SERVICE MANUAL. File DGO-272_DGK11F

Transcription

1 SERVICE MANUAL File DGO-272_DGK11F

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 DGK11F. 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 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 Main Parts and Feature Main Component Service Data Technical Specification Generator Tightening Torque Specific Tightening Torque General Tightening Torque Periodical Check for Engine Trouble Shooting Generator Engine Error Code Error Code (Digital Display) Error Code (Flash Pattern) After Repair Elimination of Past Malfunction Wiring Diagram 31

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 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 DGK11F Generator Type - Revolving Field Brushless Armature Connection - ZigZag-W Rated Frequency Hz 60 Rated Output(Prime) kva 11 kw 11 Standby Output kva 12 kw 12 Rated Voltage V 240/120 Rated Current A 45.8 Phase Single phase Power Factor Insulation class - F Excitation - Self Excitation (brushless) No. of Poles - 4 Type - Vertical Water-Cooled 4-Cycle Diesel Model(Manufacturer) - Kubota D1503 No. 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 - No.2-D,S15 EPA regulation Lubricating Oil - CD class or higher Fuel Tank Capacity gal./liters 16/62 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 40/1012 Dry Weight lbs./kg 1246/565 Net Weight lbs./kg 1411/640 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 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. 5-3 Main Component Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Volt Meter Selector Dial Feature: Dial to change voltage. Ampere Meter Selector Dial Feature: Dial to select the output current. Frequency Meter Feature: Display frequency of the generator. 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. 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. Ampere Meter Selector Switch Feature: Select the output current. 10

14 Right Side Door Fuel Inlet Feature: Inlet to the inject fuel. Cooling Water Drain Plug Feature: Drain cooling water (coolant) from the top cover. Fuel Return Feature: Outlet to return fuel from the external tank. Oil Drain Plug Feature: Drain the old oil from the oil tank. Spill Containment Drain Plug Feature: Drain a liquid from the spill containment. Refer to page 36 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. Fuel Drain Plug Feature: Drain the old fuel from the fuel tank. 11

15 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. Note: The 3-way valve lever is set at position A at delivery from a factory. 12

16 Left Side Door Standard Accessory 1 Owners Manual 2 Engine Warranty Manual 3 Starter Key 1 copy 1 copy 1 set (2 pcs) 13

17 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 Insulation Preheat time Items Reference Value Note Armature winding Exciter field 3MΩ or more Approx. 1 sec. with coolant temperature 30 (86 F) and approx. 10 sec. with coolant temperature -15 (5 F) Min. rpm at no load 1200min -1 Max. rpm at no load 60Hz: 1800min -1 Lubricant oil pressure 0.24~0.44MPa{2.5~4.5kgf/cm²} DC500V Megger Tester Automatic preheating system Coolant temperature 70~95 (158~203 F) Frame temperature limit within 80 (176 F) Sealed bearing temperature limit within 80 (176 F) Speed regulation Momentary within 10% Steady-state deviation within 5% Momentary within 20% Voltage regulation Steady-state deviation within 1.0% Frequency Idle: 40 Hz, Rated: 60 Hz Variable voltage (60Hz) 197~255V 60±0.1Hz Protective device 1 Low oil pressure Working Pressure MPa{0.5kgf/cm²} Engine Stop 2 High water temp. Working Temperature 115 (239 F) Engine Stop 3 Diagnosis Engine Malfunction - - Insufficient Battery 4 Charge - Battery voltage: below 8V - 5 Over Speed - above 2070 min -1 Engine Stop 6 Boost Intake Temperature 85 (185 F) - 14

18 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 15

19 (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: 11kVA No load 0.38A Full load( power factor=1.0) 0.63A (2) Resistance Value Nominal resistance of the winding is tolerated within ± 10% at 32 F(220 ) of the ambient temperature.the resistance must be measured by low resistance tester. It can not be measured by multi-purpose tester cause of index error. Main Stator Exciter Stator Rotor Armature Exciter Winding J-K Exciter Field Armature U-W A B B C C A Ω 0.97Ω 23.2Ω 11.0Ω 2.7Ω [Color Code] (B) (W) (R) (G) (Y) (Br) (L) (Or) (Gr) (Vi) Black White Red Green Yellow Brown Blue Orange Gray Vioret (3) Armature (Main Stator) U W Low resistance tester Measure the resistance among the U~W by the low ohm tester. Each shall be 0.25Ω. 16

20 (4) Excitation Winding (Main 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 0.97Ω. 17

21 (5) Stator J (Gray)-K (Violet) K (Vi) J (Gr) Measure resistance among the J~K by the low ohm tester. It shall be 23.2Ω. (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 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. 18

