm 55/1390 Width in./mm 28/704 Height in./mm 47/1204 Dry Weight lbs./kg 1378/625 Net Weight lbs./kg 1669/757 Specifications subject to change without notice. 4

8 4. General 4-1 Appearance 4-2 Dimension Unit in the drawings below is shows by mm. 5

9 EXHAUST GAS OUTLET WATER INLET AIR OUTLET 6

10 5. General Parts Description 5-1 Equipment Tie-Down Lifting Hook Radiator Plate Operation Panel Door Tie-Down Fuel Inlet Cover Terminal Cover Fuel Drain Plug Spill Containment Drain Valve Spill Containment Drain Plug Fan Guard Radiator * Shown with side-plate removed. 7

11 Air Cleaner Oil Filler Coolant Sub-Tank Engine Check Door Alternator Check Door Oil Filter Battery Oil Level Gauge Fuel Tank (Inside) Fuel Filter 3way Fuel Valve Oil Drain Plug Water Separator Coolant Drain Plug External Fuel Inlet External Fuel Return 8

12 5-2 Operation Panel Configuration Main Circuit Breaker 11 Hour Meter 2 Voltmeter 12 Warning Indicators 3 Pilot Lamp 13 Engine Monitor 4 Glow Lamp 14 Fuel Meter 5 Throttle Switch 15 Oil Pressure/ Water Temperature / Speed Selector Switch 6 Voltage Regulator 16 Display Selector Switch 7 Starter Switch 17 Available Output Monitor 8 Accessory Switch 9 Over Crank / Speed Signal Indicator 10 Spill containment Overflow Warning Indicator 9

13 5-3 Main Parts and Feature (1) Unit Serial Number Provide both serial number of unit and engine to your local service shop for update parts and warranty information. (2) Engine Serial Number Engine Serial. Label 10

14 5-4 Main Component Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Voltage Adjusting Dial Feature: Adjust voltage. Voltage Meter Feature: Display output voltage. Starter Switch Feature: Start and Stop engine. Fuel Meter Feature: Display volume of the fuel left in the fuel tank. Circuit Breaker Feature: Protect electrical circuit from damage by overload or short circuit. DisplaySelector Switch Feature: Select the available generating level per each phase. Accessory Switch Feature: Display the fuel level and air vent for the fuel system. during engine stops. Idle Control Switch Feature: Switch to set the engine speed idle when electric supply is not performed to reduce noise and fuel consumption. Set the switch to IDLING at starting and change it to RUN during operation. Serial Number Plate Printed Circuit Board (Main Controller) Feature: Adjust voltage and control engine rpm. etc. Print Circuit Board Feature: Warm up and start engine automatically. Fuse ECU (Engine Control Unit) Feature: Control engine. Printed Circuit Board Feature: Operate the fuel pump for few minutes during the air vent of the fuel system. 11

15 Coolant temperature sensor Function: Detects coolant temperature, and display it on meter. Glow Plug Function: the chamber for the efficient starting Air Cleaner Feature: Remove the solid particulates (dust) from the air. Fuel Filter Feature: Filter dust in the fuel. Oil Filter Feature: Remove contaminant from the engine oil. Battery (12V 55Ah) Feature: Supply power to engine and printed circuit. Fuel Pump Feature: Supply fuel to the injection pump. Water Separator Separate water from fuel. Oil pressure senser Function: Detects oil pressure, and display it on meter. 12

16 Water Temp. Switch Feature: Detect coolant temp. in the radiator and stop the engine when the temp. is higher. Coolant Water Temp. Sensor Function: Detect the coolant temp. Oil Pressure Switch Feature: Detect oil pressure and transmit the signal to the Engine Control Unit to stop the engine when the oil pressure is lowered. Alternator Feature: Charge a battery and send a charging signal. Generator Refer to check winding resistance on page 19 for inspection. 13

17 Fuel Inlet Feature: Inlet to the inject fuel. Fuel Return Feature: Outlet to return fuel from the external tank. Cooling Water Drain Plug Feature: Drain cooling water (coolant) from the engine and radiator. Oil Drain Plug Feature: Drain the old oil from the engine. Fuel Drain Plug Feature: Drain the old Fuel from the fuel tank. Spill Containment Drain Valve Feature: Drain a liquid from the spill containment. Refer to page in the operator s manual. Spill Containment Drain Plug Feature: Drain a liquid from the spill containment. Refer to page in the operator s manual. 14

