SUPPLEMENTARY SERVICE MANUAL

WARNING
CAUTION:
NOTE:
FOREWORD
This Supplementary Service Manual has been
prepared to introduce electrical new service
and electrical new data for the EDL20000TE,
EDL26000TE. For complete information, on
service procedures, it is necessary to use this
Supplementary Service Manual together with
diesel engine workshop manual:
DIESEL ENGINE WORKSHOP MANUAL:
(97897-01644) E.F.D. June 2002
NOTICE
This manual was written by the Yamaha Motor
Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible
to put an entire mechanics education into one
manual, so it is assumed that persons using this
book to perform maintenance and repairs on
Yamaha generators have a basic understand-
ing of the mechanical concepts and procedures
inherent in generators repair. Without such
knowledge, attempted repairs or service to this
model may render it unfit to use and/ or unsafe.
Yamaha Motor Company, Ltd. is continually
striving to improve all models manufactured by
Yamaha. Modifications and significant changes
in specifications or procedures will be for-
warded to all Authorized Yamaha dealers and
will, where applicable, appear in future editions
of this manual.
OE022
EDL20000TE, EDL26000TE
SUPPLEMENTARY SERVICE MANUAL
2002 by Yamaha Motor Co., Ltd.
1st Edition, September 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor,
Co., Ltd. is expressly prohibited.
Printed in Japan.
HOW TO USE THIS MANUAL
Particularly important information is distin-
guished in this manual by the following nota-
tions:
The Safety Alert Symbol means ATTENTION!
BE ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting or
repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the machine.
A NOTE provides key information that can
make procedures easier or clearer.
MANUAL FORMAT
All of the procedures in this manual are orga-
nized in a sequential, step-by-step format. The
information has been compiled to provide the
mechanic with an easy to read, handy reference
that contains comprehensive explanations of all
inspection, repair, assembly, and disassembly
operations.
If this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required to correct the prob-
lem will follow the symbol, e.g.,
S Bearings
Pitting/ Damage ! Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams be-
fore each disassembly section to facilitate cor-
rect disassembly and assembly procedures.
CONTENTS
ELECTRICAL
GENERATOR ASSEMBLY 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OUTPUT VOLTAGE OF STATOR COIL 2 . . . . . . . . . . . . .
CHECKING EXCITER FIELD COIL RESISTANCE 3 . . . . . . . . . . . . . . .
CHECKING STATOR COIL RESISTANCE 3 . . . . . . . . . . . . . . . . . . . . . .
CHECKING OUTPUT VOLTAGE DETECTION CIRCUIT
RESISTANCE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTOR FIELD COIL RESISTANCE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXCITER COIL RESISTANCE 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR (EDL20000TE) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER SOURCE (EDL20000TE) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR (EDL26000TE) 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER SOURCE (EDL26000TE) 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL FUNCTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.C OUTPUT TERMINAL 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL WIRING DIAGRAM (380/ 220 V) 13 . . . . . . . . . . . . . . . . . . . . . . .
PANEL WIRING DIAGRAM (220/ 127 V) 14 . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (380/ 220 V) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (220/ 127 V) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (D.C 12 V) 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR TROUBLESHOOTING 18 . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CAN BE STARTED AND NO OUTPUT VOLTAGE 18 . . .
DIFFICULT TO TAKE OFF OUTPUT VOLTAGE
CONTINUOUSLY 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
MACHINE IDENTIFICATION 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERIAL NUMBER 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING SERIAL NUMBER 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/ LUBRICATION INTERVALS 22 . . . . . . . .
SPECIAL TOOLS/ TESTERS 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTERS 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON RING COMPRESSOR 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL/ FUEL FILTER WRENCH 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDL20000TE SPECIFICATIONS 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERVICE DATA 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR SERVICE DATA 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDL26000TE SPECIFICATIONS 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERVICE DATA 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR SERVICE DATA 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (380-220 V/ 50Hz) 30 . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (220-127 V/ 60Hz) 32 . . . . . . . . . . . . . . . . . . . . . . . . .
