TRB Gen Overall Troubleshooting

OVERALL TROUBLESHOOTING and REPLACEMENT PART’S PROCEDUREs
GENSET - OVERALL TROUBLESHOOTING
Product: IBIS-FM, FMT, Rover, ArcSAR

Components: PD50S - Voyager4010
Update: April 8, 2019
NOTICES
This procedure collects all the troubleshoot tasks referred to diesel generator (called “GENSET”), both
in the PD50S version and in the Voyager 4010 version.
Both versions are based on a Yanmar L70N, air-cooled, vertical single-cylinder, 4-stroke, direct
injection engine.
REQUIRED TOOLS
Given the multiplicity and variety of activities addressed in this procedure, the availability of the entire tool box is
required.
Below, only the customized tools or materials referred to in the manual are listed:
Tool IDS Georadar code Image
RS232 female to female 861962
24Vdc Supplier 857997
Supply cable AMF25 858528
PDC_2019_019 Rev. 1.0 Page 1

USB to Serial converter 861954
PDC_2019_019 Rev. 1.0 Page 2

TABLE OF CONTENTS
NOTICES.............................................................................................................................................................................. 1
REQUIRED TOOLS ............................................................................................................................................................... 1
SCOPE......................................................................................................................................................................... 6
1.1. STANDARD INFORMATION NEEDED FOR TROUBLESHOOTING ACTIONS ................................................................... 6
PROCEDURES .............................................................................................................................................................. 7
HOW TO ACCESS THE ENGINE....................................................................................................................................11
GENERAL NOTE..........................................................................................................................................................14
PURELY MECHANICAL OPERATIONS ..........................................................................................................................14
5.1. MOTOR OIL AND OIL FILTER ..................................................................................................................................... 15
5.1.1. GENERAL INFORMATION ..................................................................................................................................... 15
5.1.2. ENGINE OIL REFILLING AND OIL FILTER REPLACEMENT ....................................................................................... 15
5.2. FUEL FILTER .............................................................................................................................................................. 17
5.3. AIR FILTER ................................................................................................................................................................ 18
5.4. AIR PURGE FROM FUEL CIRCUIT ............................................................................................................................... 21
5.5. CLOGGED UP EXHAUST MUFFLER ............................................................................................................................ 22
ELECTRICAL (ON BOARD OF THE ENGINE) ..................................................................................................................24
6.1.1. PD50S – ELECTRICAL PANEL OVERVIEW .............................................................................................................. 24
6.2. GENERAL INFORMATION ......................................................................................................................................... 26
6.2.1. VOYAGER 4010 - ELECTRICAL BOARD .................................................................................................................. 26
6.2.2. PD50S – ELECTRICAL PANEL OVERVIEW .............................................................................................................. 26
6.3. OIL PRESSURE SWITCH ............................................................................................................................................. 28
6.4. TEMPERATURE SENSOR ........................................................................................................................................... 30
6.5. ALTERNATOR’S CAPACITOR ..................................................................................................................................... 32
6.6. RELAY 12V AND 20A FUSE.......................................................................................................................................... 36
6.7. ELECTROVALVE (EV) ................................................................................................................................................. 39
6.8. STARTER (MODEL: PD50S ONLY) ................................................................................................................................. 46
6.9. BATTERY CHARGER REGULATOR .............................................................................................................................. 48
6.10. HOURMETER (MODEL: PD50S ONLY)........................................................................................................................... 50
6.11. BATTERY UNIT (MODEL: PD50S ONLY)......................................................................................................................... 52
6.12. EMERGENCY CONTACT AND EMERGENCY BUTTON (MODEL: PD50S ONLY) ................................................................. 53
6.13. CIRCUIT BREAKER (MODEL: PD50S ONLY) ................................................................................................................... 55
CABLING AND ELECTRICAL (RELATED TO CONTROL PANEL/AMF25); .........................................................................57
7.1. PROBLEM: CRANKING TIME/BATTERY ALARM DELAY.............................................................................................. 57
7.2. PROBLEM: GENSET ERROR 447 “SD RPMMEASFAIL” ............................................................................................... 58
7.3. PROBLEM: MAINTENANCE WARNING ..................................................................................................................... 59
7.4. CHECK: AMF25 SUPPLYING (MODEL: VOYAGER4010 ONLY) ....................................................................................... 60
MISCELLANEOUS .......................................................................................................................................................63
8.1. REPLACEMENT OF DIESEL SENSOR – MODEL SA01817 (MODEL: PD50S ONLY) ........................................................... 63
8.2. REPLACEMENT OF DIESEL SENSOR – MODEL SA03302 ............................................................................................ 68
8.3. UPGRADE OF AMF25 AIL CONFIGURATION.............................................................................................................. 72
8.4. SET GENSET RUNNING HOURS ................................................................................................................................. 79
8.5. REPLACEMENT OF A VOYAGER4010 .......................................................................................................................... 82
ALARM/ERROR CODE ...............................................................................................................................92
SUPPLY LOG FILES .....................................................................................................................................94
TABLE OF FIGURES
PDC_2019_019 Rev. 1.0 Page 3

FIG. 1 – RIGHT LATERAL PANEL ..................................................................................................................................................... 11

FIG. 2 – BLACK (UPPER) AND RED (LOWER) FRONTAL PANELS ............................................................................................................. 11
FIG. 3 – LEFT LATERAL PANEL ....................................................................................................................................................... 12
FIG. 4 – GENSET PD50S - “NORMAL MODE” CONFIGURATION .......................................................................................................... 12
FIG. 5 – GENSET RCD ................................................................................................................................................................ 13
FIG. 6 – GENSET ROTATING PANEL ................................................................................................................................................ 13
FIG. 7 – OIL CHART .................................................................................................................................................................... 15
FIG. 8 – ENGINE OIL REFILLING/OIL FILTER REPLACEMENT .................................................................................................................. 16
FIG. 9 – FUEL FILTER .................................................................................................................................................................. 18
FIG. 10 – VOYAGER4010 – AIR FILTER .......................................................................................................................................... 19
FIG. 11 - VOYAGER4010 – AIR FILTER REMOVING ........................................................................................................................... 19
FIG. 12 – REMOVING AIR FILTER COVER ......................................................................................................................................... 20
FIG. 13 – PD50S -AIR FILTER REMOVING....................................................................................................................................... 20
FIG. 14 – VOYAGER4010 – FUEL PRIMER PUMP.............................................................................................................................. 21
FIG. 15 – PD50S - AIR PURGE SCREW ........................................................................................................................................... 21
FIG. 16 – LOWER EXHAUST MUFFLER ............................................................................................................................................. 22
FIG. 17 – EXHAUST SYSTEM – FLEXIBLE JOINT .................................................................................................................................. 23
FIG. 18 – EXAMPLE OF A CLOGGED-UP EXHAUST MUFFLER ................................................................................................................. 23
FIG. 19 – VOYAGER4010 – ELECTRICAL BOARD .............................................................................................................................. 26
FIG. 20 – PD50S – ELECTRICAL PANEL OVERVIEW (FRONT SIDE)......................................................................................................... 27
FIG. 21 - PD50S – ELECTRICAL PANEL OVERVIEW (BACK SIDE) ........................................................................................................... 27
FIG. 22 – OIL PRESSURE SWITCH ................................................................................................................................................... 28
FIG. 23 – UNSCREW THE BOLT WHICH FIX THE PS CABLE. ................................................................................................................... 28
FIG. 24 – UNSCREW THE PRESSURE SWITCH .................................................................................................................................... 29
FIG. 25 – TEMPERATURE SENSOR ................................................................................................................................................. 30
FIG. 26 – SENSOR BRACKET/HOUSING LOCKING NUT ........................................................................................................................ 30
FIG. 27 – TEMPERATURE SENSOR’S SUPPORT BRACKET/HOUSING ........................................................................................................ 31
FIG. 28 – REMOVING OF THE BATTERY ........................................................................................................................................... 32
FIG. 29 – UNSCREW BOLTS FROM ALTERNATOR COVER ..................................................................................................................... 32
FIG. 30 – REMOVING ALTERNATOR COVER ..................................................................................................................................... 33
FIG. 31 – REMOVE TIE-WRAP TO RELEASE THE CAPACITOR ................................................................................................................. 33
FIG. 32 – UNPLUG WIRES FROM CAPACITOR ................................................................................................................................... 34
FIG. 33 – VOYAGER4010 - CAPACITOR .......................................................................................................................................... 35
FIG. 34 – COLLAR SCREW (A) AND CAPACITOR’S CAP (B).................................................................................................................... 35
FIG. 35 – RELAY LOCKING SCREW.................................................................................................................................................. 36
FIG. 36 – REMOVING THE RELAY................................................................................................................................................... 36
FIG. 37 – RELAY BOARD .............................................................................................................................................................. 37
FIG. 38 - 20A FUSE (PD50S) ...................................................................................................................................................... 38
FIG. 39 – 20A FUSE (VOYAGER4010)........................................................................................................................................... 38
FIG. 40 – EV POSITION ............................................................................................................................................................... 39
FIG. 41 – DISMOUNTING THE EV (STEP 1) ..................................................................................................................................... 39
FIG. 42 - DISMOUNTING THE EV (STEP 2) ...................................................................................................................................... 39
FIG. 49 - DISMOUNTING THE EV (STEP 11) .................................................................................................................................... 43
FIG. 50 - MOUNTING THE NEW EV (STEP 1) ................................................................................................................................... 43
FIG. 55 – STARTER BOX BLACK COVER RING REMOVING ..................................................................................................................... 46
FIG. 56 – STARTER BOX (REAR VIEW) ............................................................................................................................................. 46
FIG. 57 – STARTER BOX ELECTRICAL CONNECTIONS ........................................................................................................................... 47
FIG. 58 – BATTERY CHARGER REGULATOR DISMOUNTING .................................................................................................................. 48
FIG. 59 - BATTERY CHARGER REGULATOR’S CONNECTOR UNPLUGGING ................................................................................................. 48
PDC_2019_019 Rev. 1.0 Page 4