18 3-Way Valve Lever 3-Way Valve Feature: Valve to change fuel supply from a built-in or external tank. Position A Position B 3-Way Valve Position A (to use a built-in fuel tank) Position the 3-way valve lever to LEFT to use fuel from the external fuel tank. Position B (to use an external fuel tank) Position the 3-way valve lever to RIGHT to use fuel from a built-in fuel tank. te: The 3-way valve lever is set at position A at delivery from a factory. 15

19 Remote Start Terminal Feature: Start engine when the remote start terminal turns to close while the starter switch set at AUTO. (See p.11) Circuit Breaker (1-Phase) Feature: Protect electrical circuit from damage caused by overload or short-circuit. Ground-Fault Circuit Interrupter (GFCI) 1-Phase Receptacle (20A) Feature: 1. Supply AC output. 2. Detect the electric leakage and shut off the output. 1-Phase Receptacle (30A) (120/240V) Feature: Supply AC output. 1-Phase Receptacle (50A) (120/240V) Feature: Supply AC output. Standard Accessory 1 Owner s Manual 1 copy 2 Engine Manufacturer s Warranty Manual 1 copy 16

20 6. Service Data ELECTRIC SHOCK WARNING Never touch the output terminal during operation to avoid electric shock. Always stop the engine and remove the starter key during a service maintenance. Stop the engine before you will start any maintenance! 6-1 Technical Specification Items Reference Value te Insulation Armature winding Exciter field 1MΩ or more DC500V Megger Tester time Approx. 3 sec. with coolant temperature 86 F (30 ) and approx. 5 sec. with coolant temperature 5 F (-15 ) Automatic preheating system Min. rpm at no load 1200min -1 Max. rpm at no load 60Hz: 1800min -1 Lubricant oil pressure 35~65psi. {2.5~4.5kgf/cm²} Coolant temperature 158~203 F (70~95 ) Frame temperature limit within 176 F (80 ) Sealed bearing temperature limit within 176 F (80 ) Speed regulation Momentary within 10% Steady-state deviation within 5% (9.8kW) Voltage regulation Momentary within 20% Steady-state deviation within 1.0% (9.8kW) Frequency Idle: 40 Hz, Rated: 60 Hz Variable voltage 197~255V 60±0.1Hz Protective device 1 Low oil pressure Working Pressure 7.1psi. {0.5kgf/cm²} Engine Stop 2 High water temp. Working Temp. 239 F (115 ) Engine Stop 3 Insufficient Battery Charge Engine Over Speed Spill Containment Fluid Overflow Rotation signal loss When the battery charging is low. Engine Stop - above 2070 min -1 Engine Stop Spill containment accumulated fluid exceeds the specified above about4.5gal(17 liters) Engine Stop level at near the fill. When the rotation signal Flashing Engine Stop disappears. 17

21 6-2 Generator Thermo label Rear bracket Main stator Thermo label 要確認 Bolt Exciter armature Exciter stator Main bearing Rotor Exciter field Armature Fan cover Stator Rotor 18

22 (1) Exciting Amperage Amperage fluctuates based upon the winding temperature. Following is for reference only. Frequency/Rated Output Load Exciting Amperage (Measured) 1-Phase 60Hz: 240V 14kVA load 0.37A Full load( power factor=1.0) 0.72A (2) Resistance Value minal resistance of the winding is tolerated within ± 10% at 68 F(20 ) of the ambient temperature. The resistance must be measured by low resistance tester. It cannot be measured by multi-purpose tester cause of index error. Main Stator Exciter Stator Rotor Armature Exciter Winding Field Winding Exciter Field Armature Between Between J-K A B U N - - U W B C (Gray) (Violet) W N C A 0.09Ω 0.18Ω 0.97Ω 23.2Ω 11.0Ω 2.7Ω [Color Code] (B) (W) (R) (G) (Y) (Br) (L) (Lg) (Or) (Vi) (Gr) (P) Black White Red Green Yellow Brown Blue Light Green Orange Violet Gray Pink Stator Armature Rotor Armature Rotor Exciter Field Exciter Stator Stator Exciter Winding 19

23 (3) Armature (Main Stator) U W Back View of the Output Terminal Box N U W N Measure the resistance among the U-W by the low resistance tester. It shall be 0.18Ω. Measure the resistance among the U-N and W-N by the low resistance tester. It shall be 0.09Ω. 20

24 (4) Exciter Winding (Main Stator) AVR A B C B A C Remove the wire harness from the AVR and measure; The resistance among A~B, B~C and C~A by the low ohm tester. Each shall be 0.97Ω. 21