1
Order Job/ Part Qty Remarks
Disassembling the generator
Bracket
EX field coil assembly
Cover
Stator assembly
Bearing
Rectifier assembly
Rotor assembly
1
1
1
1
1
1
1
1
2
3
4
5
6
7
ELECTRICAL
GENERATOR ASSEMBLY
2
CAUTION:
CHECKING OUTPUT VOLTAGE
OF STATOR COIL
When the alternator is revolved at 3000
r/ min. (50 Hz)/ 3600 r/ min. (60 Hz) with DC
12 V connected on the exciter field coil (F+)
(F).
Terminals Generated voltage
(U) (V)
(V) (W)
(W) (U)
380/ 220 V model:
Approx. 480 V
220/ 127 V model:
Approx. 290 V
(O) (U)
(O) (V)
(O) (W)
380/ 220 V model:
Approx. 277 V
220/ 127 V model:
Approx. 170 V
To perform this test, remove A.V.R.
When the alternator is revolved at 3000
r/ min. (50 Hz)/ 3600 r/ min. (60 Hz) with
A.V.R and other lead wire disconnected.
Terminals Generated voltage
(U) (V)
(V) (W)
(W) (U)
380/ 220 V model:
Approx. 90 V
220/ 127 V model:
Approx. 50 V
(O) (U)
(O) (V)
(O) (W)
380/ 220 V model:
Approx. 52 V
220/ 127 V model:
Approx. 29 V
3
CHECKING EXCITER FIELD
COIL RESISTANCE
Check the resistance between (F+) (F)
terminals in the control panel.
Resistance (@ 20_C)
24.90 (22.41 X 27.39 )
Out of specification ! Repair wiring or re-
place the coil.
CHECKING STATOR COIL
RESISTANCE
Check the resistance between (U) (V), (V)
(W), (W) (U) terminals in the control pan-
el.
Resistance (@ 20_C)
EDL20000TE: 0.97 (0.87 X 1.07 )
EDL26000TE: 0.62 (0.55 X 0.69 )
Out of specification ! Repair wiring or re-
place the coil.
CHECKING OUTPUT VOLTAGE
DETECTION CIRCUIT
RESISTANCE
Check the resistance between (3) (4) ter-
minals in the control panel.
Resistance (@ 20_C)
EDL20000TE: 0.24 (0.21 X 0.27 )
EDL26000TE: 0.16 (0.14 X 0.18 )
Out of specification ! Repair wiring or re-
place stator coil.
ROTOR FIELD COIL
RESISTANCE
Check the resistance between two terminals
on the rotor.
Resistance (@ 20_C)
EDL20000TE: 9.35 (8.42 X 12.24 )
EDL26000TE: 10.90 (9.81 X 14.27 )
Out of specification ! Replace the rotor as-
sembly.
4
A
B
C
EXCITER COIL RESISTANCE
Check the resistance between (U) (V), (V)
(W), (W) (U) terminals on the rotor.
Resistance (@ 20_C)
0.713 (0.64 X 0.79 )
Out of specification ! Replace the rotor as-
sembly.
A (U) (V)
B (V) (W)
C (W) (U)
1 (U) terminal
2 (V) terminal
3 (W) terminal
5
GENERATOR (EDL20000TE)
Unit EDL20000TE
A.C Output:
Rated Voltage V 380/ 220 220/ 127
Type Brush-less A.C generator self-exciting
Frequency Hz 50 60
Rated output KVA (kW) 15.5 (12.4) 17.5 (14.0)
Maximum output KVA (kW) 17.0 (13.6) 19.0 (15.2)
Rated voltage V 380/ 220 220/ 127
Rated current A 23.6 45.9
Number of pole 2
Phase 3 phase 4 wire
Excitation method Self-excitation with magnetized
Voltage regulator A.V.R. (Automatic Voltage Regulator)
Power factor 0.8
Driving method Direct coupling
Safety device (type) N.F.B. (Non Fuse Breaker)
N.F.B capacity A 25 45
A.C Output method Terminal
Recommended battery capacity V/ Ah 12/ 65 (65B26R)
Voltage fluctuation % Less than 2.5
Frequency fluctuation % Less than 5
POWER SOURCE (EDL20000TE)
Frequency Power Source
Max. power take off
Frequency Power Source
EDL20000TE
60 Hz 220 V 17500VA
50 Hz 380 V 15500VA
60 Hz 127 V 5800 W
50 Hz 220 V 5100 W
60 Hz 220 V 10000 W
50 Hz 380 V 8900 W
6
GENERATOR (EDL26000TE)
Unit EDL26000TE
A.C Output:
Rated Voltage V 380/ 220 220/ 127
Type Brush-less A.C generator self-exciting
Frequency Hz 50 60
Rated output KVA (kW) 21.0 (16.8) 24.0 (19.2)
Maximum output KVA (kW) 23.0 (18.4) 26.0 (20.8)
Rated voltage V 380/ 220 220/ 127
Rated current A 31.9 63
Number of pole 2
Phase 3 phase 4 wire
Excitation method Self-excitation with magnetized
Voltage regulator A.V.R. (Automatic Voltage Regulator)
Power factor 0.8
Driving method Direct coupling
Safety device (type) N.F.B. (Non Fuse Breaker)
N.F.B capacity A 32 63
A.C Output method Terminal
Recommended battery capacity V/ Ah 12/ 70 (75B31R)
Voltage fluctuation % Less than 2.5
Frequency fluctuation % Less than 5
POWER SOURCE (EDL26000TE)
Frequency Power Source
Max. power take off
Frequency Power Source
EDL26000TE
60 Hz 220 V 24000VA
50 Hz 380 V 21000VA
60 Hz 127 V 8000 W
50 Hz 220 V 7000 W
60 Hz 220 V 13800 W
50 Hz 380 V 12000 W
7
CONTROL FUNCTION
1 Fuel tank cap
2 Control box
3 Radiator
4 Oil drain plug
5 Fuel filter
6 Generator assembly
7 Fuel tank
8 Fuel gauge
9 Battery housing
10 Battery (Not included in the package)
11 Oil filter
12 Reserve tank
13 A.C output terminal
14 Oil filler cap
15 Exhaust outlet
16 Air filter
17 Fuel cock
8
CONTROL BOX
1 Warning lamp
2 Voltage meter
3 Frequency meter
4 Ampere meter
5 Pilot lamp
6 Key switch
7 Voltage adjuster
8 Hour meter
9 A.C switch (N.F.B)
10 A.C output terminals
9
Order Job/ Part Qty Remarks
Disassembly control box
Panel
Panel
Panel cover
Panel cover
Key switch
Voltage adjuster
A.C switch (N.F.B)
Pilot lamp
Ampere meter
Frequency meter
Voltage meter
Hour meter
Warning lamp
A.V.R
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10
Order Job/ Part Qty Remarks
Fuse holder
Fuse holder
Terminal 2
Terminal 1
Lamp timer
Timer relay
1
1
1
1
1
1
15
16
17
18
19
20
11
Order Job/ Part Qty Remarks