FIG. 60 – VOYAGER4010 – BATTERY CHARGER REGULATOR (POSITION)............................................................................................... 49

FIG. 61 – BATTERY CHARGE REGULATOR – ELECTRICAL CONNECTIONS .................................................................................................. 49
FIG. 62 – ACCESS TO HOURMETER(A) – HOURMETER REAR VIEW (B) ................................................................................................... 50
FIG. 63 – HOURMETER REMOVING ............................................................................................................................................... 50
FIG. 64 – UNPLUG THE OLD HOURMETER/PLUG THE NEW ONE. .......................................................................................................... 51
FIG. 65 – PD50S – BATTERY UNIT ............................................................................................................................................... 52
FIG. 66 – ACCESS THE EMERGENCY BUTTON AND CONTACT.......................................................................................................... 53
FIG. 67 – EMERGENCY CONTACTS – REAR VIEW ............................................................................................................................... 53
FIG. 68 - EMERGENCY BUTTON – REAR VIEW ................................................................................................................................... 54
FIG. 69 – EMERGENCY BUTTON METAL RING REMOVING ................................................................................................................... 54
FIG. 70 – ACCESS THE PD50S BREAKER AND REAR VIEW ................................................................................................................... 55
FIG. 71 – BREAKER REMOVING (STEP 1) ........................................................................................................................................ 55
FIG. 72 - BREAKER REMOVING (STEP 2) ......................................................................................................................................... 56
FIG. 73 - BREAKER REMOVING (STEP 3) ......................................................................................................................................... 56
FIG. 74 – INTELILITE™ AMF 25 ................................................................................................................................................... 59
FIG. 75 – DIESEL SENSOR MODEL SA01817 .................................................................................................................................. 63
FIG. 76 – REMOVING THE SENSOR COVER ....................................................................................................................................... 63
FIG. 77 – UNPLUGGING FUEL SENSOR CONNECTOR .......................................................................................................................... 63
FIG. 78 – REMOVING CONNECTOR PLASTIC CASE.............................................................................................................................. 64
FIG. 79 – PULLING OUT THE THREE WIRES ...................................................................................................................................... 64
FIG. 80 – REMOVAL OF THE FUEL SENSOR....................................................................................................................................... 64
FIG. 81 – INSERT THE NEW SENSOR ............................................................................................................................................... 65
FIG. 82 – FIXING THE NEW SENSOR FRAME ..................................................................................................................................... 65
FIG. 83 - REMOVING CONNECTOR PLASTIC CASE .............................................................................................................................. 65
FIG. 84 - REASSEMBLING CONNECTOR PLASTIC CASE ......................................................................................................................... 66
FIG. 85 – REFUELLING THE TANK .................................................................................................................................................. 66
FIG. 86 – CHECK THE FULLNESS OF THE TANK (1) ............................................................................................................................. 66
FIG. 87 - CHECK THE FULLNESS OF THE TANK (2) .............................................................................................................................. 67
FIG. 88 - DIESEL SENSOR MODEL SA03302 ................................................................................................................................... 68
FIG. 89 - REMOVING THE SENSOR COVER ....................................................................................................................................... 68
FIG. 90 - UNPLUGGING FUEL SENSOR CONNECTOR ........................................................................................................................... 68
FIG. 91 – PULLING OUT THE CONNECTOR ....................................................................................................................................... 69
FIG. 92 - REMOVAL OF THE FUEL SENSOR (1) .................................................................................................................................. 69
FIG. 93 - REMOVAL OF THE FUEL SENSOR (2) .................................................................................................................................. 69
FIG. 94 – INSERT THE NEW FUEL SENSOR ........................................................................................................................................ 70
FIG. 95 - REFUELLING THE TANK ................................................................................................................................................... 70
PDC_2019_019 Rev. 1.0 Page 5

SCOPE
The purpose of this document is to describe the possible troubleshootings and the correct procedures to follow when
electrical or mechanical problems occur to the GENSET.
1.1. STANDARD INFORMATION NEEDED FOR TROUBLESHOOTING ACTIONS

• Genset age / run hours;
• Conditions when problem occurred:
o During running;
o At start (no problems during the last run);
o Resumed to work after long time.
• Weather conditions (mainly temperature, at least hot/cold weather);

• Returned error from the AMF25.
PDC_2019_019 Rev. 1.0 Page 6

PROCEDUREs
A first approach to dealing with the resolution of GENSET’s problems is to follow the flowchart below:
Try to turn ON the

engine with
Controller
YES
Standard
Does it works?
maintenance
NO
Try to turn ON the engine with

the key (PD50S) or with test
cables (Voyager4010)
The problem is in YES

the AMF25 that
Does it works?
turns OFF the
engine
NO
The problem is in
the engine
NO
Does it turn ON
Electric problem
during cranking?
YES
Verify the engine (oil, gasoil, air filters) –

