Clarke YC6 (Internal) Super-Silent Air-Cooled

Clarke YC6 (Internal) Super-Silent Air-Cooled
Operation & Maintenance Manual
6.0kVA 3000rpm
YC6
(Internal)
Super-silent Air-cooled
Diesel Generator
Clarke International
Hemnall Street
Epping
Essex CM16 4LG
Tel 01992 565335
Fax 01992 561562
www.clarkeinternational.com
Email export@clarkeinternational.com
YC6
(Internal)
Part Number 498-047, Issue A
E & OE.
Contents
Section
Contents
Page
2.0
2.1
2.2
Specification
Figure 1 General Dimensions
Table 1 General Specification
4
5
3.0
3.1
3.2
3.3
3.4
Safety
General Precautions and Warning Labels
Electrical Safety and Earthing
Lifting
Hazards to Health and Electrocution
7
14
14
15
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Operation and User’s Instructions
Engine Control Module
Engine Oil
Starting
Stopping
Power Output Connections
Shut Down Protection Devices
Control Panel
17
17/21
18
18
18
18
20
5.0
5.1
5.2
5.3
5.4
Fault Finding
Engine Fails to Start
Engine Starts but then Stops
Other Engine Faults
No Electrical Output
21
22
22
23
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
Maintenance
Service Schedule - Kubota
Engine Oil & Coolant
Fuel System
Engine Valve Clearances
Battery
Alternator
Earth Leakage Unit and Miniature Circuit Breaker (MCB’s)
Control Module
Battery Charging
Canopy and Trolley
General Inspections
Light Loading
Maintenance Record Sheet
24
25
25
25
25
25
25
25
25
26
26
26
27
7.0
7.1
7.2
Spares and Service
Contact Details
Spares List
28
28
8.0
8.1
Long Term Storage
Long Term Storage
29
9.0
9.1
9.2
9.3
9.4
Wiring Diagrams
DC wiring
AC wiring
Remote Start Wiring
Remote Start Leads
30
31
32
33
10.0
11.0
Notes
Warranty Statement
34
35
YC6 (Internal)
3
Section 2 Specification
2.1 Figure 1 – General Dimensions
4
YC6 (Internal)
Section 2 Specification
2.2 Table 1 – General Specification
Model Name
Super-Compact Welf-Air
Basic configuration
Standard Mecc Alte version with 230V output.
Powered by Yanmar Diesel engine
For fixed / long term installation use, either in cabins or as a standby set.
Engine
Oil capacity
Oil specification
Yanmar L100AE-DEG
8.8 hp / 6.5 kW
1.65 litres
15W40
API grade CG or better
Fuel
Diesel
Cooling
Forced air
Alternator
Mecc Alte SW20
Generator Power
Output:
AC Power
Power factor pf
4.8kW
6.0kVA
0.8
Dimensions (approx):
Height
Length
Width
Weight dry for shipping
Weight with engine oil
and full fuel
1113mm
825mm
506mm (excluding mounting brackets)
198 kg
221 kg
Output Voltages
230V
Sockets
1 x 16A, 1x 32A BS4343
Sound Level
2006 EC Stage 2 Regulations
LWA 95 dB
80db (A) @7 metres.
YC6 (Internal)
5
Section 2 Specification
Model Name
Protection
IP Rating
Fuel Tank Capacity
Fuel run time at 75% power
Super-Compact Welf-Air
MCB & RCD protected
IP23
32 litres
21.5 hours approx.
Low fuel shut down
Yes
Low oil pressure shut down
Yes
Over cranking protection
Yes
Hours run counter
Yes
Electric battery start
Yes
Battery
Easy access to oil dip stick
44 Ah maintenance-free unit
Yes
Standard Colour
White
Maximum ambient operating
temperature
45°C
Minimum ambient operating
temperature
(using standard diesel fuel)
-5° C
Maximum altitude above sea level
(without affecting performance
significantly)
6
1000 m
YC6 (Internal)
Section 3 Safety
3.1 General Precautions
The generator is fitted with a number of labels that alert the User to the safe operation and safety
requirements. A full explanation of these is contained here. If any of the labels are missing or unreadable
a duplicate should be obtained and fitted. All labels are quantity 1 unless otherwise indicated.
Label
Location and Part No.
On top, adjacent to control module.
Description
CHECK ENGINE OIL LEVEL
DAILY
Label Part No: 499-090/07
The oil level should be seen on
the oil dip stick as per the
diagram on the label.
Inside the RH access door, on the fuel
tank.
Label Part No: 499-090/01
On top and on the sides, next to the air
vents. Qty 3 off.
Label No: 499-090/02
On RH side, next to exhaust outlet.
DIESEL FUEL ONLY
This generator must only be filled
with commercial diesel fuel. If
special grades of diesel e.g. BioDiesel are to be used consult
HGI first to discuss its suitability.
INLET AND OUTLET VENTS
TO BE KEPT CLEAR
These must be kept free from
obstructions to allow a free flow
of cooling air or the engine and
alternator could over heat.
CAUTION HOT EXHAUST
Label part No: 499-090/03
The exhaust pipe is shielded as
much as is practical but the final
outlet is hot.
On side panels
ELECTRICITY IS DANGEROUS
Part of label No: 499-090/09
If in doubt about the correct use
consult a qualified electrician or
contact our Technical Help Line.
On side panels
CHECK ENGINE OIL LEVEL
DAILY
Part of label No: 499-090/09
Check the oil level each day and
top up if necessary to the top
mark given in the oil level
diagram
above.
If
oil
consumption
is
excessive
investigate further.
YC6 (Internal)
7
Section 3 Safety
On side panels
Part of label No: 499-090/09
OPERATING THE
GENERATOR AT LOW LOADS
LEVELS FOR LONG PERIODS
OF TIME MAY CAUSE
EXCESSIVE SMOKE AND
REDUCE EFFICIENCY DUE TO
CARBON BUILD UP.
