SERVICE MANUAL. File DGO-331_DGK45FU

Transcription

1 SERVICE MANUAL File DGO-331_DGK45FU

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 DGK45FU. 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 equipments without prior notice, and without obligation to make alterations to equipments previously manufactured. For service of the engine, refer to Workshop (Service) Manual provided by the engine manufacturer described below. MANUFACTURER ISUZU MODEL 4LE2X

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 Service Data Technical Specification Generator Trouble Shooting Generator Inspection & Adjustment Check Winding Resistance Periodical Check for Engine Tightening Torque Specific Tightening Torque General Tightening Torque Engine Error Code Error Code (Digital Display) Error Code (By Monitor Lamp Flash) After Repair Wiring Diagram Engine Error Code Chart 43

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 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

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 By 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. 2 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 make 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.

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! STSTOP 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. No 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 DGK45FU Generator Type - Revolving Field Brushless Rated Frequency Hz 60 Rated Output(Prime) Three phase kva 45 kw 36 Single phase kva 27 [13.5] *1 kw 27 [13.5] *1 Standby Output Three phase kva 50 kw 40 Single phase kva 30 [15] *1 kw 30 [15] *1 Rated Voltage Three phase V 208/240/ [480] *1 Single phase V 120/139/240/[277] *1 Three phase-208v A 108 Three phase-240v A 108 Rated Current Three phase-480v A 54 Single phase-120v A [56.3 x 2]*1 Single phase-240v A [56.3]*1 Power Factor - Three phase 0.8, Single phase 1.0 Insulation class - F Excitation - Self Excitation (brushless) No. of Poles - 4 Type - Vertical Water-Cooled 4-Cycle Diesel Model(Manufacturer) - 4LE2X(ISUZU) No. of Cylinders (bore stroke) (in./mm) 4(3.35x3.78/85x96) Continuous Rated Output hp 59 Rated Speed rpm 1800 Displacement cu.in./liters 133/2.179 Combustion System - Direct injection (Turbo-charged) Cooling Method - Water cooled Starting Method - Electric Fuel - No.2-D,S15 EPA regulation Lubricating Oil - API service-type CJ-4 class Fuel Tank Capacity gal./liters 79/300 Lubricant Volume gal./liters 3.0/11.5(including filter 0.1/0.5) Cooling Water Volume gal./liters 2.9/11(including sub-tank 0.4/1.5) Starting Motor Capacity V-kW Charging Alternator Capacity V-A Battery Capacity V-Ah Length in./mm 83/2,100 Width in./mm 37/950 Height in./mm 61/1,550 Dry Weight lbs./kg 2,635/1,195 Net Weight lbs./kg 3,262/1,480 *Outputs shown in above *1 are when the voltage selector switch is set at 480V. **Specifications subject to change without notice. 4

8 4. General 4.1 Appearance 4.2 Dimension Unit: mm. 5

9 EXHAUST GAS OUTLET WATER INLET AIR OUTLET 6

10 5. General Parts Description 5.1 Equipment 7

11 8

12 9

13 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. Engine Model Engine Serial Number 10

14 5.3 Main Component Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Voltage Meter Feature: Display the output voltage from the generator. Ampere Meter Feature: Display the output current from the generator. Frequency Meter Feature: Display frequency of the generator. Serial Number Plate Voltage Adjust Dial Feature: A dial to adjust voltage. 1-Phase Circuit Breaker Feature: Protect an electrical circuit from damage by overload or short circuit. Voltage Selector Switch Feature: Switch to change voltage. Ampere Meter Selector Switch Feature: select the output current. Breaker Trip Selector Switch Feature: select the tripping order due to short-circuit or overload. 3-Phase Circuit Breaker Feature: Protect an electrical circuit from damage by overload or short circuit. Engine Operation Switch Refer to pages 12 & 38. ECM (Engine Control Module) Feature: Control engine in accordance to emission standard. AVR 11