Verify that no air is pumped in the gasoil filter
NO
Still in good
Service the engine
shape?
YES
Remove the cable from the oil pressure sensor and unplug
temperature sensor (Voyager 4010 only)
Try to start the

engine
YES NO
Let it works for 2 minutes, then
Possible air in the high pressure
circuitPDC_2019_019 Rev. 1.0 Page 7
touch the oil pressure sensor Does it works?
or damaged EV
with its cable
OVERALL TROUBLESHOOTING and
Remove the REPLACEMENT
cable from PART’S
the oil pressure sensor and
temperature sensor (Voyager 4010 only)
unplug PROCEDUREs
Try to start the

engine
YES NO
Let it works for 2 minutes, then
Possible air in the high pressure
touch the oil pressure sensor Does it works?
circuit or damaged EV
with its cable
NO
Change oil pressure Unscrew the nut on the metal
It still works?
sensor pipe, start cranking
YES
Plug the
temperature sensor YES
Is gasoil coming out Fix the nut, try a
immediately? start
NO NO
Change
It still works?
temperature sensor
Try the cranking for some
second, to check if gasoil comes
YES out
Let it works for 10 minutes, then turn OFF the

engine, screw back in place the cable on the oil YES
pressure sensor. Try again to start.
Is gasoil coming out?
NO
Fix the nut, verify 12Vdc on the EV

during crank
NO YES
Remove the EV,
Check EV supply
unplug the pump Is it okay?
circuit
and try a cranking
The problem can be:

NO
• Injector
• Valves
Does it work?
• Piston
Manage Service with
YANMAR/MASE
YES
PDC_2019_019 Rev. 1.0 Page 8

Another analysis of the GENSET’s problems can be made based on the error code displayed on the AMF25, according to the
table below:
DISPLAYED
ERROR WORDING SUGGESTED PAGE REF.
ERROR TYPE ORIGIN OF THE FAULT
CODE (IBIS CONTROLLER / SPARE or NOTES
AMF25)
LOW FUEL NA -
AIR IN FUEL CIRCUIT NA 14
DIRTY FUEL FILTER Fuel filter 17
FUEL/OIL
DIRTY TANK CAP NA -
CIRCUIT
TANK SWITCH OFF NA -
OIL SENSOR BROKEN Pressure switch 28
LOW OIL NA -
EMERGENCY BUTTON/SWITCH NOT Emergency stop
53
439 SD START FAIL RELEASED OR BROKEN button / switch
BROKEN STARTER ENGINE Starter 46
ELECTRICAL
BROKEN STARTER ENIGINE RELE' Relay 36
(Motor)
Electrovalve
BROKEN ELECTROVALVE 39
(L N series)
BROKEN ELECTROVALVE RELE' Relay 36
BROKEN ELECTROVALVE RELE' (KAD) Relay 12V 36
ELECTRICAL
BROKEN STARTER ENIGINE RELE' 36
(Panel) Relay 12V
(KAV)
To be checked by qualified
ALTERNATOR BROKEN Alternator
personnel MASE®
Alternator
CAPACITOR BROKEN 32
capacitor
ELECTRICAL To be checked by qualified
DIODE BROKEN Alternator diode
(Motor) personnel MASE®
Alternator To be checked by qualified
VARISTOR BROKEN
varistor personnel MASE®
447 SD RPM MeasFail
GENERAL SWITCH TURNED OFF OR
Int diff 55
BROKEN
AC CABLE FROM GENSET TO PANEL Power cable
CABLES -
NOT ATTACHED OR BROKEN genset-AMF25
FUSE (FU1) DAMAGED INSIDE FUSE ON R2 WIRE:
4A Fuse
ELECTRICAL GENERATOR CONTROL PANEL 4A 10x38mm
(Panel) GENERATOR VOLTAGE CONNECTOR REAR OF AMF25:
NA
DISCONNECTED N2 and R91 WIRES
ELECTRICAL INTERNAL LOW VOLTAGE To be checked by qualified
NA
(Motor) ALTERNATOR BROKEN personnel MASE®
BRIDGE RECTIFIER INSIDE GENSET To be checked by qualified
Diode bridge
CONTROL PANEL BROKEN personnel MASE®
23/24/131/132
disconnected from bridge
LOOSE INTERNAL WIRES ON BRIDGE
NA rectifier (note: 32VAC
RECTIFIER
444 ChargeAlt Fail between 132 and 131 with
ELECTRICAL
engine on)
(Panel)
KD RELAY BROKEN Relay 24V 36
13 (D+) disconnected from
POWER CONNECTOR on rear
LOOSE INTERNAL WIRE ON OF
NA of AMF25; D+ is 0V (8) when
AMF25
engine is off; D+ is 12V (70)
when engine is on;
ELECTRICAL EMERGENCY BUTTON ON GENSET
NA 53
(Motor) PRESSED WHILE ENGINE IS ON
LOW FUEL NA -
436 SD UNDERSPEED
FUEL/OIL AIR IN FUEL CIRCUIT NA 14
CIRCUIT DIRTY FUEL FILTER Fuel filter 17
DIRTY TANK CAP NA -
PDC_2019_019 Rev. 1.0 Page 9

TANK SWITCH OFF NA -

OIL SENSOR BROKEN Pressure switch 28
LOW OIL NA -
GCB feedback (BI1/ 500
ELECTRICAL wire) is 0V (8) when GCB is
437 GCB FAIL KAG RELAY BROKEN Relay 12V
(Panel) closed: open circuit when
GCB is open
EMERGENCY STOP ON PANEL
NA 53
PRESSED OR BROKEN
emergency button released:
ELECTRICAL LOOSE INTERNAL WIRES NA 85/86/87 must be 12V (70);
442 EMERGENCY STOP
(Panel) 88 must be at 0V (8)
KEM RELAY BROKEN Relay 12V 36
88 must be connected to BI3
LOOSE INTERNAL WIRES ON AMF25 NA
on the rear of AMF25
ELECTRICAL Alternator
413 SD Gen L1 < V CAPACITOR BROKEN 32
(Motor) capacitor
GENSET RUNNING
WITHOUT CHARGING ELECTRICAL Remote control
NA KLG BROKEN
BATTERY (only on IBIS (PANEL) switch
Controller)
Not spillable AMF25 OFF / GENSET
GENSET BATTERY FLAT
ELECTRICAL battery WOULD NOT START ON KEY
(Motor) AMF25 OFF / GENSET
20 A FUSE BROKEN 20A Fuse
WOULD NOT START ON KEY
10 POLE CONTROL CABLE
10 Pins cable AMF25 OFF
DISCONNECTED OR BROKEN
CABLES
RS485 CABLE DISCONNECTED OR RS485 cable
-
BROKEN AMF25-PSM
Electromechanic
KPP RELAY OFF OR BROKEN AMF25 OFF
al switches
FUSE (FU2) DAMAGED INSIDE AMF25 OFF / FUSE on 70: 4A
4A Fuse
GENSET TIMEOUT GENERATOR CONTROL PANEL 10x38mm
ELECTRICAL
NA (only on IBIS AMF25 OFF / power
(Panel) LOOSE POWER CONNECTOR OF
Controller) NA connector disconnected on
AMF25
the rear of AMF25
LOOSE COMMUNICATION 509,510 must be connected
NA
CONNECTOR OF AMF25 to communication of AMF25
ELECTRICAL LOOSE COMMUNICATION
NA Js3 disconnected from PSC
(Supply Unit) CONNECTOR OF PSC
AC CABLE FROM PANEL TO SUPPLY Power cable
CABLES -
UNIT NOT ATTACHED OR BROKEN AMF25-PSM
AC SWITCH OFF OR BROKEN NA -
ELECTRICAL Battery charger
(Supply Unit) BATTERY CHARGER BROKEN Promec 48
(PPSTD602)
For more information, details and support:
MASE GENERATORS SPA

Via Tortona, 345
47023 Cesena (FC) Italy
Tel.+39-0547-354311 Fax. +39-0547-317555
PDC_2019_019 Rev. 1.0 Page 10

As per table and flowchart above, the ERROR TYPEs can be divided mainly in 3 group:
1) Purely mechanical (Air, Fuel/Oil circuit);