If the generator is not required
switch it off and avoid running
with light or no load wherever
possible.
On side panels
Part of label No: 499-090/09
ENSURE GENERATOR IS AT
LEAST 1 METRE AWAY FROM
BUILDINGS, VEHICLES etc.
WHEN IN USE.
Ensure exhaust and air exit vents
are not restricted or obstructed.
On side panels
Part of label No: 499-090/09
OPERATE ONLY IN WELL
VENTILATED AREAS.
EXHAUST FUMES CAN KILL.
Generally the generator will be
operated out of doors or in large
well
ventilated
industrial
buildings. If the generator is to be
operated in a small room or
compartment an optional exhaust
extension should be used to duct
the exhaust gas straight outside
and sufficient air grilles for
ventilation should be provided.
For such applications consult the
Technical Help Line if in doubt.
On side panels
Part of label No: 499-090/09
STOP ENGINE AND ALLOW
TO COOL DOWN FOR A FEW
MINUTES BEFORE
REFUELLING.
In addition DO NOT SMOKE
while refuelling, use a funnel or
similar to prevent fuel spillage,
avoid over filling the fuel tank
and wipe up any spilt fuel. Avoid
contact of fuel with skin.
On side panels
DO NOT SPILL FUEL ONTO
HOT SURFACES
Part of label No: 499-090/09
The exhaust outlet and the box
around it in particular are hot.
8
YC6 (Internal)
Section 3 Safety
On side panels
Part of label No: 499-090/09
DO NOT ADJUST THE SPEED
OF THE ENGINE UNLESS YOU
HAVE BEEN TRAINED TO DO
SO
If the generator is not producing
enough power for the application
or you suspect a problem do not
adjust the engine speed. This
may
damage
the
engine,
alternator
and
any
power
equipment plugged into the
generator.
On side panels
Part of label No: 499-090/09
KEEP CHILDREN AT A SAFE
DISTANCE FROM THE
EQUIPMENT AND DO NOT
ALLOW THEM TO OPERATE IT
This is a mandatory Health and
Safety Requirement for this
equipment. A version with a key
switch is available if required.
On side panels
DO NOT OPERATE WITH ANY
COVERS OPEN
Part of label No: 499-090/09
If covers are open (or missing)
the generator will exceed the
European Noise Regulations and
the cooling of the engine and
alternator will be affected which
could cause damage to them.
On side panels
ONLY OPERATE ON A LEVEL
SURFACE
Part of label No: 499-090/09
Generally the generator will only
be used on a level surface. It can
be used on small inclines but
additional precautions may be
needed to stop it moving due to
vibration and this may also affect
fuel autonomy.
YC6 (Internal)
9
Section 3 Safety
On side panels
Part of label No: 499-090/09
THIS GENERATOR SHOULD
ONLY BE USED TO POWER
DOUBLE INSULATED CLASS II
ELECTRICAL EQUIPMENT
UNLESS THE OPTIONAL
EARTH LEAKAGE TRIP (RCD)
IS FITTED.
In the UK it is currently
permissible to use small mobile
generators for short periods
without
an
external
earth
connection being made. But
ONLY double insulated electrical
equipment can be powered by
the generator. All modern
electrical equipment intended for
out doors use should be double
insulated and marked with the
logo.
On side panels
Part of label No: 499-090/09
IF AN EARTH LEAKAGE TRIP
(RCD) IS FITTED THE
GENERATOR’S BRASS
EARTH STUD SHOULD BE
CONNECTED TO AN
EXTERNAL EARTH FOR THE
RCD TO WORK CORRECTLY.
THIS EXTERNAL EARTH CAN
BE AN EARTH SPIKE OR ANY
SUITABLE EARTH POINT. THE
RCD SHOULD BE TESTED
DAILY BY PRESSING THE
TEST BUTTON AND
CHECKING IT DOES TRIP.
If the generator is to be used for
a fixed installation or installed on
the same site for a long period it
should be installed by a
competent person. The User
should be shown where the
TEST button is located and
shown how to use it. An earth
spike kit is available as an
optional extra
On the front face of the base.
Label part No: 499-/90/95
10
LWA 95 dB
This is the sound level. At this
level the generator should not be
operated in a small space
occupied by people.
YC6 (Internal)
Section 3 Safety
On control panel.
EARTH POINT
Label No: 499-090/11
If an earth leakage trip (RCD)
or centre tapped to earth
alternator is fitted an M8 brass
earth stud is supplied next to
the output sockets for the
external earth connection.
On the main access panels. Qty 2 off.
AUTOMATIC MACHINERY –
MAY START WITHOUT
WARNING
Label part No: 499-090/22
This is only fitted if the
generator is an AMF
(automatic mains failure)
version intended to start the
set automatically if the mains
electricity fails OR a Remote
Start Version.
While checking the oil level or
doing any type of maintenance
on this generator it should be
made safe so it cannot start
automatically by removing the
control fuse.
On main access panels. Qty 2 off.
DANGER – MOVING
MACHINERY INSIDE DOOR
Label part No: 499-090/15
Moving parts will be present
whilst the machine is in
operation. Stop the machine
and isolate before removing
the door/access panel.
YC6 (Internal)
11
Section 3 Safety
On the Battery Access Covers.
Qty 2 off.
Part of label No: 499-090/05
On the Battery Access Covers.
Qty 2 off.
Part of label No: 499-090/05
On the Battery Access Covers.
Qty 2 off.
The battery is 12 V DC and care
should be taken not to come into
contact with the terminals.
DANGER ACID
The battery contains acid and if
any liquid is seen check the
source, but assume first that it is
acid. Care should be taken in
cleaning up acid. See Section 3
Safety.
WARNING EXPLOSIVE
MATERIAL
Part of label No: 499-090/05
The battery can under certain
conditions give off small quantities
of hydrogen gas. Do not smoke or
use naked flames while working
on a battery. NEVER attempt to
burn a battery as a method of
disposal.
On the Battery Access Covers.