15 Engine Operation Switch Table Nomenclature Function Remarks ISOCHLONOUS Maintain rated speed (1800 rpm) automatically at any load factor. SPEED INC. Increase rpm. per 10 sec/hz. Increase up to 110% of rated rpm. Speed Manual switch ON. SPEED DEC. Decrease rpm. per 10 sec/hz. Decrease down to 1000rpm. Speed Manual switch ON. 1. Starter Switch ON. 2. Push Memory Clear switch for 3 sec. 3. Memory Clear switch ON. MEMORY CLEAR Clear record of the engine fault. 4. Turn Starter Switch STOP and, after10 sec., turn the switch to RUN. Refer to How to clear Trouble Code in Engine Troubleshooting Manual prepared by Isuzu for details. EGR Valve Common Rail Fuel Supply Pump Oil Cooler Oil Filter 12

16 Main Fuel Filter Pre Fuel Filter 3-Way Valve 3-Way Valve Feature: Valve to change fuel supply from a built-in or external tank. 3-Way Valve Lever Position B Position A 3-Way Valve Position A (to use a built-in fuel tank) Position a 3-way valve lever to UPWARD to use fuel from the external fuel tank. Position B (to use an external fuel tank) Position a 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. 13

17 Standard Accessory 1 Owner s Manual 2 Engine Warranty Manual 3 Starter Key 1 copy 1 copy 1 set (2 pcs) 14

18 6. Service Data ELECTRIC SHOCK WARNING Never touch the output terminal during operation to avoid electric shock. Always stop engine and remove the starter key before and during a service maintenance. Stop engine before you will start any maintenance! 6.1 Technical Specification Insulation Preheat time Items Reference Value Note Armature winding Exciter field 3MΩ or more Approx. 10 sec. with coolant temperature -20 (-4 F) and approx. 0.5 sec. with coolant temperature 30 (86 F) Min. rpm at no load 1000 min -1 Max. rpm at no load 60Hz: 1800 min -1 Lubricant oil pressure 0.2~0.6MPa{2~6kgf/cm²} DC500V Megger Tester Automatic preheating system Coolant temperature Frame temperature limit Sealed bearing temperature limit 75~90 (167~194 F) within 80 (212 F) Speed regulation Momentary within 10% Steady-state deviation within 5% Momentary within 20% Voltage regulation Steady-state deviation within 1.0% Frequency Rated: 60 Hz Idle: 33.3 Hz Variable voltage 195~255V Protective device 1 Low oil pressure Working Pressure 0.98MPa{1.0kgf/cm²} Engine Stop 2 High water temp. Working Temperature 100 (212 F) Engine Stop 3 Over Speed - above 2070 min -1 Engine Stop 15

19 6.2 Generator Thermo label Rear bracket Main stator Thermo label Bolt Exciter armature Exciter stator Main bearing Rotor Exciter field Armature Fan cover Stator Rotor 16

20 (1) Exciting Amperage Amperage fluctuates based upon the winding temperature. Following is for reference only. Frequency/Rated Output Load Exciting Amperage (Measured) 3-Phase 60Hz: 36 kw No load 0.5A Full load( power factor=1.0) 0.7A (2) Resistance Value Nominal resistance of the winding is tolerated within ± 10% at 20 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. Generator Exciter Stator Rotor Stator Rotor Armature Exciter Winding Exciter field J (Gray)-K (Purple) Armature Between 1-10, 11-N 2-20, 21-N 3-30, 31-N A B B C C A - U-V V-W W-U 0.09Ω 0.9Ω 5.3Ω 22.4Ω 0.66Ω [Color Code] (B) (W) (R) (G) (Y) (Br) (L) (Or) (Gr) Black White Red Green Yellow Brown Blue Orange Gray Rotor Exciter Field Stator Armature Rotor Armature Exciter Stator Stator Exciter Winding 17

