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Infolinks 2014

ED sherman outboard engines Troubleshooting Electric Starter Circuits repair guide

First let’s have a quick look at Figure 6-6 to see what we’re talking about. The illustration shows a typical starter circuit on a outboard engine with remote controls. But be aware that not all engines have the remote control harness plug in the location shown here. On many installations, the harness plug is located under the engine cowl.If your outboard engine doesn’t have remote controls, it will simply have a starter button on the engine. It may also have a neutral safety switch integrated with the mechanical gear-shift linkage under the cowl cover. A simplified wiring diagram of this circuit is shown in Figure 6-7.

Figure 6-6. An overview of a remotely controlled starter circuit.

Figure 6-6. An overview of a remotely controlled
starter circuit.

Figure 6-7.Fig. 5-4b The integrated starter circuit

Figure 6-7.Fig. 5-4b The integrated starter circuit

 

It should be pointed out that your engine may have some of these connections at a wiring junction box. Also, starter circuits are commonly used by manufacturers to add extra wires feeding additional circuits on your engine—so refer to your engine’s specific diagram, and narrow it down to what you see in this drawing. These are the only components you should be focusing on if your troubles are starter-related,All outboard engines use what is referred to as an inertia type of starter motor. Midsize and large engines also employ a remotely mounted solenoid. Unlike automotive starters, these units rely on the inertia created by the spinning starter motor to “throw” the starter drive gear upward, engaging it with the teeth of the fly wheel ring gear. Often, the problem with these systems is simply that the starter spins too slowly to engage the drive gear. Slow spinning can be caused by a weak battery, or an electrical connection that is loose or corroded, causing excessive resistance in the circuit.

So, as with the charging system, the first thing for you to check is the power source—the battery, and all its related connections. Perform the “open circuit voltage test” described earlier under Testing Your Battery to determine its state of charge. If needed, charge the battery to bring it up to snuff before proceeding with any circuit tests. Of all the electrical circuits found on your boat, the starter probably draws the greatest amperage when cranking, so it needs all the battery can give until the engine starts.

Once you are certain your battery is fully charged, you can begin tracing circuits. To test the smaller integrated system found on low-powered engines without remote controls, you will check for voltage at points throughout the circuit at the correct time.Figure 6-8 shows the points to check in numerical sequence, but before you begin, make sure your engine ground point and the ground bolt or strap (the heavy black cable) are corrosion-free, and the mounting bolts tight.

Begin at Point 1, checking the power source to the push-button switch. While your meter’s black test lead makes contact with a good ground on your engine (the bolt or cable grounding the starter motor to the engine is a good point, or you could ground directly to the battery negative terminal if the battery is located close to the engine) you will probe through the circuit with the red test lead from the meter.

Point 1. The voltage reading here should be very nearly the same as the direct reading across the battery. If not, there is a bad or broken connection between the battery and the connection at Point 1. If the voltage reading is good here, proceed to:

Point 2. At this point you should also disable the ignition system to prevent the engine from starting as you perform the next four tests. Now press in the starter button while holding your red test lead probe on Point 2. You should get a reading of approximately 12 volts. If not, your starter button is defective and will need replacement. If 12 volts is present at Point 2, proceed to:

Point 3. Again, with the starter button depressed, you should get a 12-volt reading. If not, the connection is bad, or the wire connecting the push-button switch to the neutral safety switch has a break in it. Repair or replace as needed. Next, be certain the engine is in the neutral position and move your meter probe to:

Point 4. With the starter button engaged, you should get a 12-volt reading at this point. If not, then the neutral switch is either defective or out of adjustment. To check for an adjustment problem, use a small screwdriver and manually depress the safety switch button completely. If that doesn’t give you a 12-volt reading at Point 4, the switch must be replaced.