Disassembly A.C output terminal
Panel
Terminal
Cover
Cover
1
4
1
1
1
2
3
4
A.C OUTPUT TERMINAL
12
1 Warning lamp
2 Key switch
3 Fuse holder
4 A.V.R.
5 Terminal 1
6 Lamp timer
7 Timer relay
8 Terminal 2
9 A.C switch (N.F.B.)
10 Pilot lamp
11 Ampere meter
12 Frequency meter
13 Hour meter
14 Voltage meter
15 Voltage adjuster
13
3
0
5
0
A
C
1
9
1
2
3
4
5
6
7
8
4 5 6
321
2 4
31
F
-
F
+
4
3
2
0
0
E
3
2
0
0
3
O
W
V
U
G
1
.2
5
W
1
.2
5
R
2
W
/B
1
.2
5
G
1
.2
5
B
1
.2
5
B
1
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5
G
/W
1
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5
Y
1
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5
Y
3
L
1
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5
L
1
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5
Y
1
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5
R
3
W
/R
1
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5
R
1
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5
-4
S
Y1.2 5
Y1.2 5 Y1.2 5
R 1 . 2 5
R
1
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5
-4
R
1
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5
-4
R1.2 5 - 4 S
L M F C
W
/R
1
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5
R1.2 5 - 4
R
1
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5
-6
T
M
E
D
6
3
0
8
2
0
F
6
7
R
1
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5
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R
1
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5
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R 1 . 2 5
L 1 . 2 5
Y 1 . 2 5
Y 1 . 2 5
L 1 . 2 5
W 1 . 2 5
W 1 . 2 5
L
M
F
C
L M F C
B
/R
1
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5
R
1
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5
G
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1
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5
G
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1
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5
W
/B
1
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5
L
1
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5
L
1
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5
G
/R
1
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5
W
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1
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5
R
1
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5
W 1 . 2 5
R 1 . 2 5
Y 1 . 2 5
Y
3
W
1
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5
Y
1
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5
P
1
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5
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1
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5
G
Y
1
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5
O
1
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1
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1
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5
U
A
A
VW
U
N
.
F
.
B
A
.
V
.
R
VW
1
A
1
A
1
A
1
A
1
A
1
A
1
A
1
A
2
A
-+
B
B
PANEL WIRING DIAGRAM (380/220 V)
14
R 1 . 2 5
R
1
.2
5
-4
R
1
.2
5
-4
R
1
.2
5
-6
R
1
.2
5
-4
R 1 . 2 5
L 1 . 2 5
Y 1 . 2 5
Y 1 . 2 5
L 1 . 2 5
W 1 . 2 5
W 1 . 2 5
G
1
.2
5
W
1
.2
5
-+ T
M
E
D
6
3
0
8
2
0
F
R
1
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5
-3
L
1
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5
L
1
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5
1
2
3
4
5
6
7
8
3
0
5
0
A
C
1
9
Y
3
L
1
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5
L
1
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5
Y
1
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5
R
3
W
/R
1
.2
5
Y1.2 5
Y1.2 5 Y1.2 5
R1.2 5 - 4 S
R1.2 5- 4
G
/B
1
.2
5
1
A
1
A
1
A
1
A
1
A
1
A
1
A
1
A
2
A
W
/B
1
.2
5
L
1
.2
5
Y 1 . 2 5
F
-
F
+
4
3
2
0
0
E
3
R
1
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5
-4
S
Z
P
1
. 2
5
. 2
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1
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5
W
1
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5
Y
1
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Y
1
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5
O
1
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5
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R
1
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5
R
1
5
4 5 6
321
B
1
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5
G
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1
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5
Y
1
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5
W
/R
1
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5
2 4
31
2
0
0
3
O
W
V
U
R
2
W
/B
1
.2
5
G
1
.2
5
B
1
.2
5
L
M
F
C
W 1 . 2 5
R 1 . 2 5
B
/R
1
.2
5
R
1
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5
G
/R
1
.2
5
W
/G
1
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5
R
1
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5
Y
3
L M F C
L M F C
G
/W
1
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5
B
B
U
A
A
VW
UV
N
.
F
.
B
A
.
V
.
R
W
PANEL WIRING DIAGRAM (220/127 V)
15
E
X
.
2

