SERVICE MANUAL. File DGO-571_DGK70F

Transcription

1 SERVICE MANUAL File DGO-571_DGK70F

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 DGK70F. 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: ISUZU Diesel Engine 4JJ1 WORKSHOP MANUAL #IDE-2730 ) MANUFACTURER ISUZU MODEL 4JJ1X

3 Table of Contents 1. Attention Statement 1 2. General Safety Instructions 2 3. Specifications 3 4. General Appearance Dimension 4 5. General Parts Description Equipment Operation Panel Configuration 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 General Tightening Engine Error Code Error Code (Digital Display) Error Code (Flash Pattern) After Repair Elimination of Past Malfunction Wiring Diagram Engine Error Code Chart 49

4 1. Attention Statement 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. 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 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 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.

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. 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. 2

7 3. Specifications Alternator Engine Unit Model Unit DGK70F Generator Type - Revolving Field Brushless Rated Frequency Hz 60 Rated Output (Prime) Three phase kva 70 kw 56 Single phase kva 42 [21] *1 kw 42 [21] *1 Standby Output Three phase kva 77 kw 61.6 Single phase kva 46.2 [23.1] *1 kw 46.2 [23.1] *1 Rated Voltage Three phase V 208/240/ [480] *1 Single phase V 120/139/240/[277] *1 Three phase-208v A 168 Three phase-240v A 168 Rated Current Three phase-480v A 84 Single phase-120v A [87.5 x 2]*1 Single phase-240v A 175 [175]*1 Power Factor - Three phase 0.8, Single phase 1.0 Insulation Class - F Excitation - Self-Excitation (brushless) No. of Pole - 4 Type - Vertical Water-Cooled 4-Cycle Diesel Model (Manufacturer) - 4JJ1X (ISUZU) No. of Cylinder (bore stroke) (in./mm) 4 (3.76 x 4.13/95.4 x 104.9) Continuous Rated Output hp 86.5 Rated Speed rpm 1,800 Displacement cu.in./liters 183/2.999 Combustion System - Direct injection (Turbocharged) Cooling - Water cooled Starting - Electric Fuel - No.2-D,S15 EPA regulation Diesel Exhaust Fluid ISO or API standard Lubricating Oil - API Service Classification: CJ-4 class Fuel Tank Capacity gal./liters 106/400 DEF Tank Capacity gal./liters 7.4/28 Lubricant Volume gal./liters 4.1/15.5 (including filter 0.1/0.5) Cooling Water Volume gal./liters 3.7/14 (including sub-tank 0.4/1.5) Starting Motor Capacity V-kW Charging Alternator Capacity V-A Battery Capacity V-Ah Length in./mm 102/2,590 Width in./mm 37/950 Height in./mm 69/1,750 Dry Weight lbs./kg 3,869/1,755 Net Weight lbs./kg 4,773/2,165 *1: Output in the brackets shows when the selector switch set at 480V. **Specifications subject to change without notice. 3

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

9 5

10 5. General Parts Description 5.1 Equipment Radiator Plate Lifting Hook Operation Panel Door Tie-Down Fuel Inlet Cover Inspection/Cleaning Panel Spill Containment Drain Plug Terminal Cover Fuel Drain Plug Spill Containment Drain Valve SCR Check Panel Tie-Down DEF Tank Check Panel Inspection / Cleaning Panel 6

11 DEF Inlet Cover Fan Guard Radiator Intercooler Alternator Check Door Engine Check Door Intercooler Drain Plug Air Cleaner Oil Level Indicator Oil Filler Oil Filter Coolant Sub-Tank Fan Guard Alternator Check Door Engine Check Door Fuel Filter (Pre) Battery External Fuel Inlet External Fuel Return 3-way Fuel Valve Fuel Tank (Inside) Oil Drain Plug Elctromagnetic Fuel Pump Fuel Filter (Main) Coolant Drain Plug 7

12 Muffler (SCR) Dosing Module Supply Module / Filter DEF Tank *Shown with SCR Check Panel and DEF Check Panel removed. 8

13 5-2. Operation Panel Configuration 9

14 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 Number Label (Right on the cylinder cover) EGR Valve Engine Serial Number (stampped) (location: crank case under EGR valve) 10

15 (3) SCR Unit Serial Number 3 Serial # for SCR unit: stamped at 3 locations

16 5.4 Main Component SCR Monitor Lamp Feature: Turns on light per SCR control system. Refer to p.43. Voltage Meter Feature: display output voltage. Ampere Meter Feature: Display the output current. Frequency Meter Feature: display frequency. Monitor Lamp Feature: light a monitor lamp when equipment is malfunctioned. Voltage Selector Switch Feature: select voltage. Serial Number Plate 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. 1-Phase Circuit Breaker Feature: Protect an electrical circuit from damage by overload or short circuit. Voltage Adjusting Dial Feature: adjust voltage. Ampere Meter Selector Switch Feature: select the output current. Engine Operation Button Refer to pages 13, 44 & 46. DCU (Dosing Control Unit) Feature: Control urea water injected from the muffler. ECM (Engine Control Module) Feature: control engine module. AVR (Automatic Voltage Regulator) Feature: regulate the generating output. 12

