SERVICE MANUAL DGK100D DGK100DU

Transcription

1 SERVICE MANUAL DGK100D DGK100DU 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. File DG0-182_DGK100D, DGK100DU

2 This service manual is edited for authorized person to perform repair, maintenance, and trouble-shooting to Shindaiwa diesel engine generators, designated as DGK100D and DGK100DU. 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 BI-4HK1

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 Main Parts and Feature Main Components 7 6. Service Data Technical Specification Generator 14 (1) Exciting Amperage 14 (2) Resistance Value 14 (3) Technical Specifications Tightening Torque Technical Specification Technical Specification Periodical Check for Engine Trouble Shooting Wiring Diagram 22 File DG0-182_DGK100D, DGK100DU

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 STOP the equipment immediately when Generators and welders operate at very high abnormal circumstances are noticed! speeds and can do serious damage or injury STSTOP the equipment immediately whenever if they are misused or abused. Never allow a abnormal circumstances are noticed such person without training or instruction to as unusual noise, smell, vibration and etc. operate and serve this equipment! It may lead serious accident or fatal damage Attention to CAUTION LABEL! of the equipment or properties. 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. 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 Unit DGK100D/DGK100DU Generator Engine Dimension Revolving Filed, Brushless AC Generating Method - 3-Phase-120/240V, 1 Phase kva 100 Rated Output kw 80 Rated Voltage Rated Current 3-Phase 208, 240, 480 V 1-Phase 120, 139, 240, Phase-120V 242 x 2 (Zigzag) 1-Phase-240V 242 (Zigzag) A 3-Phase-240V Phase-480V 120 Rated Frequency Hz 60/50 (± less than 0.25%) Rated Speed min /1500 Winding - Star with Neutral Power Factor % 80 Insulation Class - Alternator: F Exciting Method - Self Excitation (Brushless) No. of Poles - 4 Method - Vertical, Water-cooled 4-Cycle, Diesel Engine Model No. - ISUZU BI-4HK1 No. of Cylinder (bore x stroke In./mm 4 (4.53 x 4.92/115 x 125) Continuous Rated Output kw{ps} 114.7{155.1}/1800 min -1 Rated Speed min /1500 Displacement Liter 5,193 Combustion System - Direct Injection, Turbo-charged, Inter-cooler Cooling Method - Water-cooling radiator Lubricating - Forced lubrication Starting - Electric Fuel - ASTM No.2 Diesel Fuel Consumption Liter 23.4/h (@full load) Lubricating Oil - SAE Class CD or higher Fuel Tank Capacity Liter 222 Lubricant Volume Liter 22 Coolant Volume Liter 23 Starting Motor Capacity V-kW 12V 2.5kW Alternator Capacity V-A 12V 110A Battery Capacity V-AH 12V 150AH Length in/mm 102/2590 Width in/mm 49/1240 Height in/mm 71/1800 Dry Weight lbs/kg 4564/2070 * Specifications subject to change without notice. 4

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

9 EXHAUST GAS OUTLET AIR OUTLET WATER INLET 6

10 5. General Parts Description 5.1 Main Parts and Feature (1) Serial Number Unit Serial Number Engine Serial Number 5.2 Main Components Pilot Lamp Feature: Indicate when generator run. Main Circuit Breaker Feature: Protect an electrical circuit from damage by overload or short circuit. Panel Light Feature: Illuminate the control panel to indicate that power is generated. Panel Light Switch Feature: Illuminate the control panel when the panel light switch is ON. Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Hour Meter Feature: Display running hour of the engine. Voltage Selector Switch Feature: Select the output phase voltage as displayed. Glow Lamp Feature: Pre-Heating lamp is ON when a starter switch is turned to PREHEAT position. 7