A
1
H
z
V
R
E
2
0
0
34
F
-
F
+
R
O
R
YW
G
L
R
O
R
YW
G
L
B
R
6 7
P P
L
A
V
UV
W
O
UV
W
O
k
l
K
L
6
234
5
7
1
4
1
2
1
1
1
0
9
8
1
3
1
5
WIRING DIAGRAM (380/220 V)
16

E
X
.
2

A
2

A
H
z
L
A
k
l
K
L
VV
R
UV
W
O
UV
W
O
E
2
0
0
34
F
-
F
+
R
O
R
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G
L
R
O
R
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G
L
B
R
6 7
P P
6
2
1
34
5
7
1
4
1
2
1
1
1
0
9
8
1
3
1
5
WIRING DIAGRAM (220/127 V)
17
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T
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1 A
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A
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5
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4
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4
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8
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6
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G
G
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R
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W
G
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Y
G
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W
Y
W
/
R
W
L
2
W
/
B
W
/
B
G
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R
W
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G
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W
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1 A
1
7
1
6
2
9
1
8
1
9
2
7
2
0
2
1
2
2
2
3
2
4
2
5
2
8
2
6
WIRING DIAGRAM (D.C 12 V)
18
GENERATOR TROUBLESHOOTING
ENGINE CAN BE STARTED AND NO OUTPUT VOLTAGE
Phenomena Check point Cause Remedy
DVolt meter
i di ti i OK
No output voltage
t t t t i l
N.F.B position Position is OFF Set to ON
indication is OK
and pilot lamp is
at output terminals
N.F.B operation (shutting off
t ti ll )
Overloaded Connecting less load
and ilot lam is
ON.
automatically)
Inspect a short circuit
Continuity of N.F.B No continuity: Defective
N.F.B
Replace N.F.B
Continuity: Output terminal
is OK.
Wire lead connected to (U)
or (O) is broken. (Volt meter
is connected to (V) and (W).)
Inspect the wiring at control
panel.
Continuity: Defective output
terminal
Replace the terminal
There is out put
voltage at output
t i l
Connected terminal or
receptacle at the load
No voltage: Defective
extension cord
Inspect or replace the
extension cord
terminals.
There is voltage: Detective
load equipment
Inspect or repair the load
equipment
DVolt meter
i di ti
Low voltage Fuse from stator Fuse is burned out Replace the fuse
indication
Defective A.V.R Replace A.V.R
Rotor field coil and exciter
coil (U)-(V), (V)-(W), (W)-(U)
Coil is broken or burnt Repair or replace the coil
Exciter Field Coil (F+)-(F) Coil is broken or burnt Repair or replace the coil
Rectifier Defective Rectifier Repair or replace the
rectifier
Fuse for A.V.R Fuse is burned out Replace the fuse
No voltage (0 V)