17 Engine Operation Mode Table Mode Function Remarks Restart the engine that stopped ESCAPE MODE Button (Color: Blue) due to a shortage of urea water Max. 30 min. operation. or caused by SCR system. 1. Press and hold the memory clear button so the engine monitor lamp turns on. 2. Monitor displays the malfunction by a different pattern. MEMORY CLEAR Button (Color: Yellow) Display the malfunction record of the engine today and in the past. When normal: no malfunction record today and in the past. 1. Turn on the engine monitor lamp for 0.3 sec. 2. Turn off the monitor lamp for 25 sec. 3. Above are repeated. When malfunctioned: The monitor lamp will indicate the error type by # of flashing 3 times. Ref. How to clear Trouble Code in Engine Trouble-shooting Manual by Isuzu. Air Cleaner Feature: Clean intake air. Oil Filter Feature: Remove contaminant from engine oil. 3-Way Valve Feature: Change fuel supply from a built-in or external fuel tank. (Not shown in the photo) Fuel Pump Feature: Supply fuel to the fuel pump. (Not shown in the photo) Main Fuel Filter Feature: Filter water and dust in the fuel. Pre Fuel Filter Feature: Filter water And dust in the fuel. 13

18 Common Rail Feature: A high-pressure pump stores a reservoir of fuel at high pressure. EGR Valve Feature: reduce a nitrogen oxide. (NOx) Intercooler Drain Plug Feature: drain water and oil in the intercooler. Fuel Supply Pump Feature: pressurize and supply fuel to the common rail. 3-Way Valve Feature: Valve to change fuel supply from a built-in or external tank. Position A Position B 3-Way Valve Lever 3-Way Valve Position B (to use a built-in fuel tank) Position a 3-way valve lever toward RIGHT to use fuel from a built-in fuel tank. Position A (to use an external fuel tank) Position a 3-way valve lever toward LEFT to use fuel from the external fuel tank. Note The 3-way valve lever is set at position B at delivery from a factory. 14

19 Muffler (*SCR) Feature: purify a nitrogen oxide (NOx) and reduce noise. *SCR: selective catalytic reduction Dosing Module Feature: inject urea water to SCR (*) in the muffler. Heater Feature: increase the bust pressure and maintain the engine output when the inside of the muffler is purged. Module/ Filter Feature: filter urea water and supply urea water to dosing module. DEF (Diesel exhaust fluid) Tank Feature: store urea water. Standard Accessory 1 Owner s Manual 2 Engine Warranty Manual 3 Starter Key 1 copy 1 copy 2 pcs. 15

20 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. 15 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 0.3~0.6MPa{3~6kgf/cm²} DC500V Megger Tester Automatic preheating system Coolant temperature 75~90 (167~194 F) Momentary within 10% Speed regulation Steady-state deviation within 5% Momentary within 20% Voltage regulation Steady-state deviation within 1% Frequency Rated: 60 Hz Idle: 33.3 Hz Variable voltage 195~255V Protective device 1 Low oil pressure Working Pressure 0.048MPa{0.5kgf/cm²} Automatically engine stops. 2 High water temp. Working Temp. 100 (212 F) Automatically engine stops. 3 Over Speed - above 2070 min -1 Automatically engine stops. 16

21 6.2 Generator Rear bracket Main stator Bolt Exciter armature Exciter Main bearing Rotor Exciter field Armature Fan cover Stator Rotor 17

22 (1) Exciting Amperage Amperage fluctuates based upon the winding temperature. Following is for reference only. Frequency/Rated Output Load Exciting Amperage (Measured) No load 0.5A 3-Phase 60Hz: 56 kw 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. A multi-purpose tester shall not be used as it displays incorrectly. 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 Ω 0.73Ω 6.7Ω 25.4Ω 0.68Ω [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 18