Qty 2 off.
DISCONNECT NEGATIVE LEAD
FIRST AND RECONNECT LAST
Part of label No: 499-090/05
This is to ensure that if a spanner
slips you cannot create a circuit
from the live battery post to the
generator chassis.
On the Battery Access Covers.
Qty 2 off.
Part of label No: 499-090/05
On the Battery Access Covers.
Qty 2 off.
Part of label No: 499-090/05
12
DANGER ELECTRICITY
NO SMOKING OR NAKED
LIGHTS
The battery can under certain
conditions give off small quantities
of hydrogen gas. Do not smoke or
use naked flames while working
on a battery.
RECYCLE
The battery contains lead and
sulphuric acid and should be
recycled at an approved facility
only and not put into a dust bin.
YC6 (Internal)
Section 3 Safety
On the LH Battery Access Cover
Label No: 499-090/13
On the RH side, above the access
panel
Label part No: 499-090/17
ENGINE OIL DRAIN
Engine oil is drained by removing
the cap on the front RHS of the
base. The oil will drain easier from
a warm engine. Observe correct
disposal practices.
FUEL FILL THIS SIDE
The fuel filler cap is located inside
this cover. Remove the cover to
access the filler and for refuelling.
DO NOT REFUEL WHILE THE
SET IS RUNNING OR HOT!
On the front access panel
AIR FILTER ACCESS
Label part No: 499-090/16
The Engine Air Filter is located
behind this panel. Remove the
panel for access to the filter for
cleaning or replacement.
On top, adjacent to the Control
Module.
Label No 499-090/14
LOW FUEL SHUTDOWN
The fuel gauge also incorporates
a low fuel shutdown facility. The
set will shut down when the level
falls to approximately 10-12% of
its capacity, thus eliminating the
need to bleed the system at
restart.
NOTE: For generator orientation, front refers to the control panel end of the
machine, thus RH and LH refer to the right and left sides when viewed from the
control panel end.
YC6 (Internal)
13
Section 3 Safety
3.2 Electrical Safety
In addition to the information given previously the generator should be installed, earthed and used with
reference to the following available from HMSO:‡
I.E.E Regulations 17th Edition (BS 7671:2004)
‡
Health and Safety Executive Publications GS27 Protection Against Electric Shock
‡
Health and Safety Executive Publications GS24 Electricity On Construction Sites
‡
Health and Safety Executive Publications PM53 Emergency Private Generation
Alternatively the HGI Technical Help Line would be pleased to advise on the best measures for your
particular application.
This generator is NOT fully waterproof and neither the generator, nor any electrical
equipment should be left out side indefinitely and operated in prolonged and heavy rain or
snow. The generator is suitable to be left outside in light rain. We would NOT recommend
operating hand held electrical equipment in light rain or snow.
DO NOT use a pressure washer to clean the generator as high pressure water may enter the electrical
system.
3.3 Lifting and Moving
In addition to the information given previously the following apply:3.3.1
Mechanically Assisted Lifting
The weight has been given previously in this manual but could be 221 kg with a full fuel tank. In Great
Britain all assisted lifting is governed by:‡
Lifting Operations & Lifting Equipment Regulations 1998 (LOLER) SI 1998 No: 2307
and the following publication should be observed:‡
HSE ACoP publication L113 Safe Use of Lifting Equipment, Lifting Operations and Lifting
Equipment Regulations.
As a guide line only you should ensure that all lifting equipment is:‡
‡
‡
‡
‡
Sufficiently strong, stable and suitable for the proposed use.
The load and anything attached must be suitable to be lifted.
Positioned or installed to prevent the risk of injury, e.g. from the equipment or the load falling or
striking people.
Visibly marked with any appropriate information to be taken into account for its safe use, e.g. safe
working loads.
Accessories, e.g. slings, clamps etc. should be similarly marked.
You must ensure that a lifting operation must be planned, supervised and carried out in a safe manner by
people who are competent.
No personnel should be present in an area where a mechanical lifting operation is taking place.
14
YC6 (Internal)
Section 3 Safety
3.4 Hazards to Health
A list of the hazards that may affect health is included with safety precautions and first aid instructions.
Material /
Location
Engine Oil
Hazard
First Aid Measures
When hot may burn the skin but not
expected to give rise to an acute hazard
under normal conditions of use. May
cause an allergic skin reaction in sensitive
individuals. Continuous skin exposure
may give rise to dermatitis.
Burns: Rinse with clean water, cover with a
sterile pad and obtain medical assistance.
Skin Contact: Remove contaminated
clothing and wash thoroughly with soap and
water. If persistent irritation occurs obtain
medical attention. If the material is injected
under high pressure into the body obtain
medical assistance immediately.
Inhalation: In the unlikely event of inhalation
of fumes if dizziness or nausea occurs move
the individual to fresh air. If symptoms
persist, obtain medical attention. If difficulties
are experienced with breathing a qualified
person should administer oxygen. If
breathing stops give artificial respiration.
Eyes: In the unlikely event that the material
enters the eye flush with copious quantities
of clean water. If persistent irritation occurs
obtain medical attention.
Ingestion: In the unlikely event that ingestion
occurs, wash out the mouth with water and
seek medical attention. Do not induce
vomiting.
Gloves, overalls and eye protection should
be worn when handling this product.
Do not burn old oil as a method of
disposal as combustion is likely to give
rise to a complex mixture of airborne
solids, liquid particulates and gases
monoxide
and
including
carbon
unidentified
organic
and
inorganic
compounds.
Old engine oil has potential health
implications and should not come into
contact with the skin.
A funnel is supplied with each generator to
make topping up with oil easy and clean.
Diesel Fuel
May cause skin irritation.
Gloves, overalls and eye protection should
be worn when handling this product.
As for engine oil above.
Fibre Glass
Insulation
The User will not normally come into
contact with this material but Service
Technicians may.