21 7. Trouble Shooting 7.1 Generator <Pre-check> Always check the volume of engine oil, coolant, and fuel before processing to trouble shooting, and refill if any of those are below a required level. Problem Possible Cause Inspection Remedy No output voltage. 1. Faulty volt meter. 2. Faulty generator. 1. Check the volt meter voltage. 2. Verify the exciting amperage and resistance value. 1. Replace the volt meter. 2. Replace the generator. (ref: pages 8 & 11) No voltage increase 1. Faulty volt meter. 2. Faulty generator. 1. Check the volt meter voltage. 2. Verify the exciting amperage and 1. Replace the volt meter. 2. Replace the generator. the value of resistance. (ref: pages 8 & 11) 3. Faulty AVR or voltage 3. Check wire cables if damaged, 3. Repair or replace the parts. adjuster. loosen or disconnected. 4. Adjust engine speed to 4. Slow rotation. 4. Check the rotation speed of the meet criteria. (ref: page 4) engine. 5. Replace wire. 5. Faulty initial 5. Check wire if damaged or loosen, excitation. High output voltage. 1. Faulty volt meter. 1. Check the voltage of the volt meter 1. Replace the volt meter. 2. Faulty adjusting AVR. 2. Check the dial in the [VOLT ADJ] 2. Adjust the voltage properly. in the AVR. 3. Broken wire, loose 3. Check wiring of voltage adjuster. 3. Inspect and repair the or disconnected cable. cable of the voltage adjuster circuit. Abnormal frequency 1. Unbalanced load. 1. Check the amperage of each 1. Balance the current. or voltage drop 2. Low engine speed. phase. when load is 2. Check engine speed. 2. Adjust engine speed. increased. 3. Over load. 3. Check amp. in each each phase. 3. Decrease the load. Circuit breaker does not function. 1. The breaker lever positions between ON and OFF. 1. Check the breaker lever position. 1. Turn the lever to OFF first and set it to ON to reset. 18

22 7.2 Inspection & Adjustment (1) AVR Check the fuse if it blows. Replace the fuse (5A) if it blowed. Follow to the procedure when the AVR is replaced. 1. Turn the output selector switch to 240/139V. 2. Turn the voltage adjusting dial to MAX. 3. Turn the VRD volume counter-clockwise to the end. 4. Adjust the VRD to read 255±2V as 3-phase output voltage. 5A FUSE 19

23 (2)Testing Main Circuit Breaker L1 L2 L3 1. Shut off engine. Turn the main circuit breaker OFF. 2. Check the resistance by a ohmmeter between upper terminal and lower terminal of; Upper Terminal L1 L2 L3 Lower Terminal L1 L2 L3 The ohmmeter should display the symbol of infinity,, or similar per the ohmmeter that you may use. 1. Shut off engine. Turn the main circuit breaker ON. 2. Check the resistance by a ohmmeter between upper terminal and lower terminal of; Upper Terminal L1 L2 L3 Lower Terminal L1 L2 L3 The ohmmeter should display approx. 0.1 ohms. 20

24 (3) Check the Adjusting Voltage Regulator 1. Shut off engine. Disconnect the CN38 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 and #2 (white/blue wire) in the CN38 connector as shown in the picture below. Note: Use the ohmmeter. Reading Resistance: 1kΩ 4. Turn the adjusting voltage knob slowly clockwise while reading the voltage in display of the ohmmeter. Voltage should increase, and, then, it turns decrease slowly and steadily. 5. Turn the knob clockwise to the end and check the resistance. Reading Resistance: approx. 0.1 kω 21

25 (4) Check Voltage Switch Selector The black dot ( ) in the diagram below indicates that each number of the voltage is conducted. Selected Voltage The black dot would indicate that #23 and #24 are conducted Confirm if it is conducted or not per the above diagram. Each number is indicated. 22

26 7-3 Check Winding Resistance (1) Main Stator Check resistance of the lead wires (#10, #11, #20, #21, #30 & #31) that are connected with the voltage selector switch. Measure the resistance with the lead wires removed from the voltage selector switch. Right View Left View Remove the lead wires (#1 through #3) from the upper in the breaker and measure resistance. Use a low resistance tester only. Measure the resistance among the 1~10, 2~20, 3~30, 11~N, 21~N and 31~N by the low ohm tester. Each shall be 0.09Ω. 23

27 (2) Excitation Winding (Stator) AVR A (Br) B (Y) C (Or) 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 0.9Ω. 24

28 (3) Exciter Field (Rotor) Remove the varnish by a sand paper and measure; the resistance among the two points as shown in the photo above by the low ohm tester. It shall be 5.3Ω. (4) J (Gray)-K (Violet) K (Vi) J (Gr) Measure resistance among the J~K by the low ohm tester. It shall be 22.4Ω. 25

29 (5) Armature (Rotor) U V W Remove the varnish by a sand paper and measure; Measure resistance among U~V, V~W and W~U by the low ohm tester. Each shall be 0.66Ω. 26