25 (5) Exciter Stator J (Gray)-K (Violet) AVR K (Vi) J (Gr) K (Vi) J (Gr) Remove the wire harness from the AVR and measure; Measure resistance among the J~K by the low ohm tester. It shall be 23.2Ω. 22

26 (6) Rotor There are two windings in the rotor and measure the resistance between #1~#4 and #2~#3. #1 #2 Rotor #3 #4 Rectifier #3 #2 #1 #4 Remove the varnish by a sand paper and measure; Exciter Field: the resistance among the two points as shown in the photo above by the low ohm tester. It shall be 11.0Ω. Armature: the resistance among the two points as shown in the photo above by the low ohm tester. It shall be 2.7Ω. 23

27 (7) Technical Specifications Items Article Method Condition to verify Criterion Shape, Dent, Blot dent, blot and deformation Check before operation Coating Oil, Coolant Joint Wiring Printed Circuit Board. Visual Inspection looseness Meet the required level Meet the criteria Lead wires to be securely fastened against abrasion and damage to bring by vibration Set the dip switch per #1 on page 26. Grounding Check Continuity Tester GROUNDING is connected; -with Engine (bolt for grounding) -with Bed (bolt for grounding) -with grounding for Receptacle(#2) Continuity is to be confirmed Insulation Check Insulation Resistance Dielectric Voltage DC500V Mega Tester Optional Tester Main Breaker ON. 1-phase Circuit protector (50A) :ON 1-phase Circuit protector (30A) :ON 1-phase Circuit protector (20A) : OFF Disconnect three couplers in AVR. Disconnect four couplers in the front panel. Disconnect four couplers in the printed circuit. Disconnect one coupler in the printed circuit for the fuel pump. Disconnect the lead N (14mm 2 -Black) located in the side door.- Remove either the lead X or Y and J or K. Insulate all terminals after removal Over 1MΩ AC1800V (1 min) Electric Current: 10mA Monitor Fuel Pump Air Filter Fuel Meter Hour Meter Spill Containment) Auto Starting Visual Inspection Engine is not running (ACC:ON) Engine is not running Turn the accessory switch ON before inspecting the fuel pump. when blue and white wires for the wire harness are grounded. Lift the float switch in the spill container. (#3) Turn the starter switch to START and accessory switch to OFF position. Fuel Pump is activated. AIR FILTER lamp ON. FUEL monitor lamp ON. Hour Meter is activated SPILL CONTAINMENT CHECK lamp ON Engine shall start after the glow lamp turns OFF. 24

28 Items Article Method Condition to verify Criterion Monitor Protection Circuit Operational Check Monitor Display Auto Starting Spill Containment Remote Starting Remote Starting Remote Starting (Over Crank) Low Oil Pressure High Water Temp. Insufficient battery charge Over Speed Breaker AVR Adjustment Visual Inspection Visual Inspection Visual Inspection Visual Inspection AC Voltage Meter Engine is running Engine is not running Turn the starter switch to START and accessory switch to OFF position. Short-circuite d the remote start terminal. Engine is not running Engine is not running Engine is not running. Crank the Engine 3 times. Engine is running Turn the starter switch to START and accessory switch to OFF position. The display selector switch shall function. engine speed / water temp./oil press. Turn the starter switch to START and accessory switch to OFF position. Lift the float switch mounted in the spill containment. (#3) Turn the starter switch to START and accessory switch to OFF position. Short-circuited the remote start terminal. (Ref. Owner s Manual P. 26) Open the remote starting terminal. 1. Remove the 2P coupler (yellow & green) in the stop solenoid. 2. Turn the starter switch to START. 3. Turn the accessory switch to OFF position. 4. Confirm that engine shall not run. Ground oil pressure wire with a unit. Ground water temp. wire with a unit, Short circuited terminal L from dynamo Ground over speed terminal with the unit. Operate at high rpm in 50 Hz and switch to 60Hz so the over speed function shall detect the rpm. difference. Main Breaker ON. Connect 9V with the connector CT1 of the harness side. Load Voltage Adj. Dial: Max. Set VRD volume in AVR at center-position. (#4) terminal L Adjust by The pilot lamp shall turns to ON. The oil pressure, water temp. and engine speed shall display in the screen. Engine shall stop. Engine stops. SPILL CONTAINMENT WARNING lamp ON. Engine stops. Engine shall start after the glow lamp turns to ON.CHARGE & OIL PRESS lamps ON. Glow Lamp ON and turns to OFF after 3~5 sec. Engine shall stops. The OVER CLAMP lamp shall turn to ON after the process below for 3 times.; 1. Turn the starter switch to START for 5 sec. 2. Crank for 5 sec. 3. Turn the starter switch to STOP. OIL PRESS lamp ON and engine stops. The glow lamp shall flash 1 time 1 sec. and 3 times for 2 sec.. WATER TEMP. lamp ON and engine stops. The glow lamp shall flash 1 time for 1 sec. and for 4 times for 2 sec. CHARGE lamp ON and engine stops. The glow lamp shall flash 1 time and 1 sec. for 3 times. Engine shall stop at 1800min -1 and the OVER SPEED lamp ON. The glow lamp shall flash for 1 time only. The main breaker lever shall trip to OFF position. Frequency (Hz) Output (V) VRE (#4) 60± ±2 25