2) Electrical (devices on board of the engine);
3) Electrical (related to Control Panel/AMF25) or cabling.
HOW TO ACCESS THE ENGINE
Follow these procedures to access to the engine:
Model: PD50S
1) Turn off the Genset switch from the Power Supply Module, unplug the cables from the Genset and press the
Emergency Stop Button.
2) Unscrew the bolts which fix the right lateral panel and remove it (Fig. 1).
Fig. 1 – Right lateral panel
3) Unscrew the bolts which fix the frontal panel to the Genset and remove it. Then, unscrew the bolts which fix the
black upper panel to the red one (Fig. 2).
Fig. 2 – Black (upper) and red (lower) frontal panels
4) Unscrew the bolts which fix the left lateral panel and remove it (Fig. 3).
PDC_2019_019 Rev. 1.0 Page 11

Fig. 3 – Left lateral panel

Perform the following tasks to restore the initial configuration (“normal mode” config):
1) Put the lateral panels in place and screw its bolts back on (see previous step 2, as reference).
2) Release the Emergency Stop Button, plug the power and the serial cables back on the Genset and turn on the Genset
switch from the Power Supply Module.
3) At the end of each task, check the proper configuration of the Genset: Emergency Stop Button released, key turned
on “STOP” position, cables properly connected, as shown in Fig. 4:
Fig. 4 – Genset PD50S - “Normal mode” configuration
Model: Voyager 4010
1) Turn off all the Isolation Points of the IBIS system: one is on the PSU Control Module; the other ones are on the
Power Supply Unit front side; turn off also Genset RCD from Circuit Breakers panel (Fig. 5);
PDC_2019_019 Rev. 1.0 Page 12

Fig. 5 – Genset RCD
2) Open the generator rotating panel, unlocking the two metal locks (Fig. 6);
Fig. 6 – Genset rotating panel
3) If needed, remove the roof cover (solar panel): in this way you have a full view and access to the top and rear side of
the Voyager generator.
PDC_2019_019 Rev. 1.0 Page 13

GENERAL NOTE
Unless otherwise indicated (Model: PD50S or

Voyager4010), the procedures are valid for both versions
of the engines.
PURELY MECHANICAL OPERATIONS
This section describes purely mechanical interventions, such as:
1) Replacement of:
a. MOTOR OIL AND OIL FILTER;
b. FUEL FILTER;
c. AIR FILTER.
2) Check for and resolution of:

d. AIR PURGE FROM FUEL CIRCUIT;
e. CLOGGED UP EXHAUST MUFFLER.
PDC_2019_019 Rev. 1.0 Page 14

5.1. MOTOR OIL AND OIL FILTER
5.1.1. GENERAL INFORMATION
It’s necessary to replace the oil filter after the first 20 hours of
operations and the motor oil after the first 50 hours of operations.
Always use oil with suitable viscosity for the temperature where the engine is being operated. Use the chart reported in Fig.
7 when choosing your engine oil. The oil tank has a capacity of 1.1 L. Besides, use motor oil that meets or exceeds the following
guidelines and classifications:
• API (American Petroleum Institute) services categories CD or higher;

• ACEA (European Automobile Manufacturers Association) services categories E-3, E-4 and E-5;
• JSO (Japanese Automobile Standards Organization) services category DH-1.
Fig. 7 – Oil chart
WARNING! SUDDEN MOVEMENT HAZARD!

Allow the engine to warm up for at least 5 minutes to allow the engine
idle speed to return to normal before engaging the transmission or any
PTO (Power Take-Off) attachments. Engaging the transmission or PTO at
an elevated engine speed could result in an expected movement of the
equipment.
5.1.2. ENGINE OIL REFILLING AND OIL FILTER REPLACEMENT
A recipient for waste oil, engine oil and a spare oil filter are required. Below the procedure step by step:
1) Stop the generator and isolate it, turning off the GENSET switch on the PSU front door and the Genset Isolation Point
switch;
2) Make sure the IBIS-Rover is on a levelled surface;
PDC_2019_019 Rev. 1.0 Page 15

3) Remove the oil dipstick to allow the engine oil to drain more easily (Fig. 8Error! Reference source not found.);
Fig. 8 – Engine oil refilling/Oil filter replacement
4) Place a recipient under the engine to collect wasted oil;
WARNING! BURN HAZARD!

If you drain the engine oil while it is still hot, stay clear of the hot engine
oil to avoid being scalded.
5) Remove the drain plug (Fig. 8), let oil come out and once finished, close the plug again;
Be environmentally responsible. Follow these procedures for hazardous

waste disposal. Failure to follow these procedures may seriously harm
the environment.
Follow the guidelines of the government agency for the proper disposal
of hazardous materials such as batteries: consult the local authorities or
reclamation sites;
Never dispose of hazardous materials irresponsibly by dumping them
into a sewer, on the ground or into ground water or waterways.
6) Remove oil filter retaining bolt, pull the oil filter cap out and remove the oil filter;
7) Clean the oil filter or replace it with a new one if damaged;
PDC_2019_019 Rev. 1.0 Page 16

8) Insert the oil filter in its housing again, pay attention the oil filter cap is fully seated;
9) Install and tighten the oil filter retaining bolt;
10) Add new motor oil;
11) Wait one minute and check oil level;
12) Add more oil if necessary but don’t exceed the max level;
13) Fully reinsert the oil dipstick and tighten it;
14) Turn on genset isolation point switch and the genset switch on the PSU and test the generator.
Only use the recommended engine oil. Other engine oils may affect
warranty coverage, cause internal engine components to cease and
shorten the engine life;
Prevent dirt and debris from contaminating the engine oil. Carefully clean
the oil cap /dipstick and the surrounding area before removing the cap;
NEVER mix different types of engine oil. This may adversely affect the
lubricating properties of the engine oil;
NEVER overfill. Overfilling may result in white exhaust smoke, engine
overspeed or internal damage;
ALWAYS keep the oil level between the upper and lower lines in the oil.
5.2. FUEL FILTER
Be environmentally responsible. Follow these procedures for hazardous

waste disposal. Failure to follow these procedures may seriously harm
the environment.
Follow the guidelines of the government agency for the proper disposal
of hazardous materials such as batteries: consult the local authorities or
reclamation sites.
Never dispose of hazardous materials irresponsibly by dumping them
into a sewer, on the ground or into ground water or waterways.
WARNING! FIRE HAZARD!

Diesel fuel is extremely flammable and explosive in certain conditions.
When you remove any fuel system component to perform maintenance
(such as changing fuel filter) place an approved container under the
opening to catch the fuel.
NEVER use a shop rag to catch the fuel. Vapors from the rag are extremely
flammable and explosive.
Wipe up any spills immediately.
Wear eye protection. The fuel system is under pressure and fuel could
spray out when removing any fuel system component.
Failure to comply will result in death or serious injury.
To replace the fuel filter:
1) Stop the generator and isolate it, turning off the GENSET switch on the PSU front door and the GENSET Isolation
Point switch;
2) Place an approved container under the fuel filter to collect possible fuel spills;
PDC_2019_019 Rev. 1.0 Page 17

3) Shut the flow valve;

4) Remove the hose clamps and the filter cartridge;
5) Place a new filter cartridge;
6) Replace the hose clamps;
7) Turn on Genset Isolation Point switch and the GENSET switch on the PSU;
8) Push the black button on the right side of the generator and check if the fuel is passing throughout
9) Test the generator running it for some minutes.
Fig. 9 – Fuel filter
5.3. AIR FILTER
The engine performance is adversely affected when the air cleaner

element is clogged with dust. Be sure to clean or replace the air filter
element periodically.
Model: Voyager4010
Below the procedure step by step:
1) Stop the generator and isolate it, turning off the GENSET switch on the PSU front door and the Genset Isolation Point
switch;
2) Open the generator sliding panel, unlocking the two metal locks;
3) Open the air filter cover, removing the #4 Philips bolts (Fig. 10);
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Fig. 10 – Voyager4010 – Air filter
4) Clean or replace the air filter (Fig. 11Error! Reference source not found.)
Fig. 11 - Voyager4010 – Air filter removing