30 8. Periodical Check for Engine Consult Service Dealer User Check Description Daily Every 100 hrs Each parts (Clean/Tightening) Engine oil (Check/Add) Engine Generator Others Engine oil (Replace) Oil filter (Replace) Coolant (Check/Add) Coolant (Replace/ Radiator Flush) Exhaust color (Check) Water separator (Check/Drain excess water and sediments) Main & Pre-fuel filter (Replace) Electric fuel pump filter (Replace) Fuel tank (Drain water) Water separator and Gauze filter (Clean) Fuel tank (Clean) Check for leaks (Fuel/Oil/Coolant) Fuel hose (Replace) Air cleaner element (Clean/Replace) Battery fluid level (Check) Battery gravity (Check) Fan belt tension (Check) Fan belt (Replace) Radiator and fins (Clean) Valve clearance (Check/Adjust) Fuel injector (Check) Supply pump (Check) Oil separator filter (Replace) Indicators, Gauges (Check) Alarms (Check) Insulation test Spill containment fluid (Check/Drain) Spill containment (Check/Clean) 1 st time at 50 hrs 1 st time at 50 hrs (Clean) Every 200 hrs (Drain) Every 400 hrs (Replace) (Replace) Every 500 hrs (Clean) Every 800 hrs Every 1000 hrs (Replace) Every 1500 hrs Every 3000 hrs 27

31 9. Tightening Torque 9.1 Specific Tightening Torque No Nomenclature 1 Drain Plug~Socket Part to be tighten Drain Plug Size Qty M Hose Joint~Oil Pan Eye Bolt M Panel~Front Door Nut, 5 M5 2 4 Stay~Engine Bolt M10x Spacer~Stator Bolt M10x Spacer~Engine Bolt M10x Rotor~Engine 10 Bolt M10x Stud Bolt 12~Inst. Plate Stud Bolt 8r~Inst. Plate Exhaust Pipe~Engine Exhaust Pipe~Muffler Nut 12 M12 7 Nut 8 M8 1 Nut 8 M8 3 Bolt, Nut M U Bolt~Stay Nut 8 M Pipe~Fuel Filter Bolt, eye M14x Pipe~Fuel Filter Bolt, eye M14x Fuel Pump~Holder, strainer Torque Allowance Nm(kgf/cm) ( ) ( ) (21-29) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) , 17 Joint~Oil Strainer Joint G-3/ Hose 14~Joint Hose 14 G-3/ Air Cleaner~Band, cleaner 20 Drain Plug~Engine - - Drain Plug M ( ) ( ) ( ) Reference Install O-ring in the groove with lubricant oil. Ref: Fig.16. Install O-ring in the groove with lubricant oil. Attention to the direction of installation. Ref: Fig.1. Attention to the direction of the bolt and nut. Align and place the U-bolt marked in the muffler and tighten the stay with double nut. Fasten the lower nut with 5N m temporarily and fasten the upper nut with the torque on the left. Ref: Fig. 17 Attention for the pipe direction. Insert the packing in both end of the tube. Apply lubricant. Ref: Fig 2 Attention for the pipe direction. Insert the packing in both end of the tube. Apply lubricant. Ref: Fig. 3 Attention for the direction of the fuel pump.ref:fig. 4 Attention for the direction of the adoptor. Apply lubricant. Ref: Fig. 5, 6 Attention for direction of the pipe installation.ref: Fig.5, 6 Attention for the direction of the air inlet. Ref: Fig. 9, 10 Loosen the plug in the EGR cooler and drain air after a coolant is added. Ref:Fig

32 No Nomenclature 21 Drain Plug~Guard 22 Drain Plug~Valve Part to be tighten Drain Plug Drain Plug Size Qty Torque Allowance Nm(kgf/cm) ( ) ( ) 23 Valve~Guard Valve Drain Plug~Guard Drain Plug Valve~Socket Valve Nipple~Valve Nipple Lead Wire~Cam Switch Bolt M Sensor~Joint Pipe Sensor 3/8-18NPTF ( ) (57-66) ( ) Reference Apply lubricant on the circular gasket and insert. Ref: Fig. 12 Put Loctite #575.Ref: Fig. 13 Put Loctite #635.Fasten as handle positions upright. Ref: Fig. 14. Put Loctite #575. Ref:Fig. 16 Put Loctite #635. Fasten as handle positions upright. Ref:Fig. 16 Put Loctite #635. Ref: Fig. 16 Bots are for the cam switch. 29 Elbow~Valve Elbow Put Locktite #635. Attention for the direction of the elbow installation. Ref: Fig Nipple~Valve Nipple Put Locktite #635.Ref: Fig Nipple~Socket Nipple Put Loctite #635. Ref: Fig Drain Plug~Socket Drain Plug - 2 Put Loctite #635. Ref: Fig Switch~Guard Switch PF1/8 (Resin) (7-10) Install the float sensor. Fig. 1 Hose Joint Installation Attention to the installation direction. Eye Bolt Oil Pan FRONT O ring Use lubricant Oil Drain Eye Bolt Oil Drain Socket REAR 29