23 7. Trouble Shooting 7.1 Generator < 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. Engine does not start Problem Possible Cause Remedy Starter motor does not drive or speed is low. Starter motor operates but engine does not start. Ambient Temp. decreases below 32 F (0 ) Engine starts but stalls immediately. Low oil pressure Overheating 1. Weak output of the battery. 2. Deteriorated battery. 3. Loosen or disconnected a battery terminal. 4. Corroded battery terminal. 5. Defect of the starter switch or relay. 6. Defect of the starter motor. 7. Defect of engine control module. (ECM) 1. Out of fuel. 2. Clogged fuel filter. 3. Water in fuel line. 4. Air in fuel line. 5. Mistakenly connected the internal or external fuel tank. 6. Misconnected the 3-way valve lever. 7. Defect of the fuel pump. 8. Defect of the emergency function. 1. Frozen diesel gas. 2. Frozen water in fuel line. 3. Defect of the preheating function. 1. Clogged by fuel in the fuel filter. 2. Water in the fuel line. 3. Air in the fuel line. 4. Improperly connected with internal or external fuel tank. 5. Clogged the air filter element. 6. Insufficient lubricant oil. 7. Defect of the emergency function. 1. Insufficient lubricant oil. 2. Clogged the oil filter. 3. Defect of the oil pressure switch. 4. Defect of the oil pressure meter. 5. Used high viscosity lubricant oil. 1. Defect of the thermostat. 2. Defect of the water temp. sensor. 3. Defect of the water temp. meter. 4. Loosen the fan belt tension. 5. Low or out of the coolant. 6. Clogged the radiator core. 1. Check battery acid or recharge. 2. Replace battery. 3. Retighten the terminal. 4. Remove the corrosion from the terminal by a sand paper. 5. Replace the starter switch or relay. 6. Replace the starter motor. 7. Replace ECM. 1. Add new fuel. 2. Clean or replace the fuel filter. 3. Drain water in the fuel filter/fuel tank. 4. Bleeding air. 5. Correctly correct the fuel tank connect. 6. Correct the 3-way valve direction. 7. Replace fuel pump and fuse. 8. Replace the fuel pump. 1. Use the winterized fuel. 2. Drain water in the fuel line after melted. 3. Replace the glow plug. 1. Check the fuel line or replace. 2. Drain water in the fuel filter or fuel tank. 3. Bleeding air. 4. Correctly connect the fuel tank. 5. Check or replace the air filter element. 6. Add lubricant oil 7. Inspect each sensor. 1. Add new lubricant oil. 2. Clean or replace the oil filter. 3. Replace the oil pressure switch. 4. Replace the oil pressure meter. 5. Change to low viscosity oil. 1. Replace the thermostat. 2. Replace the water temp. sensor. 3. Replace the water temp. meter. 4. Adjust the fan belt tension. 5. Add new coolant. 6. Clean the radiator core. 19

24 Problem Possible Cause Remedy Black smoke comes from the exhaust. White smoke comes from the exhaust. Volt. meter does not work. Volt. meter does not show the rated voltage. Volt. meter shows higher than the rated voltage. Voltage dropped right after it loaded. Breaker does not trip to ON position. 1. Clogged the air filter element. 2. Defect of the fuel injection nozzle. 3. Improper fuel. 4. Defect of the SCR system. 1. Improper oil supply to cylinder. 2. Water in the fuel line. 3. Defect of the fuel injection nozzle. 4. Coolant temp. too low. 5. Defect of the thermostat. 1. Defect of tue volt. meter. 2. Defect of AVR. 3. Disconnected electric circuit or terminal. 4. Defect of the exciter stator. 5. Defect of the alternator. 6. Defect of AVR. 1. Defect of the volt. meter. 2. Defect of AVR. 3. Defect of the voltage regulator dial. 1. Defect of the volt. meter. 2. Defect of AVR. 3. Used improper cabtyre cable. 4. The volt. selector switch is set at 480V. 1. Defect of AVR. 2. Unbalanced the load distribution to each terminal. 3. Overcurrent. 4. Overloaded. 5. AVR protective device operated. 1. The breaker lever stuck between ON and OFF position. 2. Short-circuited the load. 1. Clean or replace the air filter element. 2. Replace the fuel injection nozzle. 3. Check the fuel octane rating and alcohol contained in the fuel. Refuel as necessary. 4. Replace SCR (muffler). 1. Replace oil by API Service Classification: CJ-4 class 2. Drain water from the fuel filter or fuel tank 3. Replace the fuel injection nozzle. 4. Run engine for break-in under no load. 5. Replace the thermostat. 1. Replace the volt. meter. 2. Replace AVR. 3. Replace the wire harness or terminal. 4. Replace the exciter stator. 5. Replace the alternator. 6. Replace the fuse in the AVR. 1. Replace the volt. meter. 2. Replace AVR. 3. Replace the voltage regulator dial. (ref. p.12 & 23) 1. Replace volt. meter. 2. Replace AVR. 3. Read the operator manual (p. 25) and select the proper selection of the cabtyre cable. 4. Set the selector switch at 240V. 1. Replace AVR. 2. Balance current load to each terminal. 3. Lower the total current to the rated current. 4. Lower the total load the rated current or lower. 5. Replace the fuse in the AVR. 1. Firmly turn the lever to ON position after it has turned to OFF position. 2. Check load if it short-circuits. 20