22 (7) Technical Specifications Items Article Method Condition to verify Criterion Check before operation Shape, Dent, Blot Coating Joint Oil, Coolant Wiring Visual Inspection No dent, blot and deformation No looseness Meet the criteria Meet the required level Lead wires to be securely fastened against abrasion and damage to bring by vibration Grounding Continuity Tester GROUNDING is connected; -with Engine (bolt for grounding) -with Bed (bolt for grounding) -with grounding for Receptacle Continuity is to be confirmed Insulation Check Insulation Resistance Dielectric Voltage DC500V Mega Tester Tester Main Breaker ON. 1-phase breaker (50A) :ON 1-phase breaker (30A) :ON 1-phase breaker (20A): OFF Disconnect two couplers in AVR. Disconnect the lead N (8mm 2 -Black) located in the side door. Remove one side of the output terminal between engine block and circuited protector (50A). Initial excitation winding ~ engine block (Remove either the lead J or K) *Insulate all terminals after removal Over 3MΩ AC1800V (3 sec) Electric Current: 10mA Items Article Method Condition to verify Criterion Glow & Monitor Lamp, Hour Meter Monitor for engine displays 8888 and 8.8. is displayed in the fuel monitor. Monitor Protection Circuit Glow Lamp Air Filter Fuel Meter Spill Containment Display Selector Monitor Display Low Oil Pressure High Water Temp. Insufficient battery charge Visual Inspection After starter switch RUN position (#1) Engine is not running Glow Lamp ON and turns to OFF after 3~7 sec. CHARGE & OIL PRESS lamps ON. Hour Meter is activated. AIR FILTER lamp ON when blue and white wires for the wire harness are grounded. FUEL monitor lamp ON. SPILL CONTAINMENT lamp ON when the float switch in the Spill containment is lifted. (#2) SPILL CONTAINMENT OVERFLOW WARNING lamp ON and Engine stops when the float switch in the Spill containment positions lower. (#2) Engine is Oil press, water temp. and engine speed are displayed in running order when the display selector is pressed each time. (#3) All monitor lamps turns to OFF after engine starts. Hour meter only is operating. Ground oil pressure wire with a OIL PRESS lamp ON and engine stops. unit. Ground water temp. wire with a WATER TEMP. lamp ON and engine unit, stops. Short circuited terminal L (green wire) from dynamo. CHARGE lamp ON and engine stops. 19

23 Operational Check Over Speed AVR Adjustment Fuel Volume 1-Phase Output 1-Phase Output (Receptacle) 1-Phase Output AC Voltage Meter Visual Inspection Load Tester Frequency Meter Dynamo DC Current Meter Dynamo AC Voltage Meter Load Tester Dynamo Ground over speed terminal with a unit. Operate at high rpm in 50 Hz and switch to 60Hz. No Load Voltage Adj. Dial: Max. Set VRD volume in AVR at center-position. (#4) No Load Frequency: 60±0.1 Hz Output: 240±1V (50A receptacle, rated, X-Y) Frequency: 60±0.1Hz Power Factor: 1.0 Water Temp: 32~212 F (0~100 ) Voltage: 240±1V (50A receptacle, rated, X-Y) Frequency: 60±0.1Hz Voltage: 240V (50A Receptacle, X-Y) Load: 40±1A (50A Receptacle, X-Y) Frequency: 60±0.1Hz Engine stops during 1500min -1 and 1800min -1 and OVER SPEED lamp ON. Frequency Output Adjust by (Hz) (V) VRF (#4) 50± ±2 VRE (#4) 60± ±2 Throttle Switch kva Idle 0.0 U-W/U-N/W-N Run 11/2.4/3.6 U-W/U-N/W-N % kw V A RPM ± ±1 (0.65) ± ± ± 240± ±0.1 0 no load (0.37) Receptacle Output (30A/240V) 240±1V Receptacle Output (30A/120V) 120±1V Receptacle Output (GFCI) 120±1V Output (kva) U-V 1.4±0.2 Current Transformer and Analog Current Meter Wiring 1-Phase Output (Transient Load Change Excursions) Voltage Adjustment Load Tester Dynamo Load Tester Frequency Meter Dynamo Stop Watch AC Meter Voltage: 240±1V (50A receptacle, rated, X-Y) Frequency: 60±0.1Hz Power Factor: 1 50A Receptacle (X-Y) Output: 11.0±0.1kW Voltage: 240±1V Frequency: 60±0.1Hz Power Factor: 1 Adjust the voltage regulator Frequency: 60±0.1Hz Max. Voltage #5 #6 Min. Voltage Over 252 Below 204 #1: When coolant temp is around at 0~50. (32~122 F) #2: Spill Containment Sensor Float Sensor Feature: detect the level of liquid in a tank. #3: Oil pressure is displayed in a range between 35~57psi. #4: AVR Adjustment 20