29 Starter switch START kva Available Output Visual Inspection Load Frequency: 60±0.1 Hz Throttle Switch IDLING 0.0 U-W/U-N/W-N 14/ Throttle Switch RUN 2.4/2.4 U-W/U-N/W-N Items Operational Check Article Method Condition to verify Criterion 1-Phase Output 1-Phase Output (Receptacle) 1-Phase Available Output Current Transformer Wiring 1-Phase Output (Transient Load Change Excursions) Voltage Adjustment Load Tester Frequency Meter Dynamo DC Current Meter Dynamo AC Voltage Meter Load Tester Dynamo Load Tester Dynamo Load Tester Frequency Meter Dynamo Stop Watch AC Meter Output: 240±1V (50A receptacle, rated, X-Y) Frequency: 60±0.1Hz Power Factor: 1.0 Water Temp: 32~212 F (0~100 ) The receptacle for 50A & 30A shall output 29.2A (X-Y) Voltage: 240±1V (50A receptacle, X-Y) Frequency: 60±0.1Hz Load The breaker lever shall trip to OFF position. % kw V A RPM ± ±1 (0.72) ± ± ± ±3 0 no load (0.37) Receptacle Output (50A 120/240V) Receptacle Output (30A 120/240V) Receptacle Output (GFCI 20A 120V) Voltage: 240±1V (50A Receptacle,X-Y) Load: 40±1A (50A Receptacle, X-Y) Frequency: 60±0.1Hz Voltage: 240±1V (50A receptacle, rated, X-Y) Frequency: 60±0.1Hz Power Factor: 1 50A Receptacle (X-Y) Output: 9.8±0.1kW Voltage: 240±1V Frequency: 60±0.1Hz Power Factor: 1 50A Receptacle (X-Y) Load Adjust the voltage regulator Frequency: 60±0.1Hz Max. Voltage X - N Y - N X - Y X - N Y - N U - N W - N Available Output (kva) #5 #6-1800±10 Output Voltage 120±1V Output Voltage 240±1V Output Voltage 120±1V Output Voltage 120±1V U - W 4.4±0.2 U - N 2.2±0.1 W - N 2.2±0.1 Min. Voltage Over 252 Below 204 #1: Initial setting of the DIP Switch at delivery. DIP SWITCH S1:ON S2:OFF S3:OFF S4:ON 26

30 #2: Grounding The arrow indicates grounding. U N W N Y(W) N X(U) N Y(W) X(U) #3: Spill Containment Sensor Float Sensor Feature: detect the level of liquid in a Spill Containment. #4: AVR Adjustment Set the VRD volume in the center-position before adjustment Put the adhesive (ThreeBond #1401C) over the VRF, VRD and VRE after adjusted. #5: Load Receptacle Avail. Output (kva) U - W U - N W - N 50A (X-Y) 15.0±1A Simultaneous Side (B): GFCI (W-N) 100V/1kW 7.5± ± ±0.2 Side (A): GFCI (U N) 100V/500W Single 30A (X-Y) 100V/500W 11.1± ± ±0.1 27

31 #6: Mode Output Voltage (V) Setting Time Frequency (Hz) Setting Time Loaded Load (Transient Max.) below 288 below 2 sec. below 66 below 8 sec. Load 240±3-60±0.1 - Load Loaded (Transient Min.) over 192 below 2 sec. over 54 below 8 sec. Loaded 240±3-60± Inspection & Adjustment (1) Printed Circuit Board (Main controller) Fuse 5A Adjust as per following after replaced the main controller. Condition Hz at no load 2. Turn the voltage selector in the front panel to MAX position. 3. Dial the VRD that locates in the printed circuit to the middle position. Criterion: (1-phase):255±2V 1. Otherwise, adjust the VRE volume until it shows 255±2V. 2. Apply the screw adhesive on the thread of the VRF, VRE and VRD volume after adjusted. (2) Printed Circuit Board Follow to the procedure after replacing the printed circuit. 1. Initial setting of the DIP Switch at delivery from a factory is as illustrated below. L LED (Red) DIP Switch S4 S3 S2 S1 S1:ON S2:OFF S3:OFF S4:ON 28