25 7.2 Inspection & Adjustment (1) AVR Check fuse if it blows. Replace the fuse (5A) if it blows. (see illustration below) Always follow to the procedure when AVR is replaced. 1. Turn the output selector switch to 240/139V. 2. Turn the voltage adjusting dial to MAX position. 3. Turn the VRD volume counter-clockwise to the end. 4. Adjust the VRE volume to read 255±2V as 3-phase output voltage. Note: Do not adjust the VRF dial (see illustratin below) as it affects excitation current. VRF VRD VRE 5A FUSE (2) Check the Main Circuit Breaker (Three phase) L1L2 L3 1. Shut off engine. Turn the main circuit breaker OFF. 2. Check resistance measured by an ohmmeter between upper and lower terminal; Upper Terminal L1 L2 L3 Lower Terminal L1 L2 L3 The ohmmeter shall display the symbol of infinity,, or similar per the ohmmeter that you may use. 21

26 L1L2 L3 1. Shut off engine. Turn the main circuit breaker ON. 2. Check resistance measured by an ohmmeter between upper and lower terminal; Upper Terminal L1 L2 L3 Lower Terminal L1 L2 L3 The ohmmeter shall display approx. 0.1 ohms. (3)Check the Main Circuit Breaker (Three phase) U W 1. Shut off engine. Turn the main circuit breaker OFF. 2. Check resistance measured by an ohmmeter between upper and lower terminal; Upper Terminal U W Lower Terminal U W The ohmmeter shall 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 measured by an ohmmeter between upper and lower terminal; Upper Terminal U W Lower Terminal U W The ohmmeter shall display approx. 0.1 ohms. 22

27 (4) Check the Adjusting Voltage Regulator 1. Shut off engine. Disconnect the CN35 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 CN35 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 resistance in a display of the ohmmeter. Gradually resistance shall be reduced. 5. Turn the knob fully clockwise and check the resistance. Reading Resistance: approx. 0.1Ω 23

28 (5) Check the Voltage Switch Selector The black dot ( ) in the diagram below indicates that each number of the voltage is conducted. Selected Voltage The black dot means that #23 and #24 are conducted Confirm if it is conducted per the above diagram. Each number is identified. 24

29 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 N 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 0.04Ω. 25

30 (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 0.73Ω. 26

31 (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 6.7Ω. (4) J (Gray)-K (Violet) K (Vi) J (Gr) Measure resistance among the J~K by the low ohm tester. It shall be 25.4Ω. 27

32 (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 0.68Ω. 28

33 8. Periodical Check for Engine Consult by authorized service dealer. Check by operator. Description Clean and retighten each component. Daily Every 250 hrs Every 500 hrs Every 750 hrs Every 1000 hrs Every 1500 hrs Every 4500 hrs Check exhaust color. Check and add engine oil. Replace engine oil. Replace oil filter. 1 st time at 50 hrs 1 st time at 50 hrs Check and add coolant. Replace coolant and flush radiator. Check and drain fuel filter and sedimenter. Replace fuel filter. Drain and clean fuel tank. Clean and replace filter of electromagnetic pump. Clean and replace air cleaner element. Check & add battery fluid level. (Drain) (Clean) (Replace) (Clean) Check battery gravity. Engine Check leaking for fuel, oil & coolant. Check fan belt tension. Replace fan belt. Drain intercooler. Replace fuel, cooling water, oil hoses and antivibration rubber. Check & replace air hose of engine, intercooler, air cleaner SCR system and LLC hose Clean radiator and intercooler. Check and adjust valve clearance. Check and clean supply pump filter. Check fuel injector. Check color of exhaust gas. Check leakage of DEF. Replace DEF filter. (SCR system) Inspect SCR system. Inspect dosing module.(scr system) 29

34 Generator Description Check display, gauge and alarm. Test insulation. Daily Every 250 hrs Every 500 hrs Every 750 hrs Every 1000 hrs Every 1500 hrs Every 4500 hrs Others Check and drain spill containment. Check and drain spill containment. Check & clean the rear cover (Clean) (Clean) 30

35 9. Tightening Torque 9.1 Specific Tightening No Nomenclature Part to be tighten Size 1 Stator, ASM~Engine Bolt M10x Stator, ASM~Engine Nut, 10 M Rotor~Engine Bolt M10x Drain Plug~Guard 5 Drain Plug~Valve Drain Plug Drain Plug Qty G3/8 1 R1/2 1 Torque Allowance Nm(kgf/cm) ( ) ( ) ( ) ( ) ( ) 6 Valve~Guard Valve Drain Plug~Guard Drain Plug R1 1 8 Switch~Guard Switch G1/8 (Resin) ( ) (7-10) 9 Elbow~Valve Elbow Nipple~Valve Nipple Nipple~Socket Nipple Drain Plug~Socket Drain Plug R1/ ( ) 13 Nipple~Socket Nipple Drain Plug~Socket Pipe~Fuel Main Filter Pipe~Fuel Pre Filter Fuel Pump~ Bonnet Stay 18 Drain Plug~ Socket Drain Plug - 1 Bolt, eye M16x1.5x30 2 Bolt, eye M16x1.5x30 2 Bolt M6x35 2 Drain Plug M Valve~Socket Valve ( ) ( ) ( ) ( ) Reference Insert with spring washer. (p/n ) Insert with spring washer. (p/n ) Apply lubricant on the circular gasket. Ref: Fig.1 Replace sealing tape. Make a max. 3 wraps on thread. Ref: Fig. 1 Apply Loctite #638. Fasten as handle positions upright. Ref: Fig. 1 Replace sealing tape. Make a max. 3 wraps on thread. Ref: Fig. 1 Install the float sensor. Apply Loctite #638. Attention the direction of the elbow installation. Ref: Fig. 2 Apply Loctite #638. Ref: Fig. 2 Apply Loctite #638. Ref: Fig. 2 Apply Loctite #575. Ref: Fig. 2 Apply Loctite #638. Ref: Fig. 2 Apply Loctite #575. Ref: Fig. 2 Insert the packing in both end of the tube. Apply lubricant. Attention direction of the installation on elbow. Ref: Fig. 3 Insert the packing in both end of the tube. Apply lubricant. Attention direction of the installation on elbow. Ref: Fig. 3 Attention direction of the fuel pump. Use the spring washer. (p/n V ) Ref:Fig. 4 Install o-ring in the groove with lubricant oil. Ref:Fig. 5 Apply Loctite #638. Fasten as handle positions upright. Ref:Fig. 5 31