33 Fig. 2 Fuel Filter Pipe Fig. 3 Fig. 4 Fuel Filter Fuel Filter Fuel Pump Fuel Pump 30

34 Fig. 5 Adaptor Adaptor Adaptor 31

35 Fig. 6 Follow to the procedure below to install the adaptor. (1 2 3) Nut ENGINE O ring STRAINER Below 1 turn Washer HOSE HOSE Nut Below 1 turn Install the O-ring and washer as shown in above. HOSE Apply lubricant Turn the elbow slowly by hand until it contacts the washer surface, and return the elbow toward direction for loosening until the set position. Do not attempt to turn more than 1 as it may affect intensity of the screw due to the locknut fitting. When fastening more than 1 turn, it may deform the washer and cause for oil leak. Confirm no dirt in the thread, O-ring port and O-ring. Apply lubricant O-ring and the inside of the strainer. Fit the adaptor with a spanner so the set position does not move. Fig. 7 & 8 Put Loctite #635. REAR FRONT Elbow Nipple Put Loctite #635. Put Loctite #635. Nipple Drain Plug Put Loctite #

36 Fig. 9 & 10 Air Cleaner Intake Outlet Air Cleaner Hose Hose & Air cleaner shall be placed in parallel. Air Cleaner Air Cleaner Hose Fig. 11 ENGINE Air Cleaner Plug EGR Cooler Generator 33

37 Fig. 12, 13, 14, 15 Put Loctite #575 Apply lubricant Put Loctite #575 Fasten this nut Put Loctite #575 Fig. 16 Apply lubricant. Socket Valve Drain Plug Fasten this tube to install the nipple with valve. O-ring Put Loctite #635 Fasten this tube to install the valve with socket. Put Loctite #635 Nipple 34

38 Fig. 17 Exhaust Pipe Muffler U Bolt: Place the position marked in the muffler. Bolt Nut Nut 8, upper Nut 8, lower Stay 35

39 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) 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) 36

40 10. Engine Error Code 10.1 Error Code (Digital Display) This unit is equipped with the error code function when engine malfunctions. When engine malfunction detects, monitor lamp illuminates and indicate defect. Engine output monitor and engine monitor panel display error code and engine automatically stops depending upon the type of the malfunction. When monitor function of the engine detects malfunction, the defect number is shown in the engine output monitor. Press the display selector switch to display each error code in the engine output monitor. After error code is displayed each time, the number of malfunction displayed in the engine output monitor decreases. Refer to the Engine Error Code Chart for the details on pages Engine Monitor Display Error Code Display Monitor Lamp Output Monitor Display Display quantity of malfunction Display Selector Switch Display Selector Switch 1) Error code in the engine monitor display shows engine rpm, water temp. and oil pressure when the selector switch is pressed each time. 2) Output Monitor displays number of the malfunction if malfunctioned. Press the selector switch so the engine monitor displays the error code Error Code (by Monitor Lamp Flash) The monitor lamp is located in the front panel and indicates engine malfunction by flash pattern. To check if engine malfunctions; 1) Turn the starter switch ON. 2) Monitor lamp will flash and continues when engine malfunctions. (ref: page 39) Note: The lamp disappears after approx. 3 sec. when engine is not malfunctioned. 37

41 3) When engine malfunctioned; a) Press and hold memory switch in the engine operation switch located in the inside of the front panel. (ref: page 11) b) Current and past records of malfunction are displayed three times in the engine mode display for approx.2.4 sec. Refer to the Engine Error Code Chart for the details on pages Note a. Past record of malfunction is stored in the ECM (Engine Control Module) even after the past malfunction had cured. b. Each engine code displayed in the engine output monitor and engine monitor panel is not identical. c. Monitor lamp does not function when engine is running. d. When malfunction was not detected including the past occasion, the monitor lamp repeats ON & OFF. Monitor Lamp Engine Control Switch locates in the inside of the front panel (ref: page 11) Press and hold the memory clear switch in the engine control switch so current and past malfunction records are displayed. 38