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SANYANG JET 50/100 and JET Euro 50/100 series Troubleshooting repair guide

Compression Pressure Too Low/Difficult
To Start/Rough Idling
1. Cylinder head gasket leaking
2. Spark plug not tighten enough
3. Worn, seized or crack piston ring
4. Damaged, worn cylinder or piston
5. Poor reed

Compression Pressure Too
High/Overheat/Knock
1. Too much carbon deposit built up in
combustion chamber
Piston Noise
1. cylinder and piston worn out
2. piston pin or piston pin hole worn out
3. connecting rod small end bearing worn out

Piston Ring Noise
1. Worn, seized or crack piston ring
2. Cylinder worn out or damaged

FINAL DRIVING MECHANISM Troubleshooting repair guide

Engine can be started but scooter can not be moved.
1. Damaged drive gear
2. Burnt out or seized drive gear

Noise
1. Seized, worn or damage gear
2. Worn or loose bearing

Gear oil leaks
1. Excessive gear oil.
2. Worn or damage oil seal

CRANKCASE/CRANKSHAFT Troubleshooting repair guide

Engine noise
1. Worn bearing of connecting rod bog end
2. Bend connecting rod
3. Worn crankshaft bearing

Engine can not be started
1. No fuel in fuel tank
2. Fuel can not reach to carburetor
3. Too much fuel in cylinder
4. Clogged air cleaner

Stall after started
1. Incorrect idle speed adjustment
2. No spark on the spark plug
3. Low compression pressure
4. Rich mixture
5. Lean mixture
6. Clogged air cleaner
7. Inlet pipe leaking
8. Polluted fuel

Lean Mixture
1. Clogged carburetor jet
2. Clogged hose from carburetor to canister
3. Bend, squeezed or clogged fuel lines
4. Clogged fuel filter
5. Malfunction of float valve
6. Low fuel level in float chamber
7. Clogged vent pipe
8. Malfunction of fuel pump
FUEL SYSTEM Troubleshooting repair guide

Rich Mixture
1. Malfunction of float valve
2. Low fuel level in float chamber
3. Clogged carburetor air injector

BRAKE SYSTEM Troubleshooting repair guide

Disc Brake
Soft brake lever
1. Air inside the hydraulic
system
2. Hydraulic system leaking
3. Worn master piston
4. Worn brake pad
5. Poor brake caliper
6. Worn brake lining/disc
7. Low brake fluid
8. Blocked brake pipe
9. Warp/bent brake disc
10. Bent brake lever

Hard operation of brake
lever
1. Blocked brake system
2. Poor brake caliper
3. Blocked brake pipe
4. Seized/worn master
cylinder piston
5. Bent brake lever

Uneven brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped brake
disc
5. Restricted brake hose and
fittings

Tight brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Deformed or warped brake
disc

Brake noise
1. Dirty lining
2. Deformed brake disc
3. Poor brake caliper
installation
4. Imbalance brake disc or
wheel

Drum Brake
Poor brake performance
1. Improper brake adjustment
2. Worn brake lining
3. Worn brake drum
4. Worn brake cam
5. Improper brake lining
installation
6. Seized brake cable
7. Dirty brake lining
8. Dirty brake drum
9. Brake pad worn in brake
cam area.
10. Poor contact between
brake arm and camshaft
indent
Tight operation or low
return speed of brake
lever
1. Worn/broken/crack return
spring
2. Worn drum
3. Dirty brake lining
4. Brake seized caused from
dirty brake drum
5. Seized brake cable
6. Worn brake cam
7. Improper brake lining
installation

Brake noise
1. Worn brake lining
2. Worn drum
3. Dirty brake lining
4. Dirty brake drum

REAR WHEEL/SUSPENSION  Troubleshooting repair guide

Rear wheel wobbling
1. bend wheel rim
2. poor tire
3. loosen wheel shaft

Shock absorber too soft n
1. insufficient shock absorber spring force

Poor brake performance
1. Poor brake adjustment
2. contaminated brake lining
3. worn brake lining cam
4. worn brake cam lever
5. worn brake drum
6. improper installation of brake arm gear set.

ELECTRICAL EQUIPMENT Troubleshooting repair guide

No voltage

  • Battery discharged
  • The cable disconnected
  • The fuse is blown
  • Improper operation of the main switch

Low voltage

  • The battery is not fully charged
  • Poor contact
  • Poor charging system
  • Poor voltage regulator

No spark produced by spark plug

  • The spark plug is out of work
  • The cable is poorly connected, open or short-circuited

- Between AC.G. and C.D.I.