No residual magnetism on
the rotor.
Excite the field coil manually
by connecting battery
voltage.
Main Coil (Stator) Main Coil (Stator) is broken. Replace the stator
Wiring between alternator
and output terminals
Defective wire Repair or replace
DIFFICULT TO TAKE OFF OUTPUT VOLTAGE CONTINUOUSLY
Phenomena Check point Cause Remedy
DN.F.B shut off
automatically
Output voltage is
normal
Connected load Overloaded Connecting less load
Output voltage is
high
Terminal connection on
A.V.R
Improper connection on
A.V.R
Repair or replace the
connection
Detective A.V.R Replace A.V.R
Wiring and connection Wrong connection Connect rightly.
DLess output than
t d t t
Engine revolution
i l
Lead wire on A.V.R Wire is broken Repair or replace the wire.
rated output is normal.
Terminal connection on
A.V.R
Improper connection on
A.V.R
Repair or replace the
connection
Unstable engine
l ti
Rotor bearing Defective bearing Replace bearing
revolution
Lower engine power Inspect and repair the
engine
Governor of injection pump Defective governor function Inspect and repair the
governor system
Unstable load
DConnected load
equipment
DAlternator
Inspect load equipment.
Inspect and repair the
alternator
Engine revolution Lower engine revolution Adjust to rated engine
revolution
Low voltage Defective A.V.R Replace A.V.R
Fuse for A.V.R Fuse is burned out Replace the fuse
Fuse from stator FUse is burned out Replace the fuse
Exciter Field Coil (F+)-(F) Coil is broken or burnt Repair or replace the coil
Rotor filed coil and exciter
coil (U)-(V), (V)-(W), (W)-(U)
Coil is broken or burnt Repair or replace the coil
19
TROUBLESHOOTING
20
21
NOTE:
NOTE:
GENERAL INFORMATION
MACHINE IDENTIFICATION
SERIAL NUMBER
The serial number is stamped label 1 which
is affixed to the generator as shown.
The first three characters of this number are
for model identification, the remaining digits
are the unit production number.
STARTING SERIAL NUMBER
EDL 20000TE (380 220 V/ 50 Hz)
Q9C2 800101 X . . . .
EDL20000TE (220 127 V/ 60Hz)
Q9C2 700101 X . . . .
EDL 26000TE (380 220 V/ 50Hz)
Q9C3 800101 X . . . .
EDL 26000TE (220 127 V/ 60Hz)
Q9C3 700101 X . . . .
Designs and specifications are subject to
change without notice.
22
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable machine op-
eration and a longer service life. The need for costly overhaul work will be greatly reduced. This in-
formation applies to machines already in service as well as new machines that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
Item Remarks
PreOpera-
tion check
(daily)
Initial
50 Hr
Every
100 Hr
Every
200 Hr
Every
500 Hr
Engine Oil:
Check oil level. F
Engine Oil:
Replace. F F
Engine Oil Filter
Cartridge:
Replace. F
Air Filter:
Clean.
Replace if necessary.
F
Clean fuel cock and fuel tank filter. F
Fuel Filter:
Replace.
F
(400 Hr)
Check coolant level and leaks. F
Clean radiator fin. F
Check fan belt tension. F
C li S t
Replace fan belt. F
Cooling System:
Check radiator hose and clamps.
Replace if necessary.
F
F
Replace
(2 years)
Replace coolant; Clean radiator.
F
(2 years)
Valve Clearance: Check and adjust when engine is cold.
F
(800 Hr)
Fuel Line:
Check fuel hose for cracks or damage.
Replace if necessary.
F
F
Replace
(2 years)
Fuel Tank: Check and remove sediment. F
Injection Nozzle: Check and clean. Adjust if necessary.
F
(1500 Hr)
Exhaust System:
Check for leakage.
Retighten or replace gasket if necessary.
F
Starting System: Check operation. F
Decarbonization: More frequently if necessary. F
Generator: Check the pilot light turns on. F
Check battery fluid level. Add distilled
water.
F
Battery:
Check specific gravity and breather pipe
operation. Correct if necessary.
F
Replace
battery af-
ter 2 years.
Fittings/Fasteners:
Check all fittings and fasteners.
Correct if necessary.
F
23
SPECIAL TOOLS/TESTERS
SPECIAL TOOLS
No special tools have been made. Make
them by referring to the following figures.
Valve guide replacing tool
Application: Use to press out and press fit
the valve guide.
Crankshaft bearing 1 replacing tool
Application: Use to press out the crankshaft
bearing 1.
S Indication without [ ]: When press out or
same as press fit.
S Indication with [ ]: When press fit.
Governor gear holder bushing replacing
tool