42 Monitor Lamp Flashing when the monitor lamp will blink 3 times for approx sec. and twice shorter, this would mean that the engine code 32 was displayed, for example. Monitor Lamp: ON Monitor Lamp: OFF th digit 1 digit Lightening Pattern of Monitor Lamp when engine code 225 is displayed; t1= approx.0.3 sec. t2= approx. 0.6 sec. t3= approx.1.2 sec. t4= approx. 2.4 sec. Monitor Lamp: ON Monitor Lamp: OFF 100th digit 10th digit 1st digit 10.3 After Repair After malfunction was repaired, eliminate the malfunction from current record in following steps. 1) Turn a starter switch to RUN position. 2) Start engine and run for few minutes. 3) Turn and remain a starter switch to STOP position for more than 30 sec. 4) Turn a starter switch to RUN position. 1-4 Elimination of Past Malfunction The past malfunction record has stored in the ECM (Engine Control Module) even after it was repaired. Follow to the steps below only when the past record of the malfunction needs to eliminate from the ECM. 1) Turn a starter switch to RUN position. 2) Press and hold the memory clear switch. 3) Connect the 1-pin connector (green/blue) with a negative post (-) from the battery for more than 3 sec while the memory clear switch is continued to hold. Warning Always wear a rubber glove before connecting 1-pin connector and battery. 39

43 4) Disconnect the 1-pin connector from the battery and release the memory clear switch. 5) Turn a starter switch to RUN position. 6) When the past record is not display after the memory clear switch is pressed, the elimination work completed. 1-Pin Connector 40

44 41

45 11. Wiring Diagram 41

46 42

47 12. Engine Error Code Chart No. Error Code Blinking in Display Malfunction Detected Item Engine Response No. Error Code Blinking in Display Malfunction Detected Item Engine Response 1 P Pressure Limiter Open Pressure limiter open Automatic Engine Stop 31 P060B 36 A/D transmission Abnormal A/D transmission Automatic Engine Stop 2 P Common Rail Pressure 3 P Disconnected SCV Transmission, Short-circuited grounding 4 P Short-circuited SCV+Battery Abnormal increase of common rail pressure Disconnected or short-circuited SCV & harness Short-circuited SCV & harness Automatic Engine Stop 32 P Voltage #1 (5V) Automatic Engine Stop 33 P Voltage #2 (5V) Automatic Engine Stop 34 P Voltage #3 (5V) Short-circuited power wiring to sensor, ECM for power regulation and damaged circuit Short-circuited power wiring to sensor, ECM for power regulation and damaged circuit Short-circuited power wiring to sensor, ECM for power regulation and damaged circuit Automatic Engine Stop Automatic Engine Stop Automatic Engine Stop 5 P Low Common Rail Pressure Common rail pressure low. Fuel leakage. Automatic Engine Stop 35 P06AF 277 Injector IC Check sum & bypass Automatic Engine Stop 6 P P Intake Temp. Sensor (Low Voltage) Intake Temp. Sensor (High Voltage) Short-circuited, damaged sensor or harness. Short-circuited or damaged sensor or harness. Automatic Engine Stop 36 P Low Pressure of Common Rail (pump pressure short) Automatic Engine Stop 37 P Charge Circuit Common rail pressure low. Fuel leakage.. ECM charge circuit #1 (burn inside or disconnected) Automatic Engine Stop Automatic Engine Stop 8 P Water Temp. Sensor (Low Voltage) Short-circuited sensor or harness. Automatic Engine Stop 38 P Charge Circuit ECM charge circuit #2 (burn inside or disconnected) Automatic Engine Stop 9 P Water Temp. Sensor (High Voltage) Short-circuited or broken sensor or harness. Automatic Engine Stop 39 P EGR (zero point) Value at zero point was out of specified range No engine start 10 P P P Fuel Temp. Sensor (Low Voltage) Common Rail Pressure Sensor (Low Voltage) Common Rail Pressure Sensor (High Voltage) 13 P Cylinder (#1) Injector Circuit 14 P Cylinder (#2) Injector Circuit Short-circuited, damaged sensor or harness. Short-circuited sensor or harness. Short-circuited or broken sensor or harness. Disconnect electric wiring of cylinder (#1) injector Disconnect electric wiring of cylinder (#2) injector Automatic Engine Stop 40 P160B 36 ADIC Damaged AD-IC circuit Automatic Engine Stop Automatic Engine Stop 41 P Voltage #4 (5V) Automatic Engine Stop 42 P Jet Nozzle (common 1) Automatic Engine Stop 43 P Jet Nozzle (common 2) Automatic Engine Stop 44 P Air Pressure Sensor (Low Voltage) Short-circuited power wiring to sensor, ECM for power regulation and damaged circuit Disconnect, short-circuited power wiring for common rail #1 of injector, abnormal ECM output Disconnect, short-circuited power wiring for common rail #2 of injector, abnormal ECM output Short-circuited, damaged sensor or harness Automatic Engine Stop Automatic Engine Stop Automatic Engine Stop Automatic Engine Stop 15 P Cylinder (3#) Injector Circuit Disconnect electric wiring of cylinder (#3) injector Automatic Engine Stop 45 P Air Pressure Sensor (High Voltage) Short-circuited, damaged sensor or harness Automatic Engine Stop 16 P Cylinder (#4) Injector Circuit Disconnected electric wiring of cylinder (#4) injector Automatic Engine Stop 46 P256A 31 Idle Switch (up/down) "Idle" & "Run" switch simultaneously ON Low engine rpm. (1000 rpm.) 43