32 Initial Setting at Delivery from FACTORY S1: set (ON/OFF) S2: timer (10 sec./5 sec.) S3: Crank timer (10 sec./5 sec.) S4: timer set during crank timer is working. (ON/OFF) 2. The LED lamp should turn to ON or blink; ON: when the engine start failed three times during detecting the over cranking. Blink: when the generating voltage is not detected but the engine rpm has detected. (3) Check the Main Circuit Breaker (1-phase) U W 1. Shut off engine. Turn the main circuit breaker OFF. 2. Check the resistance with a ohmmeter between upper terminal and lower terminal of; Upper Terminal Lower Terminal U U W W The ohmmeter should display the symbol of infinity,, or similar per the ohmmeter that you may use. U W 1. Shut off engine. Turn the main circuit breaker ON. 2. Check the resistance with a ohmmeter between upper terminal and lower terminal of; Upper Terminal Lower Terminal U U W W The ohmmeter should display approx. 0.1 ohms. 29

33 (4) Check the Adjusting Voltage Regulator 1. Shut off engine. Disconnect the CN17 connector in the adjusting voltage regulator. 2. Turn the adjusting voltage regulator knob counter-clockwise to the end. 3. Connect the lead to the terminal #1(White / Yellow wire) and #2 (White / Blue wire) in the CN17 connector as shown in the picture below. te: Use the ohmmeter. Reading Resistance: 1kΩ 4. Turn the adjusting voltage knob slowly clockwise while reading the resistance in a display of the ohmmeter. #1 #2 5. Turn the knob fully clockwise and check the resistance. Reading Resistance: approx. 0.1Ω (5) Inspect the Volt meter ELECTRIC SHOCK WARNING Never touch the terminals during operation. Measure the voltage of the volt meter. 1) Start engine. 2) Connect the probe of the tester to the terminals in the back of the volt meter and measure the voltage among the terminals. 3) The volt meter is a malfunctioning if the 4) needle of the meter does not deflect. 30

34 (6) Inspect the Diode Function: convert AC (alternating current) to DC (direct current). Electric current flows Anode Cathode Anode Cathode Electric current does not flow. 1 2 Measurement ranges for diode. 1) Insert the red probe, positive (+), to the Anode and the black prove, negative (-), to the Cathode. Display shall show 0.6V, 2) Insert the black probe, negative (-), to the Anode and the red prove, positive (+), to the Cathode. Display shall show 2.6V. 31

35 7. Trouble Shooting 7-1 Engine <Pre-check> Always check engine oil, coolant, and fuel before processing to trouble shooting and Refill if any of those are below the required level. (1) Engine does not start. Does the starter motor run? Low battery voltage. Add the distilled water if insufficient. Deteriorated battery. Replace the battery. Disconnected or loosen battery terminal. Reconnect or retighten the terminal. Corroded battery terminal. Clean the battery terminal. Defect the starter switch or starter relay. Replace the starter switch or starter relay. Defect starter motor. Replace the starter motor. Defect the engine control unit. Replace the engine control unit. Is the starter motor running? Empty fuel. Clogged the fuel filter. Clogged the gauze filter. Refuel. Clean or replace the fuel filter. Clean or replace the gauze filter. Water in the fuel line. Drain water in the water separator, fuel filter or fuel tank. 32

36 Air in the fuel line. Vent air in the fuel line. Incorrectly it connected to the external tank. Connect with the internal tank. (Ref. P.15) The 3-way valve has turned to the incorrect direction. Check the 3-way valve direction. Defect the fuel pump. Check/Replace fuse. (Ref. P. 11) Check/Replace the fuel pump. Defect the solenoid. Check/Replace fuse. (Ref. P. 11) Replace the solenoid. Fuel lever at CLOSE position. Position the fuel lever to OPEN. Is the ambient temp. below 32 F (0 )? Frozen fuel. Defrost and drain fuel. Replace to the winter fuel. Frozen water in the fuel line. Drain water in of the fuel line. Replace the fuel line if deformed. Defect the glow plug. (Ref. P. 12) Replace the glow plug. (2) Engine suddenly stop. Engine suddenly stopped. Clogged the fuel filter. Clean or replace the fuel filter. Clogged the gauze filter. 33 Clean or replace the gauze filter if necessary.