5) Clean the inside of the air cleaner;
6) Install the air cleaner element into the air cleaner case;
7) Turn on Genset Isolation Point switch and the GENSET switch on the PSU and test the generator.
PDC_2019_019 Rev. 1.0 Page 19

Model: PD50S
Air filter cleaning and replacing procedure:
1) Remove the wing nut (Fig. 12 and Fig. 13 – Pos. 1):
Air cleaner
cover
Wing
nut
Fig. 12 – Removing air filter cover
2) Remove the air filter cover as shown in Fig. 13 – Pos. 2;

3) Remove the wing nut as shown in Fig. 13 – Pos. 3;
4) Remove the air cleaner element and outer foam element as shown in Fig. 13 – Pos. Error! Reference source not f
ound.4 and 5;
Fig. 13 – PD50S -Air filter removing

5) Blow air through both elements using compressed air to remove particulates. Use the lowest possible air pressure to
remove the dust without damaging elements;
6) If either element is damaged replace both;
7) Clean the inside of the air cleaner cover;
8) Install the air cleaner element into the air cleaner case;
9) Slide the outer foam element over the air cleaner element;
10) Install the wing nut and tighten it;
11) Install the air cleaner cover;
12) Install the wing nut and tighten it;
13) Perform/check the proper configuration of the Genset: Emergency Stop Button released, key turned on “STOP”
position, cables properly connected.
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5.4. AIR PURGE FROM FUEL CIRCUIT

Model: Voyager4010
If there is the need to remove the air from the fuel circuit is necessary to push the black button (Fig. 14) to activate the primer
pump. Wait until hearing a bleeding sound from fuel filter. If the filter is of the transparent type (as it normally is) you can
also see the fuel flows in the filter.
Fig. 14 – Voyager4010 – Fuel primer pump
Model: PD50S
NOTE: in standard mode, the fuel pump is automatically controlled, when required.
With engine ON, to purge any air in the diesel fuel circuit, just loosen the bolt circled in red in Fig. 15. Re-tighten the screw
as soon as the diesel fuel starts to come out.
With engine OFF, loosen the bolt (circled in red in Fig. 15) disconnect the cable of the pressure switch and switch on the ON
position the generator’s key (“cranking”). Re-tighten the screw as soon as you see the diesel fuel comes out.
Fig. 15 – PD50S - Air purge screw
Perform/check the proper configuration of the Genset: Emergency Stop Button released, key turned on “STOP” position,
cables properly connected.
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5.5. CLOGGED UP EXHAUST MUFFLER

Model: Voyager4010 only
Among the causes that prevent the engine from starting there is the possibility that the lower exhaust muffler is obstructed;
The carbon builds up could possibly be due to the engine not running hot enough to effectively burn off the carbon in the
exhaust.
Generally, before that generator failure has been reported, generator's underspeed error occurred. Operator could also
witness white smoke emitting from the air intake during attempted start-ups. Meantime, the lower exhaust emits nearly
zero emissions during attempted start-ups.
These events are suspicious that something could be blocking air flow.
The main cause can be traced back to a wrong diesel, with a high sulphur content.
Fig. 16 – Lower exhaust muffler
To access the lower muffler is necessary to remove the entire Genset from its place. Refer to replacement procedure
PDC_2017_189 “RPL_GEN_Voyager generator replacement”.
Possible ways to inspect the muffler are:
• A visual inspect of the flexible joint (Fig. 17 - it needs to be dismounted);

• with the aid of an inspection camera;
• compare the weight with a brand new muffler (if available).
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Fig. 17 – Exhaust system – flexible joint
Fig. 18 – Example of a clogged-up exhaust muffler
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ELECTRICAL (ON BOARD OF THE ENGINE)

This section describes electrical interventions to perform on board of the engine, such as:
1) Replacement of:
6.1.1. PD50S – ELECTRICAL PANEL OVERVIEW
Front view (Fig. 20):
Fig. 20 – PD50S – Electrical panel overview (front side)
Rear view (Fig. 21):
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Fig. 21 - PD50S – Electrical panel overview (back side)
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a. OIL PRESSURE SWITCH;

b. TEMPERATURE SENSOR;
c. ALTERNATOR’S CAPACITOR;
d. RELAY 12V and 20A FUSE;
e. ELECTROVALVE (EV);
f. STARTER (only PD50S)
g. BATTERY CHARGER
6.2. GENERAL INFORMATION
6.2.1. VOYAGER 4010 - ELECTRICAL BOARD
Fig. 19 – Voyager4010 – Electrical board
Legend:
1) Relay board bracket 2) Spacer 3) Relay board 4) Gasket
5) and 6) Bushing 7) Gasket 8) AC Breaker 9) Main switch
10) Battery charger regulator 11) Capacitor’s cover 12) Plastic clamp 13) Capacitor CA 25µF 450V 4F
14) Fuse 20A 15) Terminal strip 16) Switch cover 17) Cabling support
6.2.2. PD50S – ELECTRICAL PANEL OVERVIEW
Front view (Fig. 20):
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Fig. 20 – PD50S – Electrical panel overview (front side)
Rear view (Fig. 21):
Fig. 21 - PD50S – Electrical panel overview (back side)
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6.3. OIL PRESSURE SWITCH

A test to perform before proceeding with the replacement of the component is to disconnect the cable from the OIL
PRESSURE SWITCH to be sure that the component is damaged.
If the motor doesn’t start even with the cable disconnect the OIL PRESSURE SWITCH is good and it hasn’t to be replaced.
1) The Pressure Switch is installed on the lower part of the engine (Fig. 22).
Fig. 22 – Oil pressure switch
2) Unscrew the bolt which fix the cable to the Pressure Switch.
Fig. 23 – unscrew the bolt which fix the PS cable.
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3) Unscrew the damaged Pressure Switch from the engine.
Fig. 24 – Unscrew the pressure switch

4) Screw the new Pressure Switch to the engine.
5) Put the cable in place and screw it to the Pressure Switch.
6) Put the lateral panel in place and screw its bolts back on (only PD50S).
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6.4. TEMPERATURE SENSOR

Temperature sensor is located in the middle of the engine, as shown in Fig. 25:
Fig. 25 – Temperature sensor
1) To remove the temperature sensor is necessary unscrew its support bracket (that it’s also the sensor housing)
locking bolt (Fig. 26):
Fig. 26 – Sensor bracket/housing locking nut
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2) To replace temp sensor just unplug the single wire and plug it to the new sensor (Fig. 27); then reassemble the
support bracket.
Fig. 27 – Temperature sensor’s support bracket/housing
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6.5. ALTERNATOR’S CAPACITOR

Model: PD50S
NOTE: correct capacity value is 20µF
1) Open the blue and red lockers and remove them from the battery’s poles. Then remove the battery from its bay (Fig.
28).
Fig. 28 – Removing of the battery
2) Unscrew the two bolts which fix the Alternator Cover on opposite sides (Fig. 29)
Fig. 29 – Unscrew bolts from Alternator cover
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3) Remove the Alternator Cover being careful not to lose the two lateral nuts.
Fig. 30 – Removing Alternator cover
4) Cut the cable tie which keeps the Alternator Capacitor into position (Nippers) - Fig. 31.
Fig. 31 – Remove tie-wrap to release the capacitor
5) Unplug the two black wires from the damaged Capacitor and plug them in a proper position on the new Capacitor
(note that the Capacitor has two metal connectors, each one with a couple of poles: DO NOT plug the two wires to
the same connector).
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Fig. 32 – Unplug wires from capacitor
6) Fix the new capacitor to the metal bar.