Skin Contact: Remove contaminated
clothing and wash thoroughly with soap and
water. If persistent irritation occurs obtain
medical attention.
Inhalation: In the unlikely event of inhalation
of dust or fibres if irritation of the mouth and
throat occurs rinse with water. If persistent
irritation occurs obtain medical attention.
Eyes: In the unlikely event that the material
enters the eye flush with copious quantities
of clean water. If persistent irritation occurs
obtain medical attention.
(over
exhaust
pipe.)
May cause skin and respiratory tract
irritation.
Gloves, overalls, dust mask and eye
protection should be worn when handling
this product.
Other
insulation,
gaskets and
seals.
Asbestos
YC6 (Internal)
No specific hazards under normal use
conditions.
n/a
DO NOT burn as a method of disposal as
combustion is likely to give rise to a
complex mixture of airborne solids, liquid
particulates and gases including carbon
monoxide and unidentified organic and
inorganic compounds which may be
hazardous to health.
This generator is asbestos free.
n/a
15
Section 3 Safety
Battery
Acid
Battery is
located in
the battery
compartment
at the front
of the
generator.
The User and Service Technicians will not
normally come into contact with acid
unless a battery has leaked for any
reason.
This is a concentrated sulphuric acid
solution and may cause skin burns.
Protective overalls, rubber gloves and eye
protection should be worn when handling
this product.
If spilt dilute and wash away with copious
quantities of water.
Exhaust
Fumes
Exhaust fumes are very hot and contain
carbon monoxide which can cause
unconsciousness and death in humans
and animals. It is odourless and tasteless
but diesel exhaust fumes contain other
chemicals and soot which will irritate the
eyes and breathing and will usually alert
the user to the presence of fumes.
Symptoms of carbon monoxide poisoning
are dizziness, nausea, fatigue and vertigo.
Electric
Shock
‡
‡
‡
‡
‡
‡
‡
‡
‡
16
Skin Contact: Rinse skin and contaminated
clothing with copious quantities of water. If
persistent irritation or blistering occurs obtain
medical attention. If the material is injected
under high pressure into the body obtain
medical assistance immediately.
Inhalation: In the unlikely event of inhalation
of fumes move the individual to fresh air.
Obtain medical attention immediately. If
difficulties are experienced with breathing a
qualified person should administer oxygen. If
breathing stops give artificial respiration.
Eyes: In the unlikely event that the material
enters the eye flush with copious quantities
of clean water for at least 15 minutes. Place
a sterile pad over the eye and seek medical
attention immediately in all cases.
Ingestion: In the unlikely event that ingestion
occurs, wash out the mouth with water. Do
not induce vomiting. If the patient is
conscious give them water or milk to drink.
Obtain medical attention immediately.
Skin Contact: Rinse skin with water. If
persistent irritation or blistering occurs obtain
medical attention
Inhalation: In the event of inhalation of
fumes move the individual to fresh air. If
difficulties are experienced with breathing a
qualified person should administer oxygen. If
breathing stops give artificial respiration.
Obtain medical attention in all cases.
Eyes: In the unlikely event that the fumes
enter the eye flush with copious quantities of
clean water for at least 15 minutes. Place a
sterile pad over the eye and seek medical
attention immediately in all cases.
Assess the situation first.
DO NOT touch the person until it is safe for you to do so.
Identify where the electricity is coming from. DO NOT assume it is the generator
Turn off the electricity at the source.
To stop generators in an emergency press the RED stop button on the generator
control panel or remove the plug from the socket. On Automatic Mains Failure
Units (AMF) press the emergency stop button on the main control panel.
If necessary check patients airways, administer artificial resuscitation, move the
person to the recovery position.
Even if the person remains conscious anticipate that they will pass into shock.
Local burns where contact was made should be covered by a sterile dressing.
Obtain medical attention immediately.
YC6 (Internal)
Section 4 Operating Instructions
4.1 Engine Control Module
4.2 Engine Oil
Figure 2 – Deep Sea 3110 Control Module
1
2
3
Check the oil level daily and top up when
necessary. Check the oil level when the engine
is stationary. If the generator is an AMF or
Remote Start version it may automatically start
without warning if the mains electricity supply
fails. Make the generator safe first by removing
the control fuse or remote start connection.
Do not overfill. The oil level should be as marked
on the dipstick when it is screwed into the
engine.
Figure 3 Engine Oil Level
4
5
6
1
Navigation Button
Pressing this button scrolls the display to
show the various instruments.
2
Main Status Display
This displays the generator instrument and
alarm conditions.
3
Common Alarm Indicator
This illuminates when an alarm is present.
4
Stop/Reset Button
This stops the generator and also resets any
alarms present (provided the fault has been
cleared).
5
Select “Auto” Mode
This places the set in ‘Automatic’ mode
allowing the set to be operated automatically
and/or remotely.
6
Start Button
This button starts the engine. Press once
ONLY to start the engine. The unit will
automatically attempt up to three starts.
YC6 (Internal)
Replace the engine oil after the first 50 hours,
then 3 months or every 200 hours of running.
When changing the oil or topping-up, use oil of a
grade suitable for the prevailing ambient
temperatures (normally 15W40 API grade CG or
better ).
The oil filter element is a washable type, and
should be cleaned at every oil change (3 months
/ 200 hours ).
Drain the oil into a suitable waste oil container,
and follow HSE recommendations regarding the
handling and disposal of contaminated oil
products. Information on the Health and Safety
aspects of working with oil are contained in this
manual
17
Section 4 Operating Instructions
4.3 Starting Manually and Remotely
Check the lubricating oil level and fuel level, and
top up as necessary. Do not overfill. The Oil
level should be as marked on the dipstick when
it is screwed into the engine.
Press the Red Stop/Reset pushbutton once then
press the Green Run/Start pushbutton once only
and the starter motor will turn and the engine will
crank.
If the engine fails to start during cranking, the
Control Module will automatically attempt up to 3
starts before going to a Fail to Start alarm. Press
the Red Stop push button to clear the alarm.