37 Water in the fuel line. Drain water in the water separator, fuel filter or fuel tank. Air in the fuel line. Vent the air. (Ref. owner s manual, P26) Incorrectly it connects to the external tank. Insufficient engine oil. Clogged the air filter element. Defect emergency operation and detection. Connect the internal tank. (Ref. P.15) Replace the air filter element. Add engine oil. Refer to the engine manufacturer s service manual. (3) Engine does not shut off. Engine does not shut off. Defect the solenoid. Turn the fuel lever to CLOSE and shut off the engine. Replace the solenoid. Accessory switch is ON position. (Ref. P. 11) Turn Off the accessory switch. (4) Low oil pressure Is the oil pressure low? Insufficient engine oil. Add engine oil. Clogged the oil filter. Replace the oil filter. Defect the oil pressure switch. Replace the oil pressure switch. 34

38 Defect the oil pressure meter. Replace the printed circuit board. Is the oil pressure lamp ON? Replace oil. (5) Overheating the engine. Is the engine overheating? Defect the thermostat. Replace the thermostat. Defect the water temp. sensor. Replace the water temp. sensor. Defect the water temp. meter. Replace the printed circuit board. Weak tension of the fan belt. Adjust the fan belt. Insufficient coolant. Add coolant. Clogged the radiator core. Clean or replace the radiator if necessary. (6) Engine has black smoke. Black smoke is seen at the exhaust. Clogged the air filter element. Replace the air filter element. Defect the fuel injection nozzle. Replace the fuel injection nozzle. Dirt or oxidaized fuel. Replace by the new fuel. 35

39 (7) Engine has white smoke. White smoke is seen at the exhaust. Excessive engine oil in the oil pan. Ref. the engine manufacturer s service manual. Water in the fuel line. Drain water from the water separator, fuel filter or fuel tank. Defect the fuel injection nozzle. Replace the fuel injection nozzle. Low coolant temperature. Run engine for break-in. Defect the thermostat. Replace the thermostat. 7-2 Generator (1) Volt meter is not working. Is volt meter working? Defect the volt meter. Replace the volt meter. Defect the AVR. Replace the AVR. Is the nut of the terminal disconnected, loosen or separated? Tighten the nut with terminal. Re-test or replace the wire harness. Defect the initial exciter. Replace the exciter stator. Defect the alternator. Replace the alternator. 36

40 (2) Volt meter shows lower than the rated voltage. Is the volt meter working? Defect the voltage meter. Replace the volt meter. Defect the AVR. Replace the AVR. Defect the voltage regulator dial. Replace the voltage Regulator dial. (3) Volt meter shows higher than the rated output. Does volt meter show higher than the rated output at no load? (4) Voltage drops suddenly after loaded. Voltage drops suddenly. Defect the voltage meter. Defect the AVR. AVR Defect has the failed. AVR. Replace the voltage meter. Replace the AVR. Replace the AVR. Is unbalanced load among the each terminal? Is the total current of the equipment bigger than the rated current? Balance the load among each terminal. Lower the total current used by the equipment within the rated current. Overloaded. Lower the total load within the rated output. (5) Breaker does not return to ON position. Fuse for AVR is working. Check/Replace fuse. (Ref. P. 28) Breaker does not return to ON position. The breaker lever stays between ON and OFF. Turn the lever to OFF and set it to ON. Is it short-circuited? Check and lower the load as necessary. 37

41 8. Periodical Check Consult Service Dealer Engine Generator Others Description Each parts (Clean/Tightening) Engine oil (Check/Add) Engine oil (Replace) Oil filter (Replace) Coolant (Check/Add) Coolant (Replace/Radiator Flush) Exhaust color (Check) Water separator (Drain excess water and sediments) Fuel filter (Replace) Fuel tank (Drain water) Water separator and Gauze filter (Clean) Fuel tank (Clean) Check for leaks (Fuel/Oil/Coolant) Fuel/Coolant/Oil Hoses and Anti-Vibration Rubber (Replace) Air filter element (Clean/Replace) Battery fluid level (Check/Add) Battery gravity (Check) Fan belt tension (Check) Fan belt (Replace) Radiator and fins (Clean) Valve clearance (Check/Adjust) Fuel injector (Check) Elimination of carbon in the exhaust pipe line and muffler Indicators, Gauges (Check) Alarms (Check) Insulation test Spill containment fluid (Check/Drain) Spill containment (Check/Clean) User Check Daily Every 100 hrs 1 st time at 50 hrs 1 st time at 50 hrs (Clean) 1 st time at 50 hrs Every 200 hrs 1 st time at 50 hrs 1 st time at 50 hrs Every 400 hrs Every 450 hrs Every 500 hrs once in 6times cleaning or 1year (Replace) or 2years (Clean) Every 800 hrs Every 1000 hrs or 2years Every 1500 hrs or 2years 38