7) Put back the Alternator Cover and screw its nuts back on.
8) Put in place the battery, plug back the two connectors on the poles and close them.
PDC_2019_019 Rev. 1.0 Page 34

Model: Voyager4010
NOTE: correct capacity value is 25µF
The capacitor is located in the connection compartment, in front of the electrical board, as shown in Fig. 33
Fig. 33 – Voyager4010 - capacitor
To remove the capacitor is necessary loosen the collar screw, lift up the white cap and disconnect the two wires ( Fig. 34):
Fig. 34 – Collar screw (a) and capacitor’s cap (b)

Proceed in the reverse order for the installation of the new capacitor.
PDC_2019_019 Rev. 1.0 Page 35

6.6. RELAY 12V and 20A FUSE

When the “START” button is pressed, and nothing happens, relay board faulty and fuse burned are among the possible
causes.
Relay(s) replacement:
Model: PD50S
1) Check the right connection of the relay before to proceed with the replacement;
2) Unscrew the bolt which fixes the damaged relay to the inner part of the frontal panel (Fig. 35).
Fig. 35 – Relay locking screw

3) Keep note of the position of the wires connected to the Relay and remove them.
Fig. 36 – Removing the relay
PDC_2019_019 Rev. 1.0 Page 36

4) Put in place the spare Relay and reconnect the wires in the original position (see step 5 as reference).
5) Screw the new Relay to the inner part of the frontal panel (see step 4 as reference. Socket Wrench: 7 mm;
Screwdriver).
Model: Voyager4010
The relay board is located in the connections compartment; refer to Fig. 19 – Pos. 3 and Fig. 37;
1) Check the right connection of the 4 relays before to proceed with the replacement;
2) Replace one relay at a time and check the outcome;
3) Mark the replaced relays as good until the faulty one is found.
Fig. 37 – Relay board
Fuse replacement:
Model: PD50S
PDC_2019_019 Rev. 1.0 Page 37

1) Open the white fuse holder, pull out the damaged fuse, put in place the spare fuse and close the fuse holder
Fig. 38 - 20A fuse (PD50S)
Model: Voyager4010
The 20A fuse on the Voyager4010 is located in the bottom part of the electrical board;
1) Simply access the compartment and remove it (possibly, with a fuse extractor).
Fig. 39 – 20A fuse (Voyager4010)
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6.7. ELECTROVALVE (EV)

1) Locate the Electrovalve, see the component highlighted below (Fig. 40):
Fig. 40 – EV position
2) Cut the tie-wraps that hold the cables of the electrovalve to the metal pipe and unscrew the nut highlighted below
using a wrench 17mm (Fig. 41)
Fig. 41 – Dismounting the EV (Step 1)

3) Unplug the red positive wire from the electrovalve (Fig. 42):
Fig. 42 - Dismounting the EV (Step 2)
PDC_2019_019 Rev. 1.0 Page 39

4) Remove the black tube that brings the fuel to the EV (Fig. 43):

5) Remove the plates of the high-pressure pump below the electrovalve, unscrewing the 3 nuts highlighted below (Fig.
44).

Be careful to don’t lose the metallic gaskets that are between the body of the high-pressure
pump and its position on the engine body (cylinder block). It is suggested to leave the gaskets on
their place.
PDC_2019_019 Rev. 1.0 Page 40

6) Unscrew the electrovalve using a wrench 13mm together with a wrench 17mm, as shown in figure below (Fig. 47).
The 17mm wrench holding the brass part, the 13mm wrench unscrewing the electrovalve.
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7) Cut the black negative wire, and replace the faulty electrovalve
8) Using a terminal connector, wire the black cable coming from the new electrovalve to the part of black cable previously
cut;
9) Fix the new electrovalve on the metallic plate of the high-pressure pump, if necessary use the wrench 17 mm to hold
the brass part
Fig. 50 - Mounting the new EV (Step 1)
PDC_2019_019 Rev. 1.0 Page 43

10) If they were removed, fix the metallic gaskets on the 3 screws

11) Fix the metallic plate that holds the pump and the EV to his original position
Be careful, the pump nozzle must be inserted within a fork. It is possible to check if it is within that
fork from the little oval hole below the pump ingress.
If this operation is not properly done the pump will not be able to supply the engine and the
engine will not run.
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12) Tighten all the nuts that fix the plate to the generator motor (Fig. 53)
13) Insert again the tube that brings the fuel to the EV, tighten well the clamp to avoid fuel leakage or air inlet;
14) Connect the red wire of the new EV to the relevant red connector;
15) Insert the metallic tube to the pump and fix it tightening the nut with a wrench 17mm (Fig. 54);
PDC_2019_019 Rev. 1.0 Page 45

6.8. STARTER (Model: PD50S only)
1) Unscrew and remove the black cover ring from the Starter Box (Fig. 55).
Fig. 55 – Starter box black cover ring removing

2) From the inner part of the frontal panel, pull out the damaged Starter box from its bay (Fig. 56).
Fig. 56 – Starter box (rear view)
3) Keep note of the position of the wires connected to the back of the Starter box and unplug them (Fig. 57).
PDC_2019_019 Rev. 1.0 Page 46

Fig. 57 – Starter box electrical connections
4) Plug the three wires on the new starter box.

5) Put in place the new starter box.
6) Screw the black cover ring back on the Starter Box.
7) Screw the bolts which fix the black upper panel to the red one. Then, put the frontal panel in place and screw its bolts
back on.
PDC_2019_019 Rev. 1.0 Page 47

6.9. BATTERY CHARGER REGULATOR
Model: PD50S
1) Unscrew the two bolts which fix the Battery Charger Regulator (Fig. 58);
NOTE: Keep note of the position of the two wires.
Fig. 58 – Battery charger regulator dismounting
2) Unplug the black plastic wires connector from the damaged Battery Charger Regulator (Fig. 59).
Fig. 59 - Battery charger regulator’s connector unplugging
3) Connect the plastic wires connector to the new Battery Charger Regulator.
4) Put in place the new Regulator, put the two wires in the correct position and screw their two bolts back on (see step
3 as reference. Socket Wrench: 10 mm).
Model: Voyager4010
Battery Charger Regulator (ref. Fig. 19 -Pos. 10) is located into connections compartment, in front of the electrical board,
as shown in Fig. 60:
1) Unscrew the two bolts which fix the Battery Charger Regulator.
PDC_2019_019 Rev. 1.0 Page 48

Fig. 60 – Voyager4010 – Battery charger regulator (position)
2) Keep note of the position of the wires connected to the bottom of the Battery Charger Regulator and unplug them
(Fig. 61)
Fig. 61 – Battery charge regulator – electrical connections
3) Plug the wires on the new BCR and put it back in place. Remember to fix the black wire on the external side fixing
screw.
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6.10. HOURMETER (Model: PD50S only)
1) Unscrew the bolts which fix the front black panel to the Genset.
2) Open a bit the black panel and locate the rear side of the hourmeter (Fig. 62);
Fig. 62 – Access to hourmeter(a) – hourmeter rear view (b)

3) Disconnect the two white connectors plugged on the rear side of the Hourmeter, getting a note of their order;
4) Move (open) the wings to unfasten the Hourmeter from the black panel (Fig. 63);
Fig. 63 – Hourmeter removing
5) Keep the frame on the hole and pull out the white connectors, then plug them to the new Hourmeter (Fig. 64);
PDC_2019_019 Rev. 1.0 Page 50

Fig. 64 – Unplug the old hourmeter/plug the new one.