  •  Poor connection between C.D.I. and ignition coil

- Poor connection between C.D.I. and the main switch

  • Poor main switch
  • Poor C.D.I.
  • AC.G. is out of work

Starter motor does not work

  •  The fuse is blown
  • The battery is not fully charge
  • Poor main switch
  •  Poor starter switch
  • The front and rear brake switches do not  operate correctly
  • Starter relay is out of work
  • The ignition coil is poorly connected, open or short-circuited
  • The starter motor is out of work

Intermittent power supply

  • The connector of the charging system  becomes loose
  • Poor connection of the battery cable
  • Poor connection or short-circuit of the  discharging system
  • Poor connection or short-circuit of the power  generation system

Charging system does not operate properly

  • Burnt fuse
  •  Poor contact, open or short circuit
  • Poor regulator
  • Poor ACG

Engine does not crank smoothly

Primary coil circuit
- Poor ignition coil
- Poor connection of cable and connectors
- Poor main switch

Secondary coil circuit
- Poor ignition coil
- Poor spark plug
- Poor ignition coil cable
- Current leakage in the spark plug cap

Incorrect ignition timing
- Poor AC.G.
- Improper installation of the pulse sensor
- Poor C.D.I.

Weak starter motor

  • Poor charging system
  • The battery is not fully charged
  • Poor connection in the windings
  • The motor gear is jammed by foreign material

Starter motor is working, but engine does not crank

  • Poor starter motor pinion
  • The starter motor run in reverse direction
  •  Poor battery

FUEL SYSTEM Troubleshooting repair guide

Engine can not be started
1. No fuel in fuel tank
2. Fuel can not reach to carburetor
3. Too much fuel in cylinder
4. Clogged air cleaner

Stall after started
1. Incorrect idle speed adjustment
2. No spark on the spark plug
3. Low compression pressure
4. Rich mixture
5. Lean mixture
6. Clogged air cleaner
7. Inlet pipe leaking
8. Polluted fuel

Lean Mixture
1. Clogged carburetor jet
2. Clogged hose from carburetor to canister
3. Bend, squeezed or clogged fuel lines
4. Clogged fuel filter
5. Malfunction of float valve
6. Low fuel level in float chamber
7. Clogged vent pipe
8. Malfunction of fuel pump

Rich Mixture
1. Malfunction of float valve
2. Low fuel level in float chamber
3. Clogged carburetor air injector

BRAKE SYSTEM Troubleshooting repair guide

Disc Brake
Soft brake lever
1. Air inside the hydraulic system
2. Hydraulic system leaking
3. Worn master piston
4. Worn brake pad
5. Poor brake caliper
6. Worn brake lining/disc
7. Low brake fluid
8. Blocked brake pipe
9. Warp/bent brake disc
10. Bent brake lever

Hard operation of brake lever
1. Blocked brake system
2. Poor brake caliper
3. Blocked brake pipe
4. Seized/worn master cylinder piston
5. Bent brake lever

Uneven brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped brake disc
5. Restricted brake hose and fittings

Tight brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Deformed or warped brake disc

Brake noise
1. Dirty lining
2. Deformed brake disc
3. Poor brake caliper installation
4. Imbalance brake disc or wheel

Drum Brake
Poor brake performance
1. Improper brake adjustment
2. Worn brake lining
3. Worn brake drum
4. Worn brake cam
5. Improper brake lining installation
6. Seized brake cable
7. Dirty brake lining
8. Dirty brake drum
9. Brake pad worn in brake cam area.
10. Poor contact between brake arm and camshaft indent Tight operation or low return speed of brake lever
1. Worn/broken/crack return spring
2. Worn drum
3. Dirty brake lining
4. Brake seized caused from dirty brake drum
5. Seized brake cable
6. Worn brake cam
7. Improper brake lining installation

Brake noise
1. Worn brake lining
2. Worn drum
3. Dirty brake lining
4. Dirty brake drum

BRAKE SYSTEM Troubleshooting repair guide

Disc Brake
Soft brake lever
1. Air inside the hydraulic system
2. Hydraulic system leaking
3. Worn master piston
4. Worn brake pad
5. Poor brake caliper
6. Worn brake lining/disc
7. Low brake fluid
8. Blocked brake pipe
9. Warp/bent brake disc
10. Bent brake lever

Hard operation of brake lever
1. Blocked brake system
2. Poor brake caliper
3. Blocked brake pipe
4. Seized/worn master cylinder piston
5. Bent brake lever

Uneven brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped brake disc
5. Restricted brake hose and fittings

Tight brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Deformed or warped brake disc

Brake noise
1. Dirty lining
2. Deformed brake disc
3. Poor brake caliper installation
4. Imbalance brake disc or wheel