42 9. Tightening Torque 9-1 Specific Tightening Torque menclature Part to be tighten Size 1 Socket ~ Oil Pan Nipple M22 x Qty Torque Allowance Nm(kgf/cm) ( ) 2 Nipple ~ Engine Nipple R1/8 1-3 Elbow ~ Nipple Elbow Rc1/ Male Nipple 1/8 ~ Elbow Sensor ~ Male Nipple 1/8 Engine Stay ~ Engine Rotor ~ Engine (flywheel side) Male Nipple 1/8 R1/8 1 - Reference Install as the pipe outlet faces downward with a 15 limit. Put lubricant oil in the gasket surface. Ref: Fig.1 Use a liquid gasket. (#TB1207B) Ref: Fig.2 Use a liquid gasket. (#TB1207B) Attention to the direction for installation of the elbow. Ref: Fig.2 Use a liquid gasket. (#TB1207B) Ref: Fig.2 Sensor NPT1/8 1 - Ditto Ref: Fig.2 Bolt M12x1.25x30 6 Bolt M8x30 (8T) 8 8 Stator ~ Engine Bolt M10x30 (8T) 8 9 Exhaust Pipe ~ Engine Nut, 8 M Panel ~ Front Door Nut, 5 M Drain Plug ~ Socket Drain Plug M12x1.25x Fuel Pump ~ Bonnet Stay ( ) ( ) ( ) ( ) (21-29) ( ) Elbow ~ Valve Elbow Nipple ~ Valve Nipple Nipple ~ Socket Nipple Drain Plug ~ Socket Drain Plug Drain Plug ~ Valve Drain Plug R1/ ( ) ( ) 18 Valve ~ Guard Valve Drain Plug ~ Guard Drain Plug R ( ) Insert the packing. Attention to the direction for installation of the fuel pump. Ref: Fig.3 Put a Loctite #638. Wipe off the excessive adhesive. Attention to the direction for installation of the elbow. Ref: Fig.4 Put a Loctite #638. Wipe off the excessive adhesive. Ref: Fig.4 Put a Loctite #638. Wipe off the excessive adhesive. Ref: Fig.5 Put a Loctite #575. Wipe off the excessive adhesive. Ref: Fig.5 Replace the sealing tape. Make a max. 3 wraps on thread. Ref: Fig. 6 Put a Loctite #638. Fasten as the handle positions upward. Wipe off the excessive adhesive. Ref: Fig. 6 Replace the sealing tape. Make a max. 3 wraps on thread. Ref: Fig. 6 39

43 menclature Part to be tighten Size 20 Drain Plug ~ Guard Drain Plug Switch ~ Guard Switch G1/8 2 Qty Torque Allowance Nm(kgf/cm) ( ) (7-10) 22 Valve ~ Socket Valve Nipple ~ Valve Nipple Drain Plug ~ Socket Drain Plug Lead ~ Circuit Protector (50A) Lead ~ Circuit Protector (30A) Lead ~ Circuit Protector (20A) Screw M6x12 4 Screw M6x12 2 Screw M6x ( ) Reference Insert the circular gasket after the lubricant oil is put on it. Ref: Fig. 6 Float Sensor Switch Replace the sealing tape. Make a max. 6 wraps on thread. Use a liquid gasket (#TB1184) Fasten as the handle positions upward. Ref: Fig. 7 Replace the sealing tape. Make a max. 5 wraps on thread. Use a liquid gasket (#TB1184) Ref: Fig. 7 Insert the circular gasket after the lubricant oil is put on it. Ref: Fig. 7 Screws are attached. Cushion will come with the pilot Pilot Lamp ~ lamp for replacement but do Operational Panel not use the cushion. Put an adhesive. (TB PANDO) te: Refer to the following General Tightening Torque for the general torques that are not specified above. Fig. 1 Ditto Ditto Position the pipe within 15 degrees to avoid contact with the oil pan. Socket Fig. 2 Gasket 40 Nipple