11 This unit is equipped with monitoring functions and the cautioned lamp flashes to indicate defect. Investigate and correct cause(s) when any of the monitor lamp ON. 7 DIAG (Diagnosis): when an electronic control module defects. Engine will NOT automatically shut down. AIR FILTER: when the oil filter is clogged, clean or replace the filter. Engine will NOT automatically shut down. BOOST: when temperature of the manifold temperature exceeds 85. CHARGE: when a battery charge is insufficient. OIL PRESS: when oil pressure drops below 14.5 psi. Engine will automatically shut down. OVER HEAT: when temperature of the coolant will reach to 105. Engine will automatically shut down. OVER SPEED: when the engine speed exceeds 2,070 min -1. Engine will automatically shut down. Monitor Lamp Feature: Light a monitor lamp when equipment is malfunctioned. Volt Meter Selector Switch Feature: A switch to change voltage. Ampere Meter Selector Switch Feature: A switch to select the output current. Voltage Meter Feature: Display the output voltage from the generator. Ampere Meter (AC) Feature: Display the output current (phase) from the generator. Frequency Meter Feature: Display the frequency of the generator. AC Voltage Adjusting Dial Feature: A dial to adjust AC output. Water Temp. Meter Feature: Display water temperature in the radiator. Oil Pressure Meter Feature: Display oil pressure. Fuel Meter Feature: Display volume of the fuel left in the fuel tank. Decrease Increase Throttle Switch Feature: Change the engine speed. 8

12 Left Door View Output Terminal Cover Inside Terminal Rest Feature: Relay terminal block of the power output from the alternator. Circuit Breaker (1-Phase) Feature: Protect electrical circuit from damage caused by overload or short-circuit. Circuit Breaker (1-Phase) Feature: Protect electrical circuit from damage caused by overload or short-circuit. 1-Phase Receptacle (20A) Feature: Supply AC output. 1-Phase Receptacle (20A) Feature: Supply AC output. 3-Phase Circuit Breaker A (120/240V) Feature: Protect electrical circuit from damage caused by overload or short-circuit. 3-Phase Circuit Breaker B (120/240V) Feature: Protect electrical circuit from damage caused by overload or short-circuit. 1-Phase Receptacle A (30A) (120/240V) Feature: Supply AC output. 3-Phase Circuit Breaker C (120/240V) Feature: Protect electrical circuit from damage caused by 1-Phase Receptacle B (30A) (120/240V) Feature: Supply AC output. 1-Phase Receptacle C (30A) (120/240V) Feature: Supply AC output. Note: All duplex receptacles are GFCI protected and are rated at 20 amps. Other twist and lock type receptacles are rated at 30 amps (DGK100DU), 50amps (DGK100D). 9

13 Sub Tank - Coolant Feature: Keep coolant water level in the radiator. Air Cleaner Feature: Clean intake air. Alternator Feature: Charge a battery and send a charging signal. Pre Fuel Filter Feature: Filter water or dust in the fuel. Oil Filter Feature: Remove solid particulates such as dust in the oil. Main Fuel Filter Feature: Filter water or dust in the fuel. External Fuel Return Feature: Outlet to return fuel from external tank. Fuel Drain Plug Feature: Drain the old fuel from the fuel tank. External Fuel Inlet Feature: Inlet to refuel from the external tank. Coolant Drain Hose Feature: Drain coolant from the top cover. Oil Drain Plug Feature: Drain the old oil from the oil tank. CAUTION Connect pipes for the external fuel return and fuel inlet correctly with the external tank to avoid mechanical damage. 10

14 Fuel Inlet Feature: Inlet to refuel. 3-Way Valve The 3-way fuel valve is located underneath on the right side of the engine. 3-Way Valve Feature: Change fuel supply from a built-in or external fuel tank. 3-Way Valve Position A (to use external fuel tank): Position a 3-way valve lever to LEFT to use fuel from external fuel tank. Position B (to use a built-in fuel tank): Position a 3-way valve lever to RIGHT to use fuel from a built-in fuel tank. Note: The valve is positioned at position B when a unit is delivered from the factory. CLOSE OPEN CLOSE OPEN WARNING Always stop engine prior to changing the 3-way valve lever position. (Photo: Position B-for a built-in tank) Turn both green and orange plugs clockwise to open the valves when the 3-way valve is positioned in position A. So, fuel from the external tank will circulate. Turn both green and orange plugs counter-clockwise to close the valves when the 3-way valve is positioned in position B. So, circulation with the external tank is shut down. 11

15 Injection Pump Feature: Supply fuel to the injection nozzle. Right Door Inside View Accessory Standard Accessory 1 Owners Manual 2 Starter Key 2 sets 3 Warranty Statement 4 Instruction Manual of the engine 6. Service Data 12