If the engine does not start after three attempts
investigate the cause.
For Manual Starts allow the engine to warm up
for 1 minute before connecting any load to the
generator output.
If the unit is fitted with the CN222 Remote
Start/Stop
control
(Fig
4c),
use
the
corresponding buttons on the remote unit.
The RCD should be tested by pressing the
TEST button and checking that the RCD trips
and has to be reset while the generator is
running. This should be done every day.
Connect the equipment to be powered (load)
into the socket outlets on the generator control
panel.
Operating the generator at low load levels for
long periods of time may cause excessive
smoking, reduce efficiency due to carbon buildup and cause other engine problems
Do not overload the generator as this will cause
overheating, and shorten the life of the
generator. Check that the total load from all
equipment connected does not exceed the
generator rating.
The overall output is protected by a 32A circuit
breaker while the 16A socket is also protected
by an individual MCB. If the current being drawn
through the socket exceeds this for a short time
the MCB will trip. To reset the MCB when it has
tripped remove the load, wait a few minutes and
then reset.
For a Remote Start press the ‘Auto’ button. The
LCD display will show confirmation of the
selected mode. Upon receipt of the remote start
signal the Control Module will attempt to start 3
times as above.
Operating the generator at low load levels for
long periods of time may cause excessive
smoking, reduce efficiency due to carbon buildup and cause other engine problems.
4.4 Stopping Manually and Remotely
4.6 Shutdown Protection Devices
For a Manual STOP, switch off the electrical
output and disconnect the load. Allow the
generator to run off-load for 2 minutes to cool
down. Press the red Stop/Reset push button to
stop the generator.
The generator is fitted with the following
protection devices that will shut down the
generator in the event of a fault. They are
indicated on the engine control module (Fig 2):
For a Remote STOP the engine note will change
as the load is transferred back to the mains or
removed and the set will stop unless timers have
been set in which case the set will run for a preset time to allow for cooling.
In an emergency the red/yellow Emergency
Stop button should be used. Twist and pull the
button to reset it.
4.5 Power output Connections
These generators will be supplied with output
sockets as shown in Figure 5.
On models with an RCD (earth leakage device),
the M8 brass stud next to the output sockets
should be connected to an external earth point
or to an earth spike. An earth spike can be
supplied as an optional extra and should be
driven at least 600 mm into soil.
18
Fail to Start. Operates if the engine fails to start
after 3 attempts. This is to help prevent damage
to the starter motor. If the engine fails to start
then the cause should be investigated before
further attempts are made.
Low Oil Pressure. This operates if the oil
pressure falls below a safe level. This can be
caused by a lack of oil, wrong type of oil or high
temperature. Check and top up the oil level as
necessary. During starting, the alarm is held off
for 10 seconds to allow the oil pressure to build
up to normal running level. The engine will not
crank if there is no low oil pressure signal prior
to starting.
Low Fuel Level. The set will shut down when
the fuel level falls to approximately 10-12% of its
capacity, thus eliminating the need to bleed the
system at restart. In this condition, a lamp will
light on the gauge (Fig 4a) and the Control
Module will show a Common Alarm.
YC6 (Internal)
Section 4 Operating Instructions
Figure 4b – Engine Compartment
(view from Control Panel right)
Figure 4a – Fuel Gauge
A
B
A:
Contents Scale
B:
Low Fuel Alert
C:
Oil Dipstick
C
Figure 4c
CN222 Remote Start/Stop Unit.
NOTE: For safety reasons, the battery negative lead will be disconnected prior to
delivery. It is recommended that this action is repeated when moving the
generator or for long term storage.
YC6 (Internal)
19
Section 4 Operating Instructions
4.7 Control Panel
Fig. 5 – Control Panel
20
YC6 (Internal)
Section 5 Fault Finding
5.1 Engine Fails to Start
IMPORTANT: If the following checks and investigations can be completed without the use of tools then
the User can safely undertake them. If tools are needed then ONLY trained technicians can undertake
the work safely. Wiring diagrams are contained in this manual to help with electrical fault finding.
Further advice on fault-finding can be found in the Deep Sea 3000 Series Operating Manual, p.35.
Symptom
Cause and Remedy
Starter motor did not attempt to turn the engine
over. No display on the Control Module (Fig 2).
Check the control fuse or MCB has not failed/tripped.
Flat battery or wrong polarity from battery.
Check that the battery is producing over 12V DC from
the positive terminal relative to the chassis of the
generator.
Check the connections to the control module.
Starter motor did not attempt to turn the engine
over. Module display shows Fail to Start.
Check the Emergency Stop button has not been used.
The control module pulls in a slave relay to put 12V DC
onto the starter motor solenoid.
Check the control module is not faulty by swapping it.
Check it is attempting to pull in the slave relay.
Check the operation of the slave relay.
Check the connections to the starter motor.
Check the operation of the starter motor by making a
temporary connection to its solenoid.
Starter motor did not attempt to turn the engine
over. Module display shows Oil pressure fault
The control module believes that oil pressure is present
when the engine is off.
Check the oil pressure switch has not gone faulty.
Check the control module has not gone faulty by
swapping it.
Check the fuel level in the tank.
Engine turns over but will not start.
(display shows Fail to Start after 3 attempts)
No smoke seen from exhaust pipe.
Check that the fuel filter is not blocked or full of water.
Check there is a 12V DC supply to the fuel solenoid
valve.
*Check fuel is getting past the fuel solenoid valve.
*Check fuel is flowing at high pressure out of the fuel
pump located next to the fuel solenoid.
Suspect the fuel system is air locked or there is
contamination blocking the fuel system or injector.
Engine turns over but will not start.
(display shows Fail to Start after 3 attempts).
Smoke seen from exhaust pipe.
Suspect faulty fuel supply as above.
Suspect faulty fuel injector nozzle.
Suspect contaminated / unsuitable fuel.
Suspect starter motor is not turning engine over quickly
enough particularly if the temperature is too low.