Application: Use to press out and press fit
the crankshaft bearing 1.
Bushing replacing tool
Application: Use to press out and to press fit
the bushing.
S Indication without [ ]: For small end
bushing.
S Indication with [ ]: For idle gear bushing.
24
Flywheel stopper
Application: Use to loosen and tighten the
flywheel screw.
TESTERS
There are no testers only for use with the die-
sel engine (D722)
Purchase commercially available testers
1 Diesel engine compression tester
2 Engine oil pressure tester
3 Injection nozzle tester
4 Radiator tester
5 Valve seat cutter set
6 Engine oil filter wrench
Injection pump pressure tester
Make this tester by referring to the following
figure.
Application: Use to check the fuel tightness.
A Pressure gauge full scale: more than
29.4 MPa (300 kgf / cm
2
, 4267 psi)
B Copper gasket
C Flange (Material: Steel)
D Hex. Nut, 27 mm (1.06 in.) across the flat
(Material: Steel)
E Injection pipe
a Adhesive application
b Fillet welding on the enter circumference
PISTON RING COMPRESSOR
1 Piston ring compressor
90890-05158 H19 (50 X 90 mm)
25
OIL/ FUEL FILTER WRENCH
1 Oil filter / Fuel filter (80)
2 Wrench
26
EDL20000TE SPECIFICATIONS
GENERAL SPECIFICATIONS
DIMENSIONS
UNIT 380-220 V/ 50 Hz 220-127 V/ 60 Hz
Overall length Overall width
Overall height
mm 1380 700 945
Dry weight kg 340
ENGINE
Type
Vertical, Liquid cooled,
4cycle diesel engine
Total displacement cm
3
1001
Number of cylinder-Bore Stroke mm 3 76 73.6
Compression ratio 23 : 1
Rated output kW (PS) / rpm 14.0 (19.0) / 3000 16.5 (22.5) / 3600
Operating hours Hr 17 14.8
Cooling system Pressurized Radiator, Forced circulation with water pump
Cooling water (coolant) capacity 5.1 (Radiator: 2.0 + cylinder block: 3.1)
Fuel Automobile Type Diesel fuel No.2-D (ASTMD975)
Fuel tank capacity (Full) 80
Engine oil grade API service CD or CE, SAE: 10W30
Engine oil capacity 5.1
Lubrication system Forced lubrication with trochoide pump
Air cleaner type Filter-paper cyclone
Starting system Electric starter (with glow plug)
Noise level
Measured at rated operation
from 7 m distance
db A 79 83
GENERATOR
Type Brush-less AC generator self-exciting
Frequency Hz 50 60
Rated output KVA (kW) 15.5 (12.4) 17.5 (14.0)
Maximum output KVA (kW) 17.0 (13.6) 19.0 (15.2)
Rated voltage V 380/ 220 220/ 127
Rated current A 23.6 45.9
Number of pole 2
Phase 3 phase 4 wire
Excitation method Self-excitation with magnetized
Voltage regulator A.V.R. (Automatic Voltage Regulator)
Power factor 0.8
Driving method Direct coupling
Safety device (type) N.F.B. (Non Fuse Breaker)
N.F.B. capacity A 25 45
AC Output method Terminal
Recommended battery capacity V/ Ah 12/ 65 (65B26R)
Voltage fluctuation % Less than 2.5
Frequency fluctuation % Less than 5
27
- U V
- V W
- W U
-
U V
-
F+ F-
-
V W
-
W U
-
O U
-
O V
-
O W
ENGINE SERVICE DATA
UNIT 380-220 V/ 50 Hz 220-127 V/ 60 Hz
Model D1005
Type Vertical Liquid cooled 4-cycle diesel engine
Number of cylinders 3
Bore Stroke mm 76 73.6
Total displacement cm
3
1001
Rated output kW (PS) / rpm 14.0 (19.0) / 3000 16.5 (22.5) / 3600
Idling speed (without the load) rpm 3850
Combustion chamber Spherical type (E-TVCS), Indirect injection
Fuel injection pump BOSCH MD type mini. pump
Governor Centrifugal Ball Mechanical Governor
Direction of rotation Counter-clockwise (viewed from flywheel)
Injection nozzle BOSCH DN-0PD mini. Nozzle, Throttle type
Injection timing 19_ before T.D.C.
Injection order 123
Injection pressure Mpa (kg/ cm
2
) 13.73 (140)
Compression ratio 23 : 1
Lubrication system Forced lubrication with trochoid pump
Oil Pressure Indication Electrical Type Switch
Lubricating filter Full Flow Paper Filter (Cartridge Type)
Cooling system Pressurized Radiator, Forced circulation with water pump.
Starting system
Electric starter
Starting system
V-kW 12-1.0
Starting support device by Glow Plug in Combustion Chamber
Recommended battery capacity V/ Ah 12/ 65 (65B26R)
Generator for Battery charging V-W 12-480
Fuel Automobile Type Diesel fuel No.2-D (ASTMD975)
Engine oil API service CD or CE, SAE: 10W-30
Engine oil capacity 5.1
Weight kg 89 (Only engine)
Application General Power Source
Fuel consumption ratio g/ kWSh (g/ PSSh) 285 (210)
Cooling water (coolant) capacity 5.1 (Radiator: 2.0 + Cylinder block: 3.0)