16 ELECTRIC SHOCK WARNING Never touch the output terminals during operation. Never touch the output terminal during operation even though the breaker on the load being set at OFF. Be sure to check and confirm the engine stop whenever touching terminals to connect loads. 6-1 Technical Specification Items Reference Value Note Insulation Armature DC500V winding 3MΩ or more Megger Tester Exciter field Preheat time would be approx. 8 sec. Preheat time when coolant temp. read -15 and Automatic preheat it would be 1 sec. when coolant temp. system read 20. Glow lamp ON for 10 sec. Min. rpm at no load 1000±25 min -1 Max. rpm at no load 1500 min -1 50Hz 1800 min -1 60Hz Lubricant oil pressure 0.2~0.6MPa{2~6kgf/cm²} Coolant temperature 70~100 Frame temperature limit within 80 Sealed bearing temperature limit within 80 Speed regulation Momentary within 10% Steady-state deviation within 5% Momentary within 20% Voltage regulation Frequency Steady-state deviation within 1.0% Idle: 33.3 Hz Rated: 60 Hz Variable voltage 374~448V 50Hz 408~504V 60Hz Protective device Low oil pressure Working pressure Low oil pressure Working pressure 0.1MPa{1.019±0.2kgf/cm²} [Close] when activated High water temp. Working temperature Generator 13

17 (1) Exciting Amperage Amperage fluctuates based upon the winding temperature. Following is for reference only. Frequency/Rated Output Load Exciting Amperage (Measured) 3-phase 50Hz: 64 kw 60Hz: 80 kw No load 1.03A Full load( power factor=1.0) 1.40A No load 0.76A Full load( power factor=1.0) 1.22A (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. Measurement value (Ω) Armature Between T 1 -T 4,T 7 -N 10 (U) T 2 -T 5,T 8 -N 11 (V) T 3 -T 6,T 9 -T 12 (W) Generator Exciter (Measured) Stator Rotor Stator Rotor Exciter armature Exciter Field J-K Armature (3) 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 Insulation Check Continuity Insulation Resistance Tester Optional Tester Bonnet Grounding Terminal Engine Lead Wire Bonnet Grounding Terminal Receptacle Bonnet Grounding Terminal Lead Wire In the base Main and 1-phase breaker 50A ON and 1-phase breaker 20A OFF. Disconnect the coupler in the stator (9P). Continuity is to be confirmed Over 3MΩ Dielectric Voltage Tester Disconnect all wires in the AC2400V (1 sec) or AC1960V (1 min) terminal block. 14

18 Monitor Glow Lamp Battery Charge, Oil Pressure, Hour Meter Visual Inspection Starter Switch is at PREHEAT position Starter Switch is at RUN position Engine Running Preheat Lamp ON for 10 seconds Charging Lamp ON, Hour Meter is activated. DIAG lamp turns ON and then, it turns OFF. All monitor lamps OFF and Hour Meter is activated. Pilot Lamp ON during engine run. AIR FILTER lamp ON when terminals (black/yellow wires)in the air cleaner indicator are grounded. Protection Circuit Thermal Relay Terminal Cover Emergency Stop Phase rotation AVR Adjustment Visual and hearing Phase Rotation Indicator Voltage- Meter Engine Stopping Engine Running Engine Running Output selector switch is set at 208V (3-phase) No Load Voltage Adj. Dial: Max Thermal relay is set at 4.0A and auto return. Main breaker lever trips in the middle of the ON and OFF position when a test trip lever trips to TRIP. Main breaker lever trips in the middle of the ON and OFF position. OVER SPEED lamp ON and engine stops at 1725±25rpm. - Rotate as arrow shows Frequency (Hz) 60±0.1 Output (V) 253±2 *Adjust by VOLT ADJ. volume in AVR. (Ref. *6) Engine Control Switch OFF, Throttle RUN, Engine Speed 1800rpm. Operational Check 3-Phase Output (Comprehensive Voltage Regulation) 3-Phase Output (Continuous Operation under Loaded) Load Tester Frequency Meter Wattmeter DC Amp. Meter Load Tester Frequency Meter Wattmeter Stop Watch Output selector switch is set at 480V. (3-phase) Output: 80.0+/-0.8kW Voltage: 480+/-1V Frequency: 60+/-0.1Hz Power Factor: 1.0 % kw V A Hz / /-1 (1.22) /-0.6 (1.16) /-0.4 (0.89) 480+/ /-0.2 (0.80) 0 no load (0.76) 60+/-0.2 Engine Control Switch OFF, Throttle RUN, Engine Speed 1500rpm. Output selector switch is set at 480V. (3-phase) Output: 64.0+/-0.6kW Voltage: 440+/-1V Frequency: 50+/-0.1Hz Power Factor: 1.0 % kw V A Hz / /-1 (1.40) /-0.5 (1.27) /-0.3 (1.15) 440+/ /-0.2 (1.06) 0 no load (1.03) 50+/-0.2 Engine Control Switch OFF, Throttle RUN, Engine Speed 1800rpm. Output selector switch is Set at 208V, 3 phase. Output: 40.0+/-0.6kW Voltage: 240+/-1V Frequency: 60+/-0.1Hz Power Factor: 1.0 Engine Control Switch OFF, Throttle RUN, Engine Speed 1500rpm. Output selector switch is Set at 208V, 3-phase. Output: 32.0+/-0.5kW Voltage: 220+/-1V Frequency: 50+/-0.1Hz Power Factor: 1.0 *1 *2 15