Drum Brake
Poor brake performance
1. Improper brake adjustment
2. Worn brake lining
3. Worn brake drum
4. Worn brake cam
5. Improper brake lining installation
6. Seized brake cable
7. Dirty brake lining
8. Dirty brake drum
9. Brake pad worn in brake cam area.
10. Poor contact between
brake arm and camshaft indent
Tight operation or low return speed of brake lever
1. Worn/broken/crack return spring
2. Worn drum
3. Dirty brake lining
4. Brake seized caused from dirty brake drum
5. Seized brake cable
6. Worn brake cam
7. Improper brake lining installation
Brake noise
1. Worn brake lining
2. Worn drum
3. Dirty brake lining
4. Dirty brake drum

STEERING/FRONT WHEEL/SUSPENSION  Troubleshooting repair guide

Hard To Steer
1. The steering shaft bolt is too tight.
2. The steering shaft bearing are damaged
3. The ball and the top cone of the steering shaft are damaged.
4. Insufficient tire pressure.

The Steering Handle Is Tilted
1. Uneven arrangement of the front shock absorbers.
2. The front fork is bent.
3. The front wheel axle is bent.

The Front Wheel Wobbling
1. The rim is bent.
2. The wheel axle nut is not tightened improperly
3. Bend wheel rim
4. Side-worn or poor tire.
5. The bearing play of the wheel axle is too large.

Soft Shock Absorber
1. Weak front shock absorber spring

Noise In Front Shock Absorber
1. Shock absorber outer tube noise
2. The joint of the shock absorber gets loose.

REAR WHEEL/SUSPENSION Troubleshooting repair guide

Rear wheel wobbling
1. bend wheel rim
2. poor tire
3. loosen wheel shaft

Shock absorber too soft
1. insufficient shock absorber spring force

Poor brake performance
1. Poor brake adjustment
2. contaminated brake lining
3. worn brake lining cam
4. worn brake cam lever
5. worn brake drum
6. improper installation of brake arm gear set.

 

 

KYMCO DINK CLASSIC 200 Troubleshooting repair guide

LUBRICATION SYSTEM  TROUBLESHOOTING repair guide

Oil level too low Poor lubrication pressure
• Natural oil consumption • Oil level too low
• Oil leaks • Clogged oil filter or oil passage
• Worn piston rings • Faulty oil pump
• Worn valve guide
• Worn valve guide seal
Oil contamination
• Oil not changed often enough
• Faulty cylinder head gasket
• Loose cylinder head bolts

CYLINDER HEAD/VALVES  TROUBLESHOOTING repair guide

TROUBLESHOOTING
• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine
top-end noises.
Poor performance at idle speed White smoke from exhaust muffler
• Compression too low • Worn valve stem or valve guide
• Damaged valve stem oil seal
Compression too low
• Incorrect valve clearance adjustment Abnormal noise
• Burned or bend valves • Incorrect valve clearance adjustment
• Incorrect valve timing • Sticking valve or broken valve spring
• Broken valve spring • Damaged or worn camshaft
• Poor valve and seat contact • Worn cam chain tensioner
• Leaking cylinder head gasket • Worn camshaft and rocker arm
• Warped or cracked cylinder head
• Poorly installed spark plug
Compression too high
• Excessive carbon build-up in combustion
chamber

CYLINDER/PISTON TROUBLESHOOTING repair guide

• When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven
compression Excessive smoke from exhaust muffler
• Worn or damaged cylinder and piston rings • Worn or damaged piston rings • Worn, stuck or broken piston rings • Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston
• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin

• Incorrectly installed piston

DRIVE AND DRIVEN PULLEYS/ KICK STARTER TROUBLESHOOTING repair guide

Engine starts but motorcycle won‘t move Lack of power
• Worn drive belt • Worn drive belt
• Broken ramp plate • Weak driven face spring
• Worn or damaged clutch lining • Worn weight roller
• Broken driven face spring • Faulty driven face
Engine stalls or motorcycle creeps
• Broken clutch weight spring

FINAL REDUCTION  TROUBLESHOOTING repair guide

Engine starts but motorcycle won‘t move
• Damaged transmission
• Seized or burnt transmission
Abnormal noise
• Worn, seized or chipped gears
• Worn bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal

A.C. GENERATOR/STARTER CLUTCH  TROUBLESHOOTING repair guide

Refer to page 1-27 for A.C. generator troubleshooting.
Starter motor rotates but engine does not start
• Faulty starter clutch
• Starter motor rotates reversely
• Weak battery

CRANKCASE/CRANKSHAFT  TROUBLESHOOTING repair guide

Excessive engine noise
• Excessive bearing play
• Excessive crankpin bearing play
• Worn piston pin and piston pin hole

COOLING SYSTEM TROUBLESHOOTING repair guide

Engine temperature too high Coolant leaks
• Faulty temperature gauge or thermosensor • Faulty pump mechanical (water) seal
• Faulty radiator cap • Deteriorated O-rings
• Faulty thermostat • Damaged or deteriorated water hoses
• Insufficient coolant
• Passages blocked in hoses or water jacket
• Clogged radiator fins
• Passages blocked in radiator
• Faulty water pump
Temperature gauge pointer does not register
the correct coolant temperature
• Faulty temperature gauge or thermosensor
• Faulty thermostat

FUELSYSTEM/CARBURETOR/FUEL PUMP TROUBLESHOOTING repair guide

Engine does not start Engine idles roughly, stalls or runs poorly
• No fuel in tank • Incorrect idle speed
• Restricted fuel line • Rich mixture
• Too much fuel getting to cylinder • Lean mixture
• Clogged air cleaner • Clogged air cleaner
• Contaminated fuel • Intake air leak
• Faulty fuel pump • Contaminated fuel
• Faulty air-cut off valve
• Damaged vacuum tube and connectors
• Damaged carburetor insulator

Throttle does not open fully, so engine stalls Rich mixture
• Damaged vacuum piston diaphragm • Auto bystarter valve opens excessively
• Clogged diaphragm hole • Faulty float valve
• Float level too high
Lean mixture • Clogged air jets
• Clogged fuel jets • Auto bystarter valve set plate installed in
• Clogged fuel tank cap breather hole the wrong groove
• Clogged fuel filter •Clogged air cleaner
• Bent, kinked or restricted fuel line
• Faulty float valve
• Float level too low
• Faulty fuel pump or insufficient output

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING repair guide

Hard steering (heavy) Front wheel wobbling
• Excessively tightened steering stem top • Bent rim
cone race • Loose front axle
• Broken steering balls • Bent spoke plate
• Insufficient tire pressure • Faulty tire
Steers to one side or does not track straight • Improperly tightened axle nut
• Uneven front shock absorbers Soft front shock absorber
• Bent front fork • Weak shock springs
• Bent front axle or uneven tire • Insufficient damper oil
Poor brake performance Front shock absorber noise
• Worn brake pads • Slider bending
• Contaminated brake pad surface • Loose fork fasteners
• Deformed brake disk • Lack of lubrication
• Air in brake system
• Deteriorated brake fluid
• Worn brake master cylinder piston oil seal
• Clogged brake fluid line
• Unevenly worn brake caliper

REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER TROUBLESHOOTING repair guide

Rear wheel wobbling Poor brake performance
• Bent rim • Air in brake system
• Faulty tire • Deteriorated brake fluid
• Axle not tightened properly • Contaminated brake pad surface
• Worn brake pads
Soft rear shock absorber • Clogged brake fluid line
• Weak shock absorber spring • Deformed brake disk
• Damper oil leaks • Unevenly worn brake caliper
Rear wheel noise
• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork

BATTERY/CHARGING SYSTEM TROUBLESHOOTING repair guide

No power Intermittent power
• Dead battery • Loose battery cable connection
• Disconnected battery cable • Loose charging system connection
• Fuse burned out • Loose connection or short circuit in
• Faulty ignition switch ignition system
Low power Charging system failure
• Weak battery • Loose, broken or shorted wire or connector
• Loose battery connection • Faulty regulator/rectifier
• Charging system failure • Faulty A.C. generator

IGNITION SYSTEM TROUBLESHOOTING repair guide

No spark at plug Engine starts but turns poorly
• Faulty spark plug • Ignition primary circuit • Poorly connected, broken or shorted wire —Faulty ignition coil • Faulty ignition switch —Poorly connected wire or connector • Faulty ignition coil —Poorly contacted ignition switch • Faulty CDI unit • Ignition secondary circuit • Faulty A.C. generator —Faulty ignition coil
—Faulty spark plug —Faulty high-tension wire
—Poorly insulated plug cap
• Improper ignition timing
—Faulty A.C. generator
—Stator not installed properly
—Faulty CDI unit