24 Set the VRD volume in the center-position before adjustment Put the adhesive (ThreeBond #1401C) over the VRF, VRD and VRE after adjusted. #5: Analog Current Avail. Output (kva) Load Receptacle Meter (A) U-W U-N W-N U W 50A (X-Y) 15.0±1A Simultaneous 30A/120V 100V/1kW (21) (27) GFCI 100V/500W Single 30A/120V 100V/500W (12) (12) #6: Mode Output Voltage (V) Setting Time Frequency (Hz) Setting Time Loaded No Load (Transient Max.) below 288 below 2 sec. below 66 below 8 sec. No Load 240±3-60±0.1 - No Load Loaded (Transient Min.) over 192 below 2 sec. over 54 below 8 sec. Loaded 240±3-60±0.1-21

25 7. Tightening Torque 7-1 Specific Tightening Torque No Nomenclature 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 - Sensor NPT1/8 1 - Ditto 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 Fuel Pump ~ Bonnet Stay Drain Plug M12x1.25x ( ) ( ) ( ) ( ) (21-29) ( ) Elbow ~ Valve Elbow Elbow~Valve Elbow Reference Install as the pipe outlet faces downward with a 15 limit. Put lubricant oil in the gasket surface. Use a liquid gasket. (#TB1207B) Use a liquid gasket. (#TB1207B) Attention to the direction for installation of the elbow. Use a liquid gasket (#TB1207B) Insert the packing. Attention to the direction for installation of the fuel pump. Put a Loctite #635. Attention to the direction for installation of the elbow. Attention to the direction for installation of the elbow. 15 Nipple ~ Socket Nipple Put a Loctite #635. Drain Plug ~ Drain Ditto Socket Plug Drain Drain Plug ~ Valve - 1 Ditto Plug ( ) 18 Valve ~ Guard Valve Drain Plug ~ Guard 20 Drain Plug ~ Guard Drain Plug Drain Plug ( ) ( ) 21 Valve ~ Socket Valve Nipple ~ Valve Nipple Ditto 23 Drain Plug ~ Socket Drain Plug ( ) Put a Loctite #635. Fasten as the handle positions upward. Put a Loctite #635. Insert the circular gasket after the lubricant oil is put on it. Use a seal tape and put a liquid gasket (#TB1184) Insert the circular gasket after the lubricant oil is put on it.

26 No Nomenclature Part to be tighten Size Qty Torque Allowance Nm(kgf/cm) Reference 24 Lead ~ Circuit Protector (50A) Screw M6x12 4 Screws are attached. 25 Lead ~ Circuit Protector (30A) Screw M6x12 4 Ditto 26 Lead ~ Circuit Protector (30A) Screw M6x12 2 Ditto 27 Lead ~ Circuit Protector (20A) Screw M6x12 2 Ditto 28 Pilot Lamp ~ Put an adhesive. (TB Operational Panel PANDO) Note: Refer to the following General Tightening Torque for the general torques that are not specified above. 7-2 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) 23

27 8. Periodical Check for Engine Consult Service Dealer User Check Engine 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 (Check/Drain excess water and sediments) Fuel filter (Clean and Replace) Fuel Tank (Drain water) Water Separator and Gauze Filter (Clean) Fuel Tank (Clean) Check Leaks (Fuel/Oil/Coolant) Fuel/Cooling Water/Oil Hoses and A-V Rubber (Replace) Air Cleaner Element (Clean/Replace) Battery Fluid Level (Check/Add) Battery Gravity (Check) Fan Belt Tension (Check) Fan Belt (Replace) Radiator & Fins (Clean) Valve Clearance (Check/Adjust) Fuel Injector (Check) Daily 1 st time at 50 hrs 1 st time at 50 hrs Every 100 hrs (Clean) Every 200 hrs (Drain) (Clean) Every 400 hrs (Replace) (Replace) Every 500 hrs Every 800 hrs Every 1000 hrs Every 1500 hrs Eliminate carbon in the exhaust pipe and muffler Generator Others Indicators, Gauges & Alarms (Check) Insulation Test Spill Containment Fluid (Check/Drain) Spill containment (Check/Clean) (Clean) 24