6) Insert the hourmeter in its socket: pull the frame enough to be sure that the hourmeter does not move;
7) Fasten again the screws of the black panel;
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6.11. BATTERY UNIT (Model: PD50S only)
1) Open the blue and red lockers and remove them from the battery’s poles (Fig. 65). Then, remove the old battery from
its bay.
Fig. 65 – PD50S – Battery Unit
2) Put in place the spare battery, plug back the two connectors on the poles and close them (see step 3 as reference).
PDC_2019_019 Rev. 1.0 Page 52

6.12. EMERGENCY CONTACT and EMERGENCY BUTTON (Model: PD50S only)
1) Unscrew the bolts which fix the frontal panel to the Genset and remove it. Then, unscrew the bolts which fix the black
upper panel to the red one (Fig. 66).
Fig. 66 – Access the Emergency BUTTON and CONTACT
2) Using a flat screwdriver as lever, remove the Emergency Stop Button contacts (Fig. 67).
Fig. 67 – Emergency contacts – rear view
Emergency contact replacement:
3) Keeping note of their original position, unscrew the bolts which fix the wires to the damaged Emergency Stop Button
contact.
4) Plug the wires to the new Emergency Stop Button contact and screw their bolts back on (see step 6 as reference.
Screwdriver).
PDC_2019_019 Rev. 1.0 Page 53

5) Plug back the Emergency Stop Button contact
Emergency button replacement:
1) Move the plastic lever and remove the locking device (Fig. 68).
Fig. 68 - Emergency button – rear view
2) Unscrew and remove the metal ring which fix the Emergency Stop Button to the inner side of the frontal panel (Fig.
69).
Fig. 69 – Emergency button metal ring removing
3) Pull out the damaged Emergency Stop Button and put in place the spare one.
4) Screw the metal ring which fix the Emergency Stop Button to the inner side of the frontal panel back on.
5) Put in place the plastic locking device and plug back the Emergency Stop Button contacts.
PDC_2019_019 Rev. 1.0 Page 54

6.13. CIRCUIT BREAKER (Model: PD50S only)
1) Unscrew and remove the two little screws which fix the Circuit Breaker to the frontal panel (Fig. 70).
Fig. 70 – Access the PD50S breaker and rear view
2) Pull out the Circuit Breaker from the inner part of the Generator frontal panel (Fig. 71).
Fig. 71 – Breaker removing (Step 1)
PDC_2019_019 Rev. 1.0 Page 55

3) Press the two black lockers until you hear a click and then remove the metallic locking system from the damaged
Circuit Breaker (Fig. 72).
Fig. 72 - Breaker removing (Step 2)

4) Unscrew the bolts which fix the wires to the damaged Circuit Breaker and unplug them (Fig. 73).
Fig. 73 - Breaker removing (Step 3)
5) Connect the wires to the spare Circuit Breaker in the proper position (see step 7 as reference. Screwdriver).
6) Fix the metallic locking system to the new Circuit Breaker (see step 6 as reference).
7) Put the new Circuit Breaker in its socket on the frontal panel of the Genset and screw back the two bolts which fix it
(see step 4 and step 5 as reference. Screwdriver).
PDC_2019_019 Rev. 1.0 Page 56

CABLING and ELECTRICAL (related to Control Panel/AMF25);
7.1. PROBLEM: CRANKING TIME/BATTERY ALARM DELAY

One of the common problems that can happen with the generator is the Genset low battery alarm activating during cranking:
the Genset not starting. The usual fix for this would be to change the cranking time in the settings from 6 to 10 seconds. At
the same time the user must change the Batt Alarm Delay time to something longer than the cranking time you have entered.
An example is to change the Batt Alarm Delay to 12 seconds. This should allow the Genset a full 10 seconds of cranking time
to start: Low Batt alarms should not appear anymore.
Procedure
1) In the IBIS Controller, set the Genset operation on Manual. Leave the AMF25 supplied;
2) In the AMF25 press Page;
3) Select password and insert 0;
4) Select engine protect and check max crank time (default value is 6 seconds);
5) Change the value of battery undervolt to 8.0 (if it is not already that);
6) Change the value of battery volt delay to a value a bit greater of max crank time (for example put it at 10 seconds)
7) In the IBIS Controller, set the Genset operation on Automatic.
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7.2. PROBLEM: GENSET ERROR 447 “SD RPMMEASFAIL”
This kind of error happens when the genset control panel read a RPM (revolutions per minute) value lower than 3000.
Troubleshooting
1) Start the genset through the starting key.

2) Read the RPM value on the control panel.
3) If the value is not “0” but the generator hiccups when it is started turn off the generator and:
a. Open the cap of the tank, wait a few seconds a close it again (check if the problem persists).
b. Change the oil filter (check if the problem persists).
c. Turn on the generator keeping the key in the start position for a longer time.
d. If this solve the problem, change the cranking time:
i. In the genset control panel press “page”.
ii. With the down arrow move the cursor to “engine params” and press “enter”.
iii. With the down arrow move the cursor to “max cranking time” and press “enter”.
iv. With the arrows change the value between 7 s and 10 s and press “enter” (the default value should
be 6 s).
v. Be sure that the value is changed in the “max cranking time” field.
2. If the value is “0” turn off the generator and:
a. Check if the “general switch” on the generator is turned on.
b. Check if the 220 V cable is connected to the generator and to the control panel.
c. Check if inside the control panel all the cables are connected.
d. With a tester verify the continuity of the circuit:
PDC_2019_019 Rev. 1.0 Page 58

7.3. PROBLEM: MAINTENANCE WARNING
The maintenance warning is a message that appears every 250 running hours of the generator and indicates that the standard
maintenance has to be performed on the Genset (see the IBIS-FM maintenance manual). After the maintenance is performed
the warning has to be reset because it prevents the generator from starting.
Fig. 74 – InteliLite™ AMF 25
Troubleshooting
To make the warning disappear you have to follow the steps below in the AMF25 menu:
3. Press “Page” button

4. Press the arrow keys in order to select “Engine Protect”
5. Press “Enter”
6. Use the arrow keys to select “WrnMaintenance”
7. Press “Enter”
8. The current value should be “0”, modify it using the arrow keys, putting again a value of 250 (hours)
9. Press “Enter” to confirm this new value
10. Press “Page” to return up to the main menu
11. Press “fault reset” button
12. Double check that the new value has been actually registered
13. Wait some minutes and check that the warning message disappear automatically both from the AMF25 and the
Controller
14. Flag the option “automatic operation” in the Status tab of the Controller.
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7.4. CHECK: AMF25 SUPPLYING (Model: VOYAGER4010 only)
Troubleshooting
1. Open the I/O interfaces panel placed on the rear side of the Ibis Rover;
2. Locate the TRAILER SUPPLY and remove the cable plugged to the socket;
3. With a multimeter measure the DC voltage between the two pins. It has to be around 12 Vdc;
4. Check if the GENSET Isolation Point, placed on the front side of the Rover, is turned on;
5. Open the Generator external panel and the internal one;

6. Check if the big Red Button on the Voyager generator is turned on;
PDC_2019_019 Rev. 1.0 Page 60

7. Remove the 20 A yellow fuse and check it with a multimeter if it works or not. Put it again in place;
8. Measure the voltage between the two loop housing. The voltage has to be around 12 Vdc.
9. Remove the 9-poles connector place on the left upper corner of the electronic board of the generator;
PDC_2019_019 Rev. 1.0 Page 61

10. Measure the voltage between pins 1-2: it has to be around 12 Vdc;
11. Open the whole panel of the I/O interfaces using an allen key;
12. Locate the GEN C00 connection in the internal compartment of the PSU, just on the rear side of the Genset module;
13. Unplug theese connectors and measure the voltage on the plug that comes from the generator: the voltage between
the pins has to be around 12 Vdc (same order as figure above);
14. Check with a multimeter the fuse F8 placed on the rear side of the Genset module.
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MISCELLANEOUS
8.1. REPLACEMENT OF DIESEL SENSOR – MODEL SA01817 (Model: PD50S only)
Fig. 75 – Diesel sensor Model SA01817
1. Unscrew and remove the two bolts which fix the square metal cover on the top of the Genset, to access the Diesel
Sensor.
Fig. 76 – Removing the sensor cover