STARTING SYSTEM TROUBLESHOOTING repair guide

Starter motor won‘t turn Lack of power
• Fuse burned out • Weak battery
• Weak battery • Loose wire or connection
• Faulty ignition switch • Foreign matter stuck in starter motor
• Faulty starter clutch or gear
• Faulty front or rear stop switch
• Faulty starter relay Starter motor rotates but engine does
• Poorly connected, broken or shorted wire not start
• Faulty starter motor • Faulty starter pinion
• Starter motor rotates reversely
• Weak battery

SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS TROUBLESHOOTING repair guide

Lights do not come on when ignition Temperature gauge does not register
switch is “ON” correctly
• Burned bulb • Faulty temperature gauge
• Faulty switch • Faulty thermosensor
• Poorly connected, broken or shorted wire • Broken or shorted wire between
temperature gauge and thermosensor
Fuel gauge pointer does not move or
register correctly
• Faulty fuel gauge
• Faulty fuel unit
• Poorly connected wire between fuel
gauge and fuel unit
• Fuse burned out

EXHAUST EMISSION CONTROL SYSTEM TROUBLESHOOTING repair guide

High CO at idle speed
1. Damaged or clogged reed valve
2. Damaged or clogged air injection cut-off valve
3.Clogged air cleaner
Backfiring at sudden deceleration
1. Damaged reed valve (malfunction)
2. Faulty air injection cut-off valve (unable to close)
3.Carburetor incorrectly adjusted
4. Faulty air cut-off valve
5. Leaking vacuum tube
Exhaust muffler noise
1. Faulty air injection cut-off valve
2.Broken vacuum tube
3. Faulty reed valve

ingersoll-rand COMPRESSOR FAULT CODES DESCRIPTION AND repair TROUBLESHOOTING

Following, are the descriptions of the COMPRESSOR fault codes. These are indicated when the “COMPERSSOR MALFUNCTION” lamp is illuminated. The compressor malfunction lamp is shown on the control panel picture in Section 2 of this manual. It is indicated by Item number 9. The engine fault codes are indicated by the “ENGINE MALFUNCTION” lamp that is located under the “COMPRESSOR MALFUNCTION” lamp. The engine fault codes are listed in Section 10 of this manual. Be sure to determine which malfunction lamp is illuminated before beginning the troubleshooting process.

COMPRESSOR CODE 1

Engine  Speed  Less  Than  800  RPM

Explanation:

The  WEDGE  has  received  an  engine  speed  less  than  800  RPM  for 30  seconds.

Effect:

Code  1   is  a  shutdown  condition  and  will  shutdown  the  machine.

TROUBLESHOOTING  STEPS

Code  1

Action Result
Check  engine  fault  codes  for  an  engine

shutdown.    Check for engine fuel  system

restriction  (filter).

 

 

COMPRESSOR CODE 2

Engine  Speed  Greater Than  1900  RPM

Explanation:

The  WEDGE  has  received  an  engine  speed  greater than  1900  RPM  for 30

seconds.

Effect:

Code  2  is  a  shutdown  condition  and  will  shutdown  the  machine.

TROUBLESHOOTING  STEPS

Code  2

Action Result
Check  engine  fault  codes  for  an  engine

shutdown.

COMPRESSOR CODE 3

Engine  Crank  Time  Exceeded

Explanation:

The  engine  crank  time  has  exceeded  15  seconds.

TROUBLESHOOTING  STEPS

Code  3

Action Result
Crank  engine  for  less  than  15  seconds.

COMPRESSOR CODE 5

Engine  Oil  Temperature

Explanation:

The  WEDGE  has  received  an  engine  oil  temperature  greater than  252  Deg  F

Effect:

Code  5  is  an  ALERT  condition  and  will  not  halt  machine  operation.

TROUBLESHOOTING  STEPS

Code  5

Action Result
Step1:

Refer to the engine  manufacturer’s service  manual for

instructions.

COMPRESSOR CODE 6

Engine  Intake  Manifold  Temperature

Explanation:

The  WEDGE  has  received  an  engine  intake  manifold  temperature  greater than 180  deg  F.

Effect:

Code  6  is  an  ALERT  condition  and  will  not  halt  machine  operation.