Reservoir tank capacity Upper level: 0.6, Lower level: 0.1
Ambient temperature range _C (_F) 15 X 40 (5 X 104)
GENERATOR SERVICE DATA
380-220 V/ 50Hz 220-127 V/ 60Hz
Coil resistance ( 10% at 20_C)
Stator Main coil
Rotor Main field coil
Rotor Exciter armature coil U-V, V-W, W-U
Exciter field coil
0.97
0.97
0.97
9.35
0.713
24.90
0.24
0.24
0.24
9.35
0.713
24.90
Stator main coil generated voltage (AC-V)
S Without A.V.R. (Disconnected all lead wire)
S Engine should be operated at rated speed.
D , ,
D , ,
Approx. 90
Approx. 52
Approx. 50
Approx. 29
28
EDL26000TE SPECIFICATIONS
GENERAL SPECIFICATIONS
DIMENSIONS
UNIT 380-220 V/ 50 Hz 220-127 V/ 60 Hz
Overall length Overall width
Overall height
mm 1380 700 945
Dry weight kg 380
ENGINE
Type
Vertical, Liquid cooled,
4cycle diesel engine
Total displacement cm
3
1335
Number of cylinder-Bore Stroke mm 4 76 73.6
Compression ratio 23 : 1
Rated output kW (PS) / rpm 18.8 (25.5) / 3000 22.0 (30.0) / 3600
Operating hours Hr 12.9 11.1
Cooling system Pressurized Radiator, Forced circulation with water pump
Cooling water (coolant) capacity 6.0 (Radiator: 2.0 + cylinder block: 4.0)
Fuel Automobile Type Diesel fuel No.2-D (ASTMD975)
Fuel tank capacity (Full) 80
Engine oil grade API service CD or CE, SAE: 10W30
Engine oil capacity 6.0
Lubrication system Forced lubrication with trochoide pump
Air cleaner type Filter-paper cyclone
Starting system Electric starter (with glow plug)
Noise level
Measured at rated operation
from 7 m distance
db A 81 85
GENERATOR
Type Brushless AC generator self-exciting
Frequency Hz 50 60
Rated output KVA (kW) 21.0 (16.8) 24.0 (19.2)
Maximum output KVA (kW) 23.0 (18.4) 26.0 (20.8)
Rated voltage V 380/ 220 220/ 127
Rated current A 31.9 63
Number of pole 2
Phase 3 phase 4 wire
Excitation method Self-excitating with magnetized
Voltage regulator A.V.R. (Automatic Voltage Regulator)
Power factor 0.8
Driving method Direct coupling
Safety device (type) N.F.B. (Non Fuse Breaker)
N.F.B. capacity A 32 63
AC Output method Terminal
Recommended battery capacity V/ Ah 12/ 70 (75B31R)
Voltage fluctuation % Less than 2.5
Frequency fluctuation % Less than 5
29
- U V
- V W
- W U
-
U V
-
F+ F-
-
V W
-
W U
-
O U
-
O V
-
O W
ENGINE SERVICE DATA
UNIT 380-220 V/ 50 Hz 220-127 V/ 60 Hz
Model V1305
Type Vertical Liquid cooled 4-cycle diesel engine
Number of cylinders 4
Bore Stroke mm 76 73.6
Total displacement cm
3
1335
Rated output kW (PS) / rpm 18.8 (25.5) / 3000 22.0 (30.0) / 3600
Idling speed (without the load) rpm 3850
Combustion chamber Spherical type (E-TVCS), Indirect injection
Fuel injection pump BOSCH MD type mini. pump
Governor Centrifugal Ball Mechanical Governor
Direction of rotation Counter-clockwise (viewed from flywheel)
Injection nozzle BOSCH DN-0PD mini. Nozzle, Throttle type
Injection timing 19_ before T.D.C.
Injection order 1342
Injection pressure Mpa (kg/ cm
2
) 13.73 (140)
Compression ratio 23 : 1
Lubrication system Forced lubrication with trochoid pump
Oil Pressure Indication Electrical Type Switch
Lubricating filter Full Flow Paper Filter (Cartridge Type)
Cooling system Pressurized Radiator, Forced circulation with water pump.
Starting system
Electric starter
Starting system
V-kW 12-1.2
Starting support device by Glow Plug in Combustion Chamber
Recommended battery capacity V/ Ah 12/ 70 (75B31R)
Generator for Battery charging V-W 12-480
Fuel Automobile Type Diesel fuel No.2-D (ASTMD975)
Engine oil API service CD or CE, SAE: 10W-30
Engine oil capacity 6.0
Weight kg 110.0 (Only engine)
Application General Power Source
Fuel consumption ratio g/ kWSh (g/ PSSh) 285 (210)
Cooling water (coolant) capacity 6.0 (Radiator: 2.0 + Cylinder block: 4.0)
Reservoir tank capacity Upper level: 0.6, Lower level: 0.1
Ambient temperature range _C (_F) 15 X 40 (5 X 104)
GENERATOR SERVICE DATA
380-220 V/ 50Hz 220-127 V/ 60Hz
Coil resistance ( 10% at 20_C)
Stator Main coil
Rotor Main field coil
Rotor Exciter armature coil U-V, V-W, W-U
Exciter field coil
0.62
0.62
0.62
10.9
0.713
24.90
0.16
0.16
0.16
10.9
0.713
24.90
Stator main coil generated voltage (AC-V)
S Without A.V.R. (Disconnected all lead wire)
S Engine should be operated at rated speed.
D , ,
D , ,
Approx. 90
Approx. 52
Approx. 50
Approx. 29
30
G
E
N
E
R
A
T
O
R
C
O
N
T
R
O
L