Suspect serious fault with the engine.
* Care should be taken while working on the fuel system particularly when fuel is under high pressure.
YC6 (Internal)
21
Section 5 Fault Finding
5.2 Engine Starts but then Stops
Engine starts but then shuts down.
No display on the Control Module.
Check control circuit fuses and MCB.
Check the 12V DC supply from the battery has not been
lost.
Suspect faulty control module. Swap it to check it.
Engine starts but then shuts down.
Display is lit on the Control Module.
Low Oil lit: Check the oil level. Check the oil pressure
switch and wiring. Check the oil pressure.
High Engine Temperature lit: Check the engine
temperature. Check the HET switch and wiring.
Check the fuel system has not become contaminated or
defective as given previously.
Engine starts but then shuts down on Speed
Fault on the Control Module.
Speed Fault - If the engine does not run within the
required speed range it will shut down. The most
common cause of incorrect speed is air or contamination
in the fuel system. Check the fuel and filter condition,
bleed the system and try starting again. Also see 5.3
below.
5.3 Other Engine faults
Engine runs but makes excessive smoke
and/or runs erratically.
Check for contaminated fuel.
Check for contamination in the fuel system particularly
the fuel injector nozzle.
Check for blocked fuel filter or water in the filter.
Check for faulty or worn fuel injector nozzle.
Check for blocked air filter.
Suspect serious engine fault with governor, timing or
compression.
Battery goes flat or will not turn over the starter
motor fast enough.
Check the fuse in the battery charging circuit has not
failed.
Check charging system is delivering above 13V DC to
the battery. The battery must be fitted to see this.
If the unit is fitted with a refillable battery, check
electrolyte level in the battery. This can be topped up
with distilled water.
If an external mains powered battery charger is fitted
inside an AMF Panel check its operation.
22
YC6 (Internal)
Section 5 Fault Finding
5.4 No Electrical Output
Has the earth leakage (RCD) unit tripped?
Before resetting, disconnect all equipment plugged into
the sockets. Look for any obvious reasons or faults as to
why the equipment has caused the earth leakage unit to
trip.
Switch off the MCB. Reset the RCD and MCB then
reconnect and switch on equipment one piece at a time.
Do not hold the suspect equipment but use the MCB on
the generator to turn the supply ON to the suspect
equipment. If a piece of equipment trips the earth
leakage unit repeatedly make sure it cannot be used
again by removing the plug and labelling Faulty/Unsafe.
Has the miniature circuit breaker (MCB) tripped
or 2-pole circuit breaker tripped or been set to
OFF?
The total output is protected by a 2-pole MCB.The 16A
output socket has its own MCB to prevent excessive
electrical load being taken through that socket. These
are rated at 15 Amp and they will trip in a short time if
larger currents are taken through them.
If an MCB has tripped, disconnect the load equipment
before attempting to reset the breaker.
The earth leakage unit has not tripped, the
miniature circuit breakers have not tripped.
YC6 (Internal)
Connect another piece of electrical equipment that is not
faulty to confirm that the generator is faulty.
Suspect a major fault with the alternator or its voltage
regulation unit.
23
Section 6 Service
6.1 Service Schedule
Service intervals will have to be reduced if the generator is operated in dusty or severe conditions. The
first service is required after 50 hours from new then as given below. The Yanmar engine manual
contains additional checks on the fuel injection system but these are only required for California.
Servicing must be carried out by a competent engineer. A written record of the service work should be
made using the form contained in this manual or a similar form. The generator must be serviced in
accordance with our recommendations for the warranty to be valid.
DO NOT use a pressure washer to clean the generator as high pressure water may enter the electrical system. Use a
damp cloth or similar.
Maintenance Schedule
Daily
Checks
After the
first 50
hours
Every 3
months or
200 hours
Every 6
months or
400 hours
Check & replenish fuel
9
9
9
9
Check & replenish engine oil
9
9
9
9
Check fuel filter for dirt and water
9
9
9
9
Check battery fluid level
9
9
9
9
Check for oil and fuel leaks
9
9
9
9
Check operation of earth leakage unit
( RCD ) trip if fitted.
9
9
9
9
Check the hours run meter works
9
9
9
9
Change engine oil
9
9
9
Clean oil filter
9
9
9
9
Replace fuel filter
9
Check air filter clean
Replace air filter
9
Adjust valve clearances
9
Check alternator brushes & slip rings
9
Check operation of MCB’s
9
Control Module Safety Shut Down
9
Battery Charger
9
Canopy and Trolley
9
General Inspections
Run on ¼, ½, ¾ full load for 30 minutes
24
9
9
9
9
9
YC6 (Internal)
Section 6 Service
6.2 Engine Oil
6.6 Alternator
Check the oil level daily and top up if necessary
with the funnel supplied to make this clean and
easy. Check the oil level when the engine is
stationary and on a level surface. Do not overfill.
The oil level should be as marked on the dipstick
when it is NOT screwed into the engine.
Ensure that the cooling air vents do not become
blocked by dirt, debris etc
Replace the oil every 3 months or 200 hours
running. When changing the oil or topping-up,
use oil of grade suitable for the prevailing
ambient temperatures (15W40 API grade CG).
The oil filter element is a washable type, and
should be cleaned at every oil change (3 months
/ 200 hours).
6.7 Earth Leakage Unit and MCB’s
The earth leakage unit has a self test button
which can be used to apply a fault and to check
that the unit trips out when the generator is
running.
To test the MCB’s is not practical in normal
circumstances.
6.8 Control Module Safety Shutdowns
Drain the oil into a suitable waste oil container,
and follow HSE recommendations regarding the
handling and disposal of contaminated oil
products
The module will prevent the generator from
starting or shut it down if faults occur. Check the
following:-
6.3 Fuel
Hours Run
working.
Check daily and replace the fuel filter every 6
months or 400 hours. Clean the fuel strainer
located in the fuel filling neck of the fuel tank
with clean fuel.