19 Engine Control Switch OFF, Throttle RUN, Engine Speed 1800rpm 3-Phase Output (Transient Load Change Excursions) Load Tester Frequency Meter Wattmeter Stop Watch Output selector switch is Set at 208V, 3-phase. Output: 80.0+/-1.2kW Voltage: 240+/-1V Frequency: 60+/-0.1Hz Power Factor: 1.0 Engine Control Switch OFF, Throttle RUN, Engine Speed 1500rpm Output selector switch is Set at 208V, 3-phase. Output: 64.0+/-1.0kW Voltage: 220+/-1V Frequency: 50+/-0.1Hz Power Factor: 1.0 *3 *4 Engine Control Switch OFF, Throttle RUN, Engine Speed 1800rpm Single Phase Output Output selector switch is Set at 240/120V, 1-phase. Voltage: 240+/-1V Frequency: 60+/-0.1Hz Power Factor: 1.0 No Load 50A Receptacle Output Voltage (X-Y) 240+/-3 AC Voltagemeter Engine Control Switch OFF, Throttle RUN, Engine Speed 1800rpm (60Hz), 1500rpm (50Hz) Voltage Adjustment Output selector switch is Set at 480V, 3-phase. Turn Voltage Adjusting Dial at no load. No Load Voltage (V) Max. Min. 60Hz over 504 blow Hz over 448 blow 374 Operational Check Engine Speed Adjustment Continuous Load Operation Digital Tachometer Wattmeter Frequency Meter Oil Pressure Meter Water Temp. Meter Wet/Dry Thermometer Stop Watch PC EMPS III Adjust engine speed by engine control switch in control box at no load. Engine Control Switch OFF, Throttle START Idle Speed (min -1) 1000±25 *5 *5 Piping to External Fuel Supply External Fuel Tank - Fuel is to be sucked up from the fuel tank and returned to the tank. Other Frequency Hz setting is confirmed. Fuel Meter Visual Inspection Drain fuel from the tank and confirm the fuel meter. The fuel meter indicates E when empty. 16

20 *1 Criterion Mode Frequency (Hz) Setting Time Loaded No Load (Transient Max.) below 66 below 8 sec. No Load 60+/ No Load Loaded (Transient Min.) over 54 below 8 sec. No Load 60+/ *2 Criterion Mode Frequency (Hz) Setting Time Loaded No Load (Transient Max.) below 55 below 8 sec. No Load 50+/ No Load Loaded (Transient Min.) over 45 below 8 sec. No Load 50+/ *3 Criterion Mode Output Voltage (V) Setting Time Frequency (Hz) Loaded No Load (Transient Max.) below 288 below 2 sec. - No Load 240+/-3-60+/-0.2 No Load Loaded (Transient Min.) over 192 below 2 sec. - No Load 240+/-3-60+/-0.2 *4 Criterion Mode Output Voltage (V) Setting Time Frequency (Hz) Loaded No Load (Transient Max.) below 264 below 2 sec. - No Load 220+/-3-60+/-0.2 No Load Loaded (Transient Min.) over 175 below 2 sec. - No Load 2240+/-3-60+/-0.2 *5 Output Selector Switch is set at 208V, 3-phase Engine Control Switch OFF, Throttle RUN, Engine Speed 1800rpm, Speed Manual ON Criterion Room Temp. kw** V** Hz** PF* Oil Pressure Water Temp. 5~ / ~ / /-1 60+/ ~6 MPa 85~99 25~ /-0.1 * PF stands of power factor. **Connect PC and a connector for TECH2 and check engine and harness by EMPSⅢ. ***Measure rpm after operation at no load for 30 min. ***Engine RPM (No Load) 1890 min -1 or less *6 17