48 No. Error Code Blinking in Display Malfunction Detected Item Engine Response No. Error Code Blinking in Display Malfunction Detected Item Engine Response 17 P Over Heat Abnormal increase of water temp. Automatic Engine Stop 47 U CAN Bus Abnormal CAN transmission Automatic Engine Stop 18 P Over Run Abnormal engine rpm. Automatic Engine Stop Can Sensor Phase Installation of cam gear/crank shaft (angular mis-alignment) or damaged Engine continues to run 19 P Boost Pressure Sensor (Low Pressure) Short-circuited, damaged sensor or harness. Automatic Engine Stop Temp. Sensor (Low/High Voltage) Short-circuited, disconnected, damaged sensor or harness Engine continues to run 20 P Boost Pressure Sensor (High Pressure) Disconnected, damaged sensor or harness. Automatic Engine Stop Fuel Temp. Sensor (High Voltage) Disconnected, damaged sensor or harness Engine continues to run 21 P Crank Sensor (No Signal) Disconnected sensor & wiring Automatic Engine Stop Cam Sensor Broken tooth of the crank or contamination other signal Engine continues to run 22 P Crank Sensor (Abnormal Signal) 23 P EGR Valve Control 24 P EGR Position Broken tooth of the crank or contamination other signal malfunctioned, disconnected driving motor, valve blocking & sticking Short-circuited, disconnected, broken sensor or harness. Automatic Engine Stop Glow Relay Automatic Engine Stop Battery Voltage (High) Automatic Engine Stop QR Cord Short-circuited, disconnected, damaged rely or harness Short-circuited, disconnected or damaged harness Incomplete writing of QR code, Data Q Engine continues to run Engine continues to run Engine continues to run 25 P Low Oil Pressure Engine oil leakage Automatic Engine Stop Starter Relay - Cut Short-circuited, disconnected, damaged rely or harness Engine continues to run 26 P Oil Pressure Sensor (Low Voltage) Short-circuited, damaged sensor or harness Automatic Engine Stop Main Relay Damaged, short-circuited harness, relay ON (sticking). Disconnected harness, short-circuited GND, Relay OFF (sticking) No engine stop/start 27 P Oil Pressure Sensor (High Voltage) Short-circuited, damaged sensor or harness Automatic Engine Stop Boost Temp. Sensor (Low/High Voltage) Short-circuited, disconnected, damaged sensor or harness Engine continues to run 28 P ROM Abnormal ROM Automatic Engine Stop EEPROM Abnormal EEPROM Engine continues to run 29 P RAM Abnormal RAM Automatic Engine Stop P CPU Abnormal CPU Automatic Engine Stop

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