TROUBLESHOOTING  STEPS

Code  6

Action Result
Step1:

Refer to the engine  manufacturer’s service  manual for

instructions.

COMPRESSOR CODE 8

Water  in  Fuel

Explanation:

The  WEDGE  has  received  a  water  in  fuel  indication  from  the  engine.

Effect:

Code  8  is  an  ALERT  condition  and  will  not  halt  machine  operation.

TROUBLESHOOTING  STEPS

Code  8

Action Result
Step1:

Check the  machine fuel  system and engine fuel filters.

 
step  2:

Refer to the engine  manufacturer’s service  manual for

instructions.

COMPRESSOR CODE 10

Engine  Not  Responding  To  Throttle  Command

Explanation: The engine has not responded to a request from the WEDGE for engine speed change during engine start. This ALERT will only occur during the idle speed time, right after engine start.

Effect: Code 10 is an ALERT condition and will not shutdown the machine. The machine will not perform properly due to the low speed condition.

Circuit Description:

As  shown  in  the  circuits  above,  the  WEDGE  provides  three  types  of throttle

outputs:  frequency,  PWM  and  analog.

 

TROUBLESHOOTING  STEPS

Code  10

Action Result
Step1:

Measure the throttle signal  at the engine  connector.

If signal  not present,  check wiring

and  verify throttle output at

WEDGE.

step  2:

Engine  may not be able to fuel  properly due to  restricted fuel

filters

Replace fuel filter (s)
step  3:

Verify correct machine  ID  plug  is  installed.   If so,  verify

resistance value of ID  plug  and  its connection  to WEDGE

controller.

 
step  4:

Check connector pins at WEDGE  controller and  connector at

engine  controller for corrosion.

COMPRESSOR CODE 11

Too  Many  Start Attempts  During  Auto  Start

Explanation: The WEDGE has made three attempts to start the machine as commanded by the Auto Start Stop controller. The machine failed to start.

Effect: Code 11 is a SHUTDOWN condition and will shutdown the machine.

TROUBLESHOOTING  STEPS

Code  11

Action Result
Step1:

Check the  machine fuel  system and engine fuel filters.

 
step  2:

Check the condition  of the  machine  batteries.

 
step  3:

Cycle  machine  power,  activate the Auto Start input so the

machine will  make another start attempt.   Machine will  go

through  3 crank cycles to attempt start before a  Code  11  is

issued.

COMPRESSOR CODE 29

Engine  shut  itself down:  reason  unknown

Explanation: The engine has shut down. The WEDGE did not shut down the engine.

Effect: Code 29 is a SHUTDOWN condition and will shutdown the machine.

TROUBLESHOOTING  STEPS

Code  29

Action Result
Step1:

Check the  machine fuel  system and engine fuel filters.   Check

for loose fittings  in the fuel  piping  that could  allow air to  be

drawn  into the fuel  system.

 
step  2:

Verify the throttle signal from the WEDGE  is  continuously

supplied  to the engine.

A quick drop  in the throttle signal

could  cause the engine to stop

step  3:

Verify  battery + and - connections to the engine  controller,

inspect harness  connections and  measure voltage drop at

engine  ECM.

 
step  4:

In  the case of the  l-R (John  Deere) engine,  check the

connections for the  crank sensor which  is  mounted  at the front

of the engine.   Loose  pin  connections  in the  connector will

cause  code 29.

 

COMPRESSOR CODE 31

Low Air End Oil Pressure (HP1600 Only)

Explanation: The WEDGE received a closed contact from pressure switch S9, located in the air end on the HP1600 machine. This indicates a low oil pressure in the air end.

Effect: Code 31 is a shutdown condition and will shutdown the machine. The cause of the low air end oil pressure must be repaired to continue machine operation.

Circuit Description:

 

Switch  S9  is  a  12  psi,  normally  open  pressure  switch. If the  pressure  falls  below

12  psi,  the  switch  will  close,  indicating  to  the  WEDGE  controller a  low  air  end  oil pressure.

Component Location:

S9  is  located  in  the  back  of the  air end.

TROUBLESHOOTING  STEPS

Code  31

Action Result
Step1:

Check the air end oil  pressure with  a  mechanical  gauge.

If >  12  psi,  replace  S9

If not,  there  is a  harness or

WEDGE  problem.