44 Oil Pressure Sensor Apply a liquid gasket #TB1207B Male Nipple 1/8 Elbow Attention to the direction of the installation. Nipple 41

45 Fig. 3 Stay Bonnet Fuel Filter Fuel Pump Attention to direction. Gauze filter Fig.4 Fig.5 Nipple Elbow Nipple Put Loctite #575 Put Loctite #638 Put Loctite #638 Put Loctite #638 Put Loctite #638 Put Loctite #638 Socket Plug Nipple Valve (To change fuel supply.) Elbow 42

46 Fig.6 Circular Gasket Valve Apply lubricant oil. Drain Plug FIG.4 FIG.5 Put Loctite #638 Turn for fastening. Drain Plug Replace sealing tape. Make a max. 3 wraps on thread. Drain Plug (Valve side) Fig.7 Valve Make a max. 5 wraps on thread. Use a liquid gasket (#TB1184) Nipple Make a max. 6 wraps on thread. Use a liquid gasket (#TB1184) Socket ここまで Circular Gasket Drain Plug Insert the nipple to the valve Insert the socket to the valve. 43

47 9-2 General Tightening 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) minal Designation M3 0.5 minal 0.6 {6} Tightening Torque Allowance Limit 0.5 ~ 0.8 {5 ~ 8} Tightening Strength N{kgf} 845 {86} minal 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) 44

48 10. Print Circuit Board *To customize the setting of the DIP switch..1 DIP Switch Setting S1 S2 S3 S4 OFF OFF OFF OFF Timer Crank Timer timer with crank timer run. OFF 5 sec. 5 sec. OFF Accessory Switch (See p.11) Cranking.2 S1 S2 S3 S4 ON OFF OFF OFF Timer Crank Timer timer with crank timer run. ON 5 sec. 5 sec. OFF Accessory Switch Cranking.3 S1 S2 S3 S4 OFF ON OFF OFF Timer Crank Timer timer with crank timer run. OFF 10 sec. 5 sec. OFF Accessory Switch Cranking.4 S1 S2 S3 S4 ON ON OFF OFF Timer Crank Timer timer with crank timer run. ON 10 sec. 5 sec. OFF Accessory Switch Cranking.5 S1 S2 S3 S4 OFF OFF ON OFF Timer Crank Timer timer with crank timer run. OFF 5 sec. 10 sec. OFF Accessory Switch Cranking.6 S1 S2 S3 S4 ON OFF ON OFF Timer Crank Timer timer with crank timer run. ON 5 sec. 10 sec. OFF Accessory Switch Cranking 45

49 .7 DIP Switch Setting S1 S2 S3 S4 OFF ON ON OFF Timer Crank Timer timer with crank timer run. OFF 10 sec. 10 sec. OFF Accessory Switch (See p.11) Cranking.8 S1 S2 S3 S4 ON ON ON OFF Timer Crank Timer timer with crank timer run. ON 10 sec. 10 sec. OFF Accessory Switch Cranking.9 S1 S2 S3 S4 OFF OFF OFF ON Timer Crank Timer timer with crank timer run. OFF 10 sec. 5 sec. ON Accessory Switch Cranking.10 (STD set at delivery from factory) S1 S2 S3 S4 ON OFF OFF ON Timer Crank Timer timer with crank timer run. ON 5 sec. 5 sec. ON Accessory Switch Cranking.11 S1 S2 S3 S4 OFF ON OFF ON Timer Crank Timer timer with crank timer run. OFF 10 sec. 5 sec. ON Accessory Switch Cranking.12 S1 S2 S3 S4 ON ON OFF ON Timer Crank Timer timer with crank timer run. ON 10 sec. 5 sec. ON Accessory Switch Cranking 46

50 .13 DIP Switch Setting S1 S2 S3 S4 OFF OFF ON ON Timer Crank Timer timer with crank timer run. OFF 5 sec. 10 sec. ON Accessory Switch (See p.11) Cranking.14 S1 S2 S3 S4 ON OFF ON ON Timer Crank Timer timer with crank timer run. ON 5 sec. 10 sec. ON Accessory Switch Cranking.15 S1 S2 S3 S4 OFF ON ON ON Timer Crank Timer timer with crank timer run. OFF 10 sec. 10 sec. ON Accessory Switch Cranking.16 S1 S2 S3 S4 ON ON ON ON Timer Crank Timer timer with crank timer run. ON 10 sec. 10 sec. ON Accessory Switch Cranking 47

51 11. Wiring Diagram 48

52 49

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