Over cranking: Remove the 12V DC supply to
the starter motor solenoid and attempt to crank
for more than 10 seconds. After 10 seconds the
Control Module should stop the cranking and
show an alarm.
Drain and flush the fuel tank periodically to
prevent the build-up of contaminants, particularly
when the generator has operated in high
humidity and dusty environments.
6.4 Valve Clearances
Valve Clearances should be checked after the
first 6 months or 400hrs. The clearance for both
the intake and exhaust valves should be
0.15mm when the engine is cold. Refit the
rocker cover with a new gasket
6.5 Battery
Counter: Confirm
counter
is
Low Oil Pressure: With the engine off, remove
the connection to the normally closed oil
pressure switch and attempt to start the engine.
The Control Module should see an open circuit
representing oil pressure when there should be
none and prevent starting.
6.9 Battery Charging
Stop and start the engine a few times if needed
to draw off the battery.
Start the engine, allow to run for 5 minutes and
check that the battery charger is delivering at
least 13.2V DC into the battery
Check the level of the battery electrolyte every
day. This should be 30 to 35 mm from the top
surface of the battery and covering the plates.
The battery is a maintenance free unit and
should not require topping up.
Check that the positive and negative terminals
are tight and secure, and free from corrosion.
Lightly coat them with petroleum jelly or similar
to protect against corrosion.
Check that the battery securing strap is tight and
the battery is held firmly.
YC6 (Internal)
25
Section 6 Service
6.10 Canopy
Check security of fixings and fasteners on the
machine.
Lubricate hinges and latches with light machine
oil.
Ensure that the inlet and outlet louvers are kept
clean and unimpeded at all times.
Check that no sound insulation has become
loose and obstructed them.
The engine should be sucking in air from out
side the canopy. With the front panel removed,
check the foam seal is complete all around this
compartment and air can only be drawn from
outside the set
6.11 General Inspections
Inspect generally for:Fuel and Oil Leaks: Look for excessive oil in
the base tray. Look for weeps from fuel hoses
and connections. Check the insulation is dry and
not contaminated with fuel or oil.
6.12 Light Loading
Operating the generator at low load levels for
extended periods can result in high levels of
carbon build up in the engine and exhaust
system which can lead to excessive smoking,
reduced efficiency and over heating. Looking at
the silencer’s outlet will give some indication is
this has happened.
After each service the generator should be run
first on ¼, then ½, then ¾ and finally full load
using a load bank or a similar load like an
electric fan heater, to burn out any deposits of
soot in the engine and silencer.
Each level of load should be applied for at least
10 minutes or until the exhaust is clear of soot
and smoke. If you suspect the engine is badly
sooted, DO NOT apply full load but build the
load up gradually.
It should be anticipated that hot soot may be
expelled from the exhaust during this procedure
and it should be done in a safe place away from
combustible material and under supervision at
all times.
Worn or Failed Anti Vibration Mounts: When
the side panels are removed rock the engine
and check all four anti vibration mounts are
flexing slightly and have not failed or broken up.
Damaged or missing insulation and seals:
Generally look at the sound insulation and seals
and check it is still securely fitted and has not
deteriorated.
Missing Safety Labels: These labels are a
mandatory safety requirement and if any are
missing or not easy to read they should be
replaced. Full details of all labels are contained
in this manual. A replacement label kit is
available.
Chafing or Stretching of Cables: Inspect all
cables and connections and look for obvious
signs of wear or damage.
Signs of Over Heating: Look for obvious
deterioration due to heat and investigate the
cause and rectify as necessary.
Fuel Cap: Check the cap seals correctly. Check
for obvious signs of fuel spillage.
26
YC6 (Internal)
Section 6 Service
6.13 Maintenance Record Sheet
GENERATOR MAINTENANCE RECORD SHEET
( for use by owner / service agent )
Name of owner:
Address:
Name of service organisation:
Address:
Order No:
Job No:
GENERATOR DETAILS ( From Data Plate )
Date of service:
Model: SUPER-COMPACT WELF-AIR
Serial No:
Code:
Year of Manufacture:
Rated Power:
Power Factor PF:
Voltage (Current):
Fuel type:
hrs
Hours run meter reading:
Service Daily / 50hrs /
3 months 200hrs / 6 months 400hrs
General Condition:
Daily Checks:
6 months cont …
1
2
3
4
5
6
8 Check alternator vents are clear
9 Check operation of Control Module
a) Hours run meter is running
b) Over cranking cut out works
c) Low oil pressure shut down works
d) Low fuel shut down works
11 Check Canopy
a) All fixings secure
b) Inlet/outlet air louvres clear
c) Confirm all seals in the engine
compartment sound and serviceable
12 General checks
a) Anti vibration mounts are serviceable
b) All insulation/seals fitted & serviceable
c) All safety labels are fitted
d) All cables and connections sound
e) Exhaust system sound and serviceable
f) No signs of over heating
g) Check fuel cap seals
13 Run at ¼, ½, ¾ and full load
Fuel level checked
Yes/No
Oil level checked
Yes/No
Battery liquid level 30/35 mm from top Yes/No
Check for oil / fuel leaks
Yes/No
Check RCD works( if fitted )
Yes/No
Check fuel filter not contaminated
Yes/No
After first 50 hours from new.
Every 3 Months or 200 hrs Service
1
2
3
4
5
6
Complete Daily Checks
Change the engine oil
Clean the oil filter
Check the air filter clean
General inspections
Run at ¼, ½, ¾ and full load
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Every 6 Months or 400 hrs Service
1
2
3
4
5
6
7
Complete Daily Checks
Complete 200 hrs service
Check battery terminals and fixing
Replace fuel filter
Replace air filter
Set engine valve clearances
Check alternator
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Spare parts used:
Notes:
Signed:
YC6 (Internal)
Representing:
Date:
27
Section 7 General
7.1 Contact Details
General Enquiries and Sales Department
Clarke International
Hemnall Street, Epping, Essex, CM16 4LFG
Tel: 01992 565333
Fax: 01992 561562
www.clarkeinternational.com
Email: sales@clarkeinternational.com
Parts Department
Tel: 020 8988 7400
Service Department
(staffed by Service Engineers who will also help
with technical questions relating to the operation,
servicing and fault finding of the generator).