36 No Nomenclature Part to be tighten Size Qty Torque Allowance Nm(kgf/cm) 20 Nipple~Valve Nipple Hose Joint~ Engine Eye Bolt M24x Lead Wire~Cam Switch Bolt M Feed Pump~Stay Bolt M8x Valve~Stay Bolt M8x Stay ~Stay Bolt M10x1.25x Stud Bolt 12~Inst. Plate Nut 12 M Panel~Front Door Nut, 5 M Nozzle Unit~Muffler Nut M6x SCR Sensor~Muffler Sensor M12x NOx Sensor ~ Muffler DOC Front Sensor~Miffler DOC Rear Sensor~Miffler Maf Sensor~Air Cleaner Sensor M20x Sensor M12x Sensor M12x Screw M4x Air Hose~Air Cleaner Band D Wire Harness~Resister Exhaust Pipe~Engine Exhaust Pipe~ Exhaust Pipe Exhaust Pipe~ Exhaust Pipe Nut M5 12 Nut 8 M8 3 Bolt Nut 8 M8x70 4 Bolt M8x ( ) (57-66) ( ) ( ) ( ) ( ) (21-29) (62-101) ( ) ( ) ( ) ( ) (13-17) (23-27) ( ) ( ) ( ) Reference Apply Loctite #638. Ref: Fig. 5 Install O-ring in the groove with lubricant oil. Attention direction of installation. Ref: Fig. 6 Bots are used for cam switch. Ref: Fig. 7 Attention direction of the installation on elbow. Ref: Fig. 7 Fasten with nut. Ref: Fig. 7 Use nut (# ), washer (# ) and spring washer. (# ) Ref: Fig. 8 Ref: Fig. 8 Ref: Fig. 8 Do not install the front and rear sensor by reverse. Ref: Fig. 9 Do not install the front and rear sensor by reverse. Ref: Fig. 9 Ref: Fig. 10 Install the air hose at approx..45 degrees. Ref: Fig. 11 Ref: Fig. 12 & 13 Use the gasket. (Isuzu p/n ) Ref: Fig. 12 & 13 Attention direction of the installation on elbow. -Mount the valve among the two pipes. -Use the exhaust gasket. -Mount the washer and spring washer with the bolt. Ref: Fig. 12 & 13 Use the exhaust gasket. Ref: Fig. 12 & 13 32

37 No Nomenclature Part to be tighten Size Qty Torque Allowance Nm(kgf/cm) Reference 39 Exhaust Pipe~ Muffler Bolt Nut 8 M8x ( ) -Attention direction of installation on elbow. -Use the exhaust gasket. Ref: Fig. 12 & Exhaust Pipe~Stay U Bolt, Nut M10 4 Torque the nuts. Ref. 9.2 General Torque. Ref: Fig. 12 & 13 Fig. 1 Gasket Drain Plug Apply lubricant oil. Replace sealing tape. Make a max. 3 wraps on thread. Drain Plug Put Loctite #638. Drain Plug (Valve side) Turn for fastening. Valve Replace sealing tape. Make a max. 3 wraps on thread. 33

38 Fig. 2 Elbow shall direct to the front. Apply Loctite #638. Nipple Elbow Apply Loctite #638. Drain Plug FRONT Nipple (Union) REAR Apply Loctite #575. Apply Loctite #638. Socket Nipple Valve (to change fuel supply.) Apply Loctite #638. Drain Plug Apply Loctite #575 Socket (Water Drain) 34

39 Fig. 3 Pipe Eye Bolt Fuel Filter (Pre) Fuel Filter (Main) ハ イフ Stay 35

40 Fig. 4 Attention direction to the installation. Fig.5 Fuel Pump Socket (oil drain) Apply lubricant oil. Valve Drain Plug Fasten the valve to the nipple. フュエルホ ンフ O-ring Apply Loctite #638. Fasten the valve to the socket. Nipple Apply Loctite #