28 9. Trouble Shooting 9-1 Generator <Pre-check> Always check the volume of oil, coolant, and fuel before processing to trouble shooting. Problem Suspected Cause Action Starter motor does not drive or speed is low. 1. Battery output is weak 2. Battery is deteriorated 3. Battery terminal is OFF or loose 4. Battery terminal is corroded 5. Starter switch or relay is defective 6. Starter motor is defective 7. ECU(Engine Controller) is defective 1. Check/ battery liquid/ or Charge 2. Change battery 3. Fix/Tighten terminal 4. Clean terminal 5. Contact your distributor to repair 6. Contact your distributor to repair 7. Contact your distributor to repair Engine does not start Starter motor drives but engine does not start 1. Fuel is insufficient 2. Fuel filter is clogged 3. Gauze filter is clogged 4. Water is interfused in fuel line 5. Air is interfused in fuel line 6. Poor piping connection to external fuel tank 7. Fuel tank selector lever (3-way valve) position is wrong 8. Fuel cut solenoid (motor) does not work 9. Emergency operation/fault detection 1. Add fuel 2. Clean/Change fuel filter 3. Clean/Change gauze filter 4. Drain water in water sedimenter, fuel filter or fuel tank 5. Extract the air 6. Check piping connection 7. Check lever (3-way valve) 8-1. Check/Change fuse 8-2. Check/Change fuel cut solenoid 9. Contact your distributor to repair <Ambient temperature falls down below zero> 1. Fuel is frozen 2. Water in fuel line is frozen 3. Pre-heater is defective 1. Use winterized fuel 2. Drain water in fuel line 3. Contact your distributor to repair Engine starts but stalls immediately Engine oil pressure is low 1. Fuel filter is clogged 2. Gauze filter is clogged 3. Water is interfused in fuel line 4. Air is interfused in fuel line 5. Poor piping connection to external fuel tank 6. Air filter element is clogged 7. Lubricant oil is insufficient 8. Emergency operation/fault detection 1. Lubricant oil is insufficient 2. Oil filter is clogged 3. Oil Pressure switch is defective 4. Oil pressure meter is defective 5. Wrong oil is used 1. Clean/Change fuel filter 2. Clean/Change gauze filter 3. Drain water in water sedimenter, fuel filter or fuel tank 4. Extract the air 5. Check piping connection 6. Check/Change air filter element 7. Supply lubricant oil 8. Contact your distributor to repair 1. Supply lubricant oil 2. Change oil filter 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Change to proper kind and viscosity oil 25

29 Overheated 1. Engine thermostat is defective 2. Water temp sensor is defective 3. Water temp meter is defective 4. Fan belt tension is weak 5. Coolant is insufficient 6. Radiator core is clogged 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Check/Adjust fan belt 5. Check/Supply coolant 6. Clean radiator core Problem Suspected cause Action White smoke comes out from muffler Indicator does not move in voltage meter Indicator does not goes up to the rated voltage Indicator exceeds the rated voltage The voltage drops drastically when connecting to load Cannot turn the breaker to ON position 1. Air filter element is clogged 2. Fuel injection nozzle is defective 3. Improper fuel is used 1. Too much or too little oil to cylinder 2. Water is interfused in fuel line 3. Fuel injection nozzle is defective 4. Coolant temperature is too low 5. Engine thermostat is defective 1. Voltage meter is defective 2. AVR is defective 3. Disconnected circuit, loose terminal or departed 4. Initial exciter is defective 5. Alternator is defective 1. Voltage meter is defective 2. AVR is defective 3. Voltage regulator dial is defective 4. Frequency is low 5. Improper load cable connection 6. Voltage selector switch set is wrong 1. Voltage meter is defective 2. AVR is defective 3. Voltage regulator dial is defective 4. Frequency is high 5. Improper load cable connection 6. Voltage selector switch set is wrong 1. AVR is defective 2. Unbalanced loads sharing to each terminal 3. Total loads exceeds the rated current 4. Frequency Speed Switch set is wrong 1. The breaker positions stays between ON and OFF 2. Short circuit on the load 3. Terminal cover opened 4. The thermal relay activates 1. Check/Change air filter element 2. Contact your distributor to repair 3. Change to clean fuel 1. Contact your distributor to repair 2. Drain water in water sedimenter, fuel filter or fuel tank 3. Contact your distributor to repair 4. Warm-up driving is needed 5. Contact your distributor to repair 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Contact your distributor to repair 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Correctly set the connection location to the output terminal 6. Set the Voltage selector switch correct 1. Contact your distributor to repair 2. Contact your distributor to repair 3. Contact your distributor to repair 4. Contact your distributor to repair 5. Correctly set the connection location to the output terminal 6. Set the Voltage selector switch correct 1. Contact your distributor to repair 2. Balance the loads sharing to each terminal 3. Decrease the loads with in the rated output 4. Set the Speed Switch correct 1. Turning the lever to OFF first then turn it to ON position 2. Check the load circuit 3. Close terminal cover 4. Reset the thermal relay 26

30 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. 27

31 (Ref: 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) 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. 28

32 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. 29

33 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 30

34 11. Wiring Diagram 31

35 32

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