B
O
X
S
T
A
T
O
R

A
S
S
Y
R
O
T
O
R

A
S
S
Y
E
N
G
I
N
E
M
6
R
W
/
B
B
/
R
L
R
G
W
/
B
Y
B
G
/
W
W
/
R
Y
L
L
W
/
R
Y
2
A
1
A
Y
Y
Y
Y
Y
Y
Y
Y
L
L
R
Y
W
/
R
W
/
R
1
9
A
C
5
0
B
R
R
G
W
G
/
L
G
/
W
Y
Y
G
/
L
G
/W
B
/W
G
/
R
W
/B
W
/B
Y
/B
B
/Y
W
/R
W
/G
R
/B
R
R
A
C
1
9
5
0
B
O
F
F
O
N
G
L
O
W
S
T
A
R
T
W
RW
L
RW
L
UVWO
L
K
L
H
z
A
V
W
a
t
e
r

t
e
m
p
e
r
a
t
u
r
e

l
a
m
p
O
i
l

p
r
e
s
s
u
r
e

l
a
m
p
B
a
t
t
e
r
y

c
h
a
r
g
e

l
a
m
p
G
l
o
w

l
a
m
p
G
/
W
Y
G
/
W
G
/
W
W
/
B
R
N
F
B
R
R
W
/
R
W
/
B
B
/
R
B
/
W
Y
/
B
Y
/
B
B
/
Y
YR
R
/
B
W
/
B
R
G
/
R
G
/
L
W
/
G
W
/
B
W
/
R
G
R
L
M
4
R
M
8
M
4
G
/
R
L
R
L
R
B
/
R
R
G
Y
W
Y
O
R
A
-
V
-
R
R
B
R
P
P
2 0 0 3 O W V U
V
R
F
-
F
+
4
3
E
3
6
7
2
0
0
1
234
5
6
1
7
1
6
2
9
1
9
2
7
2
5
2
4
2
3
7
2
1
2
0
1
5
2
8
1
8
2
6
2
2
1
4
1
3
1
2
1
1
1
0
9
8
WIRING DIAGRAM (380-220 V/50Hz)
31
32
G
E
N
E
R
A
T
O
R
C
O
N
T
R
O
L

B
O
X
S
T
A
T
O
R

A
S
S
Y
R
O
T
O
R

A
S
S
Y
E
N
G
I
N
E
M
6
M
4
M
4
R
B
/
R
R
R
R
W
/
B
B
/
R
G
/
R
L
R
L
R
G
W
/
B
Y
B
G
/
W
W
/
R
G
Y
W
Y
O
R
A
-
V
-
R
R
B
R
P
P
L
L
W
/
R
Y
Y
2
A
1
A
Y
Y
Y
Y
Y
Y L
L
R
Y
W
/
R
R
R
W
/
R
1
9
A
C
5
0
B
R
R
B
/
R
G
W
G
/
L
G
/
W
Y Y
G
/
L
G
/W
B
/W
G
/
R
W
/B
W
/B
Y
/B
B
/Y
W
/R
W
/G
R
/B
R
R
W
/
B
A
C
1
9
5
0
B
O
F
F
O
N
G
L
O
W
S
T
A
R
T
W
RW
L
R
N
F
B
W
L
UVWO
L
K
V
R
L
H
z
A
V
W
a
t
e
r

t
e
m
p
e
r
a
t
u
r
e

l
a
m
p
O
i
l

p
r
e
s
s
u
r
e

l
a
m
p
B
a
t
t
e
r
y

c
h
a
r
g
e

l
a
m
p
G
l
o
w

l
a
m
p
G
/
W
Y
G
/
W
G
/
W
W
/
R
Y
M
8
R
G
/
R
G
/
L
W
/
G
B
/
W
B
/
W
B
/
Y
YR
W
/
R
W
/
B
W
/
R
L
R
G
W
/
B
L
R
2 0 0 3 O W V U
F
-
F
+
4
3
E
3
6
7
2
0
0
1
234
5
6
1
71
6
2
9
1
9
2
7
2
5
2
4
2
3
7
2
1
2
0
1
5
2
8
1
8
2
6
2
2
1
4
1
3
1
2
1
1
1
0
9
8
WIRING DIAGRAM (220-127 V/60Hz)
33
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
02.08 1
(E)
ITP