41 Fig.6 Hose Joint Fixture The hose joint shall position as the groove for o-ring faces to upright. View from the bottom FRONT Oil Pan Band O-ring Eye Bolt Eye Bolt Approx Hose Apply a lubricant oil to the o-ring. Hoses shall not interfere each other. REAR Fig. 7 Stay (to mount the DEF tank.) Feed Pump (S/M) Nut Stay (DEF Tank Stay) Valve (CCV) Bolt 37

42 Fig. 8 Sensor (SCR) Sensor (NOx) Unit Nozzle (D/M) Muffler (SCR) Sensor (NOx) Fig. 9 Muffler (SCR) Sensor (DOC Rear) Sensor (DOC Front) 38

43 Fig. 10 Attention direction of the installation. Sensor (MAF) Screw Air Cleaner Fig. 11 Band Air Hose Approx. 45 degrees Air Cleaner 39

44 Fig. 12 Exhaust Pipe (Middle) Exhaust Pipe (SCR) Valve (Exhaust Throttle) Exhaust Pipe (Flexible) Stay 40

45 Fig. 13 U Bolt Exhaust Gasket Bolt Bolt (with washer & spring washer) Bolt Exhaust gasket Nut 8 Nut 8 Nut (double-lock mechanism) Exhaust Gasket Nut 8 Exhaust Gasket (Note: the appearance is dedicated) 41

46 9.2 General Tightening 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) 42

47 10. Engine Error Code 10.1 Error Code (Digital Display) This unit is equipped with monitoring function. When it detects the engine error, the monitor lamp would illuminate. Refer to the 12. Engine Error Code Chart for the details in this manual on pages Error Code Display Engine Monitor Lamp Engine Monitor Display 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 (Flash Pattern) The monitor lamp that locates in the front panel indicates engine malfunction with a pattern by flash. To check 1) Turn the starter switch to RUN. 2) The Monitor lamp will flash when engine malfunctions. (ref: page 46) Note: The lamp turns on for approx. 3 sec. when engine malfunctions. 3) When engine malfunctions; a) Press and hold the Engine Operation Button located in the back of the front panel. (ref: page 44) b) The engine mode display shows current and past malfunction 3 times. (Ref: Engine Error Code Chart for the details on pages

48 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) The monitor lamp will blink when there was no malfunction today and in the past. Note: The monitor lamp will flash 3 times only when there was malfunction. Engine Monitor Lamp Engine Operation Button locates in the back of the front panel (ref: page 13 & 44 & 46.) Press and hold the memory clear switch in the engine control switch so current and past malfunction records are displayed. 44

49 Monitor Lamp Flashing when the monitor lamp will blink 3 times and twice shorter, it shows the engine code 32, for example. Monitor Lamp: ON Monitor Lamp: OFF th digit Flashing Pattern of Monitor Lamp for the engine code 225 ; 1 digit 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 th digit 10th digit 1st digit 10.3 After Repair After malfunction was repaired, eliminate the malfunction from current record in following steps. 1) Turn the starter switch to RUN. 2) Start the engine and run for few minutes. 3) Turn and remain the starter switch to STOP position for 30 sec. at least. 4) Turn the starter switch to RUN Elimination of Past Malfunction Past malfunction has recorded in the ECM (Engine Control Module) unless it has deleted. Follow the step below when the past malfunction record from the ECM should eliminate. 1) Turn the starter switch to RUN. 2) Press and hold the memory clear button. 3) Connect the 1-pin connector (green/blue) with a negative post (-) from the battery for 3 sec. at least while holding the memory clear button. Warning Always wear a rubber glove before connecting 1-pin connector and battery. 45

50 4) Disconnect the 1-pin connector from a battery and release the engine operation button. 5) Turn and remain the starter switch to STOP for more than 10 sec. 6) Turn the starter switch to RUN. 7) When there is no past record displayed when the memory clear button is pressed, it completed the elimination work. 1-Pin Connector 46