COMPRESSOR CODE 32

RT2,  Discharge  Temperature  Sensor  Fault

Explanation: The WEDGE has received an out of limits reading from the RT2 temperature sensor. This reading could be on the high or low end of the range. It is out of the normal range for temperature measurement.

Effect: Code 32 is a shutdown condition and will shutdown the machine.

TROUBLESHOOTING  STEPS

Code  32

Action Result
Step1:

Substitute the thermistor simulator (l-R # 22073878) for RT2

Use the WEDGE service diagnostics to  read  the value for RT2

It should  be approximately 32 degrees  F.

Should  read  approx.   32  Deg  F

If not,  there  is a  harness or

WEDGE  problem.

 

COMPRESSOR CODE 33

PT1 Pressure Transducer Sensor Fault

Explanation: The WEDGE has received an out of limits reading from the PT1 pressure transducer. This reading could be on the high or low end of the range. It is out of the normal range for pressure.

Effect: Code 33 is an ALERT condition and will not shutdown the machine. If the Transducer is defective, the machine could shutdown due to an out of range pressure

TROUBLESHOOTING  STEPS

Code  33

Action Result
Step1:

Substitute the  pressure transducer simulator (l-R # 22168868)

for PT1.   Use the WEDGE  service diagnostics to  read the value

for PT1.   It should  be approximately 30 - 50  psi.

Should  read  30 - 50  psi.

If not,  there  is a  harness or

WEDGE  problem.

COMPRESSOR CODE 35

Machine Over Pressure Condition

Explanation: The WEDGE has received a pressure from PT1 that is greater than 175 psi.

Effect: Code 35 is a shutdown condition and will shutdown the machine. The separator tank high pressure has been exceeded.

TROUBLESHOOTING  STEPS

Code  35

Action Result
Verify  PT1   pressure  transducer  is  reading

correctly.

The  pressure  simulator  (IR#22168868)  can

be  substituted  for  PT1.  This  will  verify

operation  of harness  and  WEDGE  controller.

Using  the  simulator,  PT1   on  the  WEDGE

Diagnostics  should  read  30-50  psi.

COMPRESSOR CODE 36

Safety Valve Open

Explanation: The WEDGE has received a switch closure from S14. This indicates the separator tank safety valve has opened.

Effect: Code 36 is a shutdown condition and will shutdown the machine.

TROUBLESHOOTING STEPS

Code 36

Action Result
Verify  PT1   pressure  transducer  is  reading

correctly.

COMPRESSOR CODE 50

 

Separator Tank Temperature

Explanation: The WEDGE has received a separator tank temperature from RT1 that is greater than 247 degrees F.

Effect: Code  50  is  a  shutdown  condition  and  will  shutdown  the  machine.

TROUBLESHOOTING STEPS

 

Code 50

Action Result
Step1:

Check for package air inlet  restrictions.

 
step  2:

Check for dirty or clogged  coolers.

 

For more information, please download the manual

cessna 1979 model u206g pilot’s operating handbook and FAA approved airplane flight manual

The pilot’s operating handbook in the ariplane at the time of delivery from cessna aircraft company contains information applicable to the 1979 model U206G airplane designated by the serial number and registration number shown on the title page of this handbook.

table of contents

  • general
  • limitations
  • emergency procedures
  • normal procedures
  • performance
  • weight & balance / descriptions
  • airplane handling,service & maintenance
  • supplements (optional systems description & operating procedures)

This pilor’s operating handbook has been prepared as a guide to help you get the most pleasure and utility from your airplane,it contains information about your cessna’s equipment,operating procedures, and performance ; and suggestions for its servicing and care, we urge you to cover,and to refer to it frequently.

Download

cessna model 172s pilot’s operating handbook and FAA approved airplane flight manual

This cessna model 172s pilot’s operating handbook has been prepared as a guide to help you get the most utility from your airplane. it contains information about your airplane’s equipment, operating procedures, performance and suggested service and care. please study it carefully and use it as a reference.
CONTENTS

  • service ceiling
  • takeoff performance
  • landing performance
  • stall speed
  • maximum weight
  • standard empty weight
  • baggage allowance
  • fuel capacity
  • oil capacity
  • engine

This handbook consists of nine sections that cover all operational aspects of a standard-equipped airplane. following section 8 are the supplements, section 9, which provide expanded operational procedures for the avionics equipment and provides information on special operations.

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