Tel: 020 8988 7400
Export Department
Tel: 00 44 (0)1992 565335
7.2 Spare Parts List (main items only)
Part Description
Part Number
Engine ( Yanmar L100AE-DEG )
Air filter element
Oil filter element
Fuel solenoid 12V
Starter motor 12V
Fuel Injector nozzle
Battery charger circuit fuse 20 Amp 1”x1/4”
Battery charger / voltage regulator
Bonnet (Rocker cover) gasket (needed when
setting valve clearances)
YN 114650-12590
YN 114250-35110 (not normally required can be cleaned)
YN 114299-76900 (or YNRDG2138 which is identical)
YN 114362-77011
YN 714650-53000
YN 29411-200000
YN 119660-77710
YN114650-11311
(was YN114650-11310 and interchangeable).
Other Fuel System
Strainer for fuel tank filler neck
Fuel filter element
Optical fuel level sensor
Replacement fuel filler cap
065-614 not normally required – can be cleaned
170-278
085-730
065-613
Electrical
Earth leakage ( RCD ) unit
Miniature circuit breaker ( MCB ) 15 Amp
Miniature circuit breaker (MCB) 32 Amp
Control Module Type DSE 3110-001-01
Fuse for control circuit 5 Amp
Control relay 12V coil
110-532
110-015
110-232
125-083
100-005
140-001
General
Battery 12V 28Ah small profile type
Exhaust pipe (also needs gasket)
Exhaust gasket
Ant vibration mounting (4 needed)
Safety information label kit ( all labels )
120-050
180-050
YN 114650-13200
070-503
499-250
28
YC6 (Internal)
Section 8 Long Term Storage
8.1 Long Term Storage
Engine
Do not run the generator out of fuel. If the engine runs out of fuel the fuel system will
become air locked and will have to bled through before the engine will restart. Leave a
small quantity of fuel in the fuel tank. Drain any water from the water separator / filter.
Run the engine for a few minutes and drain the warm oil and fill with new oil as for a
normal service.
With the decompression lever (lever with red plastic knob above the rocker cover) pulled
and held down press the starter button for three seconds. This will inject fuel into the
cylinder and valves to act as a rust inhibitor without starting the engine.
Alternator
No special requirements other than store in a dry well ventilated place.
If the generator has been stored for a considerable period of time e.g. several years the
alternator insulation winding resistance should be checked as they can absorb moisture.
The insulation resistance must be at least 2 MǷ (two megohms). If it is less than this
then the alternator windings can be dried out by placing the alternator in an oven at 6070°C for a few hours with plenty of air movement. Generally if this procedure is required,
consider replacing the alternator.
Electrical
No special requirements other than store in a dry well ventilated place.
Battery
The battery should be fully charged before storage.
Make sure the fluid level in the battery is at the normal level before storing.
Disconnect the negative then the positive connections.
It would be beneficial to trickle charge the battery periodically to maintain its condition.
General
Store in dry well ventilated place. If pneumatic tyres are fitted take the weight off the
tyres by supporting on blocks. Cover over with a sheet.
If the generator is to be stored long term it would be beneficial to start and run the
generator under electrical load for half an hour every three months and then store as
above (but no need to change the oil each time or disconnect the battery).
YC6 (Internal)
29
Section 9 Wiring Diagrams
9.1 DC Wiring
30
YC6 (Internal)
Section 9 Wiring Diagrams
9.2 AC Wiring
YC6 (Internal)
31
Section 9 Wiring Diagrams
9.3 Remote Start Wiring
32
YC6 (Internal)
Section 9 Wiring Diagrams
9.4 Remote Start Leads
YC6 (Internal)
33
Section 10 Notes
34
YC6 (Internal)
Section 11 Warranty
WARRANTY STATEMENT
Clarke Generators are covered by a 12 month or 1,000 hours warranty, whichever occurs the
soonest for sets operating at 3000rpm. At 1500rpm generators are covered for 2000 hours or one
year, whichever is the sooner. Where a product is to be used in adverse conditions or for
prolonged duration, a shorter period may apply. This does not affect your statutory rights
(Consumer Protection Axt 1987).
The manufacturer’s warranty will not apply in the following circumstances:
1.
2.
3.
4.
5.
If the product has suffered customer or user abuse.
Damage by accident or deliberate misuse.
Lack of maintenance.
Failure to ensure the machine has received reasonable care and attention.
Fitment of unauthorized parts or accessories.
Contact Clarke International for instruction on an appropriate course of action for equipment
failures during the warranty period. This may be one of the following;
i)
Goods to be returned to the local dealer/ supplier (or alternatively a site visit by dealer/
supplier at his option). All warrantable parts etc. and full technical support supplied FOC
from the factory.
or:
ii)
Goods can be returned direct to our factory by the customer. Full parts and labour repairs
carried out in our workshops. Goods returned to customer at our expense. An order number
will be required to cover non-warrantable work. A ‘Returns Number’ should be obtained prior
to returning product.
Notes
All parts supplied FOC are on condition that faulty parts are returned to the factory within 14 days of
replacement and subject to factory examination for valid claims.
Failures due to wear and tear and accidental damage are not covered.
Equipment supplied for operation outside the UK mainland will normally be dealt as described in (i)
or (iii) above.
Limited warranty applies in special circumstances where equipment operates in extreme
environmental conditions and/or for extended periods. Consult the factory.
On-site and extended warranty terms are available. Please contact the factory for details.
The Company will not be held responsible for consequential losses, or costs incurred by the
customer during a warranty repair. The Company will not accept claims of compensation.
Issue A
YC6 (Internal)
35
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