51 11. Wiring Diagram 47

52 48

53 12. Engine Error Code Chart No. Code Blinking Malfunction Detected Item Engine Response No. Code Blinking Malfunction Detected Item Engine Response 1 P P Short-circuited grounding of EVRV. Abnormal low voltage of the exciter throttle relay Short-circuit, disconnect or damage of valve & harness. Short-circuit, disconnect or damage of relay, valve & harness. 3 P Opened pressure limiter Opened pressure limiter Automatic Engine Stop 20 P Automatic Engine Stop 18 P Overrun Abnormal engine rpm. Automatic Engine Stop Automatic Engine Stop 19 P Excessive pressure Excessive pressure Automatic Engine Stop Boost Pressure Sensor (Low Voltage) Disconnected, damaged Automatic Engine Stop 4 P Common Rail Pressure Abnormal increase of common rail pressure. Automatic Engine Stop 21 P Boost Pressure Sensor (High Voltage) Short-circuited, damaged Automatic Engine Stop 5 P Disconnected SCV Transmission, Short-circuited grounding Disconnected or shortcircuited SCV & harness. Automatic Engine Stop 22 P Low Oil Pressure Engine oil leakage. Automatic Engine Stop 6 P Short-circuited SCV+Battery Short-circuited SCV & harness. Automatic Engine Stop 23 P ROM Abnormal ROM Automatic Engine Stop 7 P Intake Temp. Sensor (Low Voltage) Short-circuited, damaged Automatic Engine Stop 24 P RAM Abnormal RAM Automatic Engine Stop 8 P Intake Temp. Sensor (High Voltage) Disconnected, damaged Automatic Engine Stop 25 P CPU Abnormal CPU Automatic Engine Stop 9 P Water Temp. Sensor (Low Voltage) Short-circuited, damaged Automatic Engine Stop 26 P060A 51 IC (to detect CPU) Lost control of sub-cpu, damaged circuit between the main and sub CPU. Automatic Engine Stop 10 P Water Temp. Sensor (High Voltage) Disconnected, damaged Automatic Engine Stop 27 P060C 36 A/D transmission Abnormal A/D transmission. Automatic Engine Stop 11 P P Common Rail Pressure Sensor (Low Voltage) Common Rail Pressure Sensor (High Voltage) Short-circuited, damaged Disconnected, damaged Automatic Engine Stop 28 P06A7 56 Voltage #2 (5V) Automatic Engine Stop 29 P06A8 57 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. Automatic Engine Stop Automatic Engine Stop 13 P Cylinder (#1) Injector Circuit Damaged electric wiring of #1 cylinder injector. Automatic Engine Stop 30 P06AF 277 Injector IC Damaged the injector. (IC) Automatic Engine Stop 14 P Cylinder (#2) Injector Circuit Damaged electric wiring of #2 cylinder injector. Automatic Engine Stop 31 P Low Pressure of Common Rail (low pump pressure) Common rail pressure low. Fuel leakage. Automatic Engine Stop 15 P Cylinder (#3) Injector Circuit Damaged electric wiring of #3 cylinder injector. Automatic Engine Stop 32 P Improper charge to circuit ECM charge circuit #1 (burn inside or disconnected) Automatic Engine Stop 16 P Cylinder (#4) Injector Circuit Damaged electric wiring of #4 cylinder injector. Automatic Engine Stop 33 P Improper charge to circuit ECM charge circuit #2 (burn inside or disconnected) Automatic Engine Stop 17 P Overheated Abnormal increase of water temp. Automatic Engine Stop 34 P160B 36 ADIC Damaged AD-IC circuit. Automatic Engine Stop 49

54 No. Error Code Blinking Malfunction Detected Item Engine Response No. Code Blinking Malfunction Detected Item Engine Response 35 P Jet Nozzle (common 1) 36 P Jet Nozzle (common 2) 37 P Air Pressure Sensor (Low Voltage) Disconnected, shortcircuited 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. Disconnected, damaged Automatic Engine Stop Automatic Engine Stop Automatic Engine Stop Intake throttle position sensor (High Voltage) Fuel Temp. Sensor (Low Voltage) Fuel Temp. Sensor (High Voltage) Short-circuited, damaged Short-circuited, damaged Disconnected, damaged sensor or harness Engine continues to run Engine continues to run Engine continues to run 38 P Air Pressure Sensor (High Voltage) Short-circuited, damaged Automatic Engine Stop Low Pressure Abnormal decrease of the booster pressure Engine continues to run 39 P Common Rail (Low Voltage) 40 U ISO-CAN Bus Low common rail pressure, fuel leakage of the common rail or deteriorating of fuel flow Output circuit of ISOCAN, ECM side Automatic Engine Stop Automatic Engine Stop Crank Sensor (No Signal) Crank Sensor (Abnormal Signal) Disconnected, damaged Broken teeth of sensor, rotor. Interfere with other signal. (short-circuited the other line.) Engine continues to run Engine continues to run 41 U CAN Bus Abnormal CAN transmission. Automatic Engine Stop Cam Sensor (No Signal) Disconnected, damaged Engine does not restart. 42 U CAN (abnormal timeout) Can Sensor Phase Abnormal high voltage of the exciter throttle relay Disconnected or shortcircuited the CAN communication. Damaged the communication unit. Installation of cam gear/crank shaft (angular misalignment) or damaged. Short-circuit, disconnect or damage of the relay, valve and harness. Automatic Engine Stop Glow Relay Engine continues to run EGR Valve Control Engine continues to run (No restart engine) EGR Position Sensor Disconnected, damaged relay or harness. Malfunctioned or disconnected the driving motor side. Blocking or bonding of valve. Short-circuit, disconnect and breakage of the sensor harness. Engine continues to run Engine continues to run Engine continues to run Temp. sensor (Low Voltage) Short-circuited, damaged Engine continues to run Temp. sensor of EGR cooler outlet (Low Voltage) Short-circuited, damaged Engine continues to run 46 P Temp. sensor (High Voltage) 47 P Air flow sensor (Low Voltage) Air flow sensor at high voltage Intake throttle positioning sensor at low voltage Disconnected, damaged Disconnected, damaged Short-circuited, damaged Disconnected, damaged Engine continues to run (Inducement movement) Engine continues to run (Inducement movement) Engine continues to run Engine continues to run Temp. sensor of EGR cooler outlet (High Voltage) Exhaust Temp. sensor No.1 at diesel oxidation catalyst. (Low Voltage) Exhaust Temp. sensor No.1 at diesel oxidation catalyst. (High Voltage) Exhaust Temp. sensor at diesel oxidation catalyst. (Low Voltage) Disconnected or damaged Short-circuited, damaged Disconnection and breakage of the sensor harness. Disconnection and breakage of the sensor harness. Engine continues to run Engine continues to run Engine continues to run Engine continues to run 50