21 7. Tightening Torque 7-1 Specific Tightening Torque No Nomenclature Part to be tighten Size 1 Exciter Stator Bolt M5x Rear Bracket (Main Stator) 3 Generator Stator Qty Bolt M12x160 4 Bolt, Shim M10x Rotor Bolt M10x1.25x Fan 6 Front Bracket (Alternator Assy to install) Bolt, Shim M8x25 6 Bolt M10x1.25x Engine Stay Bolt M10x1.25x Thyristor (Stuck Fin) 9 Socket 10 Flexible Tube Terminal Rest (Welding Terminal) Battery (Terminal Attachment) Battery (Wiring) Glow Plug (Terminal) Oil Pressure Switch Screw, Shim Drain Plug Flange Nut M6x20 4 M12x1.25x13 3 M8 6 Nut M10 4 Nut M8 2 Nut M8 2 Nut M4 1 Bolt, Shim M4x Fuel Strainer Bolt M8x65 1 Torque Allowance Nm(kgf/cm) (30-50) ( ) ( ) ( ) ( ) ( ) ( ) (25-35) ( ) ( ) ( ) (50-62) (70-90) (10-18) (14-20) ( ) Reference 7T 7T Small Head (Opposite Side Distance 14) Brass Battery Accessory Battery Accessory Engine Accessory Engine Accessory Opposite Side Distance 12 Note: Refer to the following General Tightening Torque for the general torques that are not specified above. 18

22 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) Note: Refer to the following General Tightening Torque for the general torques that are not specified above 19

23 8. Periodical Check for Engine Consult Service Dealer User Check Replace Parts Items Start up Check At 50hrs Every 100hrs Checking interval Every 200hrs Every 400hrs Every 1000hrs Every 2000hrs 1 Check and Supply Fuel 2 Check and Supply Engine Oil 3 Change Engine Oil 1 st 2 nd 4 Oil Filter Change 1 st 2 nd 5 Check/Add Coolant 6 Coolant Change or 2 years 7 Clean Fuel Filter 1 st 2 nd 8 Change Fuel Filter 9 Drain Water/Clean Fuel Tank 10 Check Leakage Fuel, Oil, Water 11 Check/Add Battery Liquid 12 Clean Air Element 1 st 2 nd 13 Change Air Element 14 Adjust tension V-belt 1 st 2 nd 15 Change V-belt or 2 years 16 Clean Radiator Fin 17 Clean Radiator inside 18 Change Fuel Hose, Oil Hose, Vibration-absorbing Rubber or 2 years 19 Adjust Engine Valve Clearance Adjust Plane 20 Check/Adjust Injection Nozzle 21 Check/Adjust Injection Pump 20

24 9. Trouble Shooting <Pre-check> Always check the volume of oil, coolant, and fuel before processing to trouble shooting. 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 1. Replace the volt meter. 2. Replace the generator. resistance value. 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. 3. Faulty AVR or voltage 3. Broken wires, loose or disconnected 3. Repair or replace the parts. adjuster. cable. 4. Adjust the rotation speed 4. Slow rotation. 4. Check the rotation speed of the of the engine properly. engine. 5. Repair. 5. Faulty initial 5. Broken or loose the wire. 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 gauge [VR1] on the 2. Adjust the voltage properly. AVR. 3. Broken wire, loose 3. Check wiring of voltage adjuster. 3. Inspect and repair the or disconnected Single wire disconnected: 240 to 280V. cable. cable of the voltage Double wire disconnected: 260 to 300V. adjuster circuit. Abnormal frequency 1. Unbalanced load. 1. Check the amperage of each 1. Balance the current. or voltage drop 2. Low rotation speed. phase. when load is 2. Check the rotation speed. 2. Adjust appropriate speed. increased. 3. Over load. 3. Check the amperage of each 3. Decrease the load. phase. Can't be turned on 1. The handle of the 1. Check the position of the handle. 1. Press the handle to the the circuit breaker. breaker is positioned [OFF] position first, then set between [ON] and the handle to the [ON] [OFF] position. position to reset. 2. Over load. 2. Check the load. 2. Decrease the load. 21

25 10. Wiring Diagram 22

26 23

27 24

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