55 No. Code Blinking Malfunction Detected Item Engine Response No. Code Blinking Malfunction Detected Item Engine Response Exhaust Temp. sensor No.2 at diesel oxidation catalyst. (High Voltage) Oil Pressure Sensor (Low Voltage) Oil Pressure Sensor (High Voltage) Temp. sensor of the intercooler inlet No. 1. (Low Voltage) Temp. sensor of the intercooler inlet No. 1. (Low & High Voltage) Battery Voltage (High) Disconnected, damaged Disconnected, damaged Short-circuited, damaged Short-circuited, damaged Disconnected, damaged Over-charged or aged battery. Short-circuited, disconnected or broken the Engine continues to run Engine continues to run Engine continues to run Engine continues to run Engine continues to run Engine continues to run Temp. sensor of the intercooler outlet. (low voltage) Temp. sensor of the intercooler outlet. (high voltage) Temp. sensor of the boost at outlet of intercooler. (low voltage) Temp. sensor of the boost at outlet of intercooler. (high voltage) Increased performance of the intercooler. EGR valve is not closed.(#1) Short-circuited, damaged Disconnected, damaged Short-circuited, damaged Disconnected, damaged Increased the cooling efficiency of the intercooler, aged or plugged intercooler. EGR valve is not closed. Engine continues to run Engine continues to run Engine continues to run Engine continues to run Engine continues to run Engine continues to run QR Code Incomplete writing of QR code, Data Q Engine continues to run Malfunction of Switching Integrated Circuit Malfunction of internal circuit in SWIC-1 Engine continues to run Cut the starter relay Intake Throttle Control Main Relay does not turn on Main Relay does not turn off Voltage #1 (5V) Voltage #4 (5V) Voltage #5 (5V) IC communication of injector Short-circuited, disconnected, damaged relay or harness Malfunctioned or disconnected the driving motor. Blocking or bonding of valve. Disconnected harness or short-circuited grounding. Bonded the relay to off direction. Short-circuited harness (+B). Bonded the relay to on direction. 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 IC communication of injector lines Engine continues to run Communication error of Switching Integrated Circuit Engine continues to run EEPROM Engine does not start SCR SYSTEM Engine does not stop. 91 P207F 611 Abnormal quality of urea water Engine continues to run 92 P20C9 611 SCR SYSTEM Engine continues to run Decreased cooling efficiency of Exhaust Gas Recirculation. Malfunction of communicating line on SWIC-1 Malfunction or defect of EEPROM device or deterioration Detected SC relating parts by DCU. Detected malfunction of density in urea solution by DCU. Detected SC relating parts by DCU. Decreased cooling efficiency of Engine Exhaust Gas Recirculation. (plugged internal cooler) Engine continues to run Engine continues to run Engine continues to run Engine continues to run but lower output. Engine continues to run but lower output. Engine continues to run Engine continues to run Overtime for purge. Failed purge 3 times. Engine continues to run Engine continues to run 95 P2BAA 611 Malfunction of SCR SYSTEM Detected SC relating parts by DCU. Engine continues to run but lower output. 51

56 No. Code Blinking Malfunction Detected Item Engine Response No. Code Blinking Malfunction Detected Item Engine Response Check sum of IC on injector Control circuit of ECU. Engine continues to run 96 U010E 83 DCU communication Disconnect or short-circuit of ISOCAN wiring. Detected CAN unit. Engine continues to run but lower output. Note Engine Code is displayed only when; 1) Parts relating to the operating control malfunctioned. 2) Engine continue to run but lower output. Note EGR: Exhaust Gas Recirculation SWIC: Switching Integrated Circuit SCR: Selective Catalytic Reduction EEPROM: Electrically Erasable PProgrammable Read-Only Memory DCU: Dosing Control Unit ECU: Electronic Control Unit CAN: Controller Area Network 52

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