2. From the right lateral room of the Genset, unplug the fuel sensor connector.
Fig. 77 – Unplugging fuel sensor connector
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3. Keep note of the position of the three wires plugged to the white support. Press the three metal tabs and remove the
three connectors from the white support.
Fig. 78 – Removing connector plastic case
4. From the top of the Genset, pull out the three wires.
Fig. 79 – Pulling out the three wires
5. Unscrew the six bolts which fix the Diesel Sensor and remove it.
Fig. 80 – Removal of the fuel sensor
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6. Insert the new Diesel Sensor in the tank. Be careful to orientate it properly (use the following picture as reference).
Fig. 81 – Insert the new sensor
7. Screw the six bolts back on putting under one of them the black wire’s metal connector (it has to be properly in contact
with the metal ring). Be careful not to fasten the bolts too much in order not to damage the black plastic support.
Fig. 82 – Fixing the new sensor frame
8. Remove the plastic support from the connector (see step 3 as reference) and let the cable pass between the tank and
the generator metal frame.
Fig. 83 - Removing connector plastic case
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9. Plug back the three wires in the plastic connector. Be careful to place them in a proper position (see step 3 as
reference).
Fig. 84 - Reassembling connector plastic case

10. Plug back the Fuel Sensor connector (see step 2 as reference).
11. Put in place the square metal cover and screw its bolts back on (see step 1 as reference).
12. Release the Emergency Stop Button, plug the power and the serial cables back on the Genset and turn on the Genset
13. Fill the tank and read the fuel value from the AMF25 (reference value for a full tank: > 95%).
Fig. 85 – Refuelling the tank

14. Unscrew the two bolts which fix the small metal panel on the left side of the generator and remove the safety plastic
cover from the upper tap.
Fig. 86 – Check the fullness of the tank (1)
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15. Insert a rubber tube on the upper tap and put its opposite end in an empty tank. Open the tap in order to drain the
fuel. Once the tank is empty, check the fuel level from the AMF25 (reference value for an empty tank: < 5%).
Fig. 87 - Check the fullness of the tank (2)

16. Close the upper tap, remove the rubber tube from it and put back the plastic cover.
17. Refill the tank and check that no fuel comes out from the upper tap.
18. Put back the metal panel and screw its bolts back on.
19. Close the lateral panel of the Generator and screw its bolt back on.
20. Check the proper configuration of the Genset: Emergency Stop Button released, key turned on “STOP” position, cables
properly connected.
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8.2. REPLACEMENT OF DIESEL SENSOR – MODEL SA03302
Fig. 88 - Diesel sensor Model SA03302
1. Unscrew and remove the four bolts which fix the square metal cover on the top of the Genset, in order to expose the
Diesel Sensor.
Fig. 89 - Removing the sensor cover

2. From the right lateral room of the Genset, unplug the fuel sensor connector.
Fig. 90 - Unplugging fuel sensor connector
3. From the top of the Genset, pull out the three wires.
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Fig. 91 – Pulling out the connector

4. Unscrew the six bolts which fix the Diesel Sensor.
Fig. 92 - Removal of the fuel sensor (1)
5. Pull out the damaged Diesel Sensor. If the sensor hasn’t been extracted for a long time, you may have to use a
screwdriver as a lever on opposite points of the plastic cap before extracting the tube: be careful not to damage cap.
Fig. 93 - Removal of the fuel sensor (2)
PDC_2019_019 Rev. 1.0 Page 69

6. Insert the new Diesel Sensor in the tank and screw its bolts back on: be careful not to fasten the bolts too much in
order not to damage its cap (Screwdriver).
Fig. 94 – Insert the new fuel sensor

7. Plug back the Fuel Sensor connector (see step 4 as reference).
8. Put in place the square metal cover and screw its bolts back on (see step 3 as reference. Screwdriver).
9. Release the Emergency Stop Button, plug the power and the serial cables back on the Genset and turn on the Genset
10. Fill the tank and read the fuel value from the AMF25 (reference value for a full tank: > 95%).
Fig. 95 - Refuelling the tank
PDC_2019_019 Rev. 1.0 Page 70

11. Unscrew the two bolts which fix the small metal panel on the left side of the generator and remove the safety plastic
cover from the upper tap (Pliers).
12. Insert a rubber tube on the upper tap and put its opposite end in an empty tank. Open the tap in order to drain the
fuel. Once the tank is empty, check the fuel level from the AMF25 (reference value for an empty tank: < 5%).
13. Close the upper tap, remove the rubber tube from it and put back the plastic cover.
14. Refill the tank and check that no fuel comes out from the upper tap.
15. Put back the metal panel and screw its bolts back on.
PDC_2019_019 Rev. 1.0 Page 71

8.3. UPGRADE OF AMF25 AIL CONFIGURATION

This procedure describes how to upgrade the internal AIL Configuration file of the AMF25 Generator Control Unit. Procedures
are different if the AMF25 is installed on the old Control Panel box, in the new PSU Genset Module or as standalone AMF25
dismounted from the Genset Module.
Table describing the AIL configuration file to be used according to IBIS systems configurations:
Which system I have? Which .ail file to load on the AMF25?

IBIS FMT: MK5 series and earlier with Sensor Veglia IDS_20131023_Veglia5330_FMT.ail
IBIS FMT: MK5 series and earlier with Sensor Tube IDS_20130521_MontelTub180.ail
IBIS FMT (from MK6 series) IDS_20190304.ail
IBIS FM: Old PD50S Generator (854680) IDS_20111028_Veglia5330_oldPD50S.ail
IBIS FM: New PD50S Generator (853862) IDS_20141030_MontelTub240.ail
IBIS Rover IDS_20190304.ail
IBIS ArcSAR IDS_20190304.ail
It’s possible to download .ail configuration files from the IDS Georadar website.
PROCEDUREs
Power Supply Module (854693) with Genset module (854680) – External Control Panel box
1. In the IBIS Controller, set the Genset operation on Manual. Leave the AMF25 supplied;
2. On the AMF25, press Page placed in its keypad;
3. Select the item Enter Password on the list appeared (first item of the list) then press Enter in the AMF25 keypad;
4. Type the password (the standard password is 0) to enable the possibility to modify the AMF25 configuration;
5. Scroll the list and select Communication mode for COM1: use up/down arrows buttons on the keypad to scroll the list;
6. Press Enter and change the communication mode from “modbus” to “direct”;
7. Open the door of the AMF25 Box and locate the serial port;
8. Connect the RS232 female to female from the computer to the serial port;
9. Start Lite Edit software v. 4.6.5 on the computer;
PDC_2019_019 Rev. 1.0 Page 72

10. Execute the command Connection → Open Direct then wait till the connection is activated;
11. Execute the command Controller → Enter Password and type the password (the standard password is 0). This
command will enable the possibility to update the AMF25 configuration.
12. Execute the command Controller → Configuration → Select;
13. Select the new configuration file (.ail);
14. Execute the command Write to Controller following the wizard;
15. Once the new configuration file is written on the AMF25, the application will open some windows;
16. One of them is called Setpoints: activate this window;
17. Click on the Basic Settings group;
18. In the Gen-set Name field, delete the current value and write the name of the configuration file just uploaded (file
name only, without the .ail extension (e.g.: if you uploaded the file IDSv01_20111028.ail, in the Gen-set name field
you will write just IDSv01_20111028);
19. Press Enter on your computer keyboard in order to confirm this value;
20. It should be possible reading the current configuration file from the AMF25 (page → basic settings → genset name);
21. Quit the Lite Edit software;
22. Type again the password on the AMF25 (Step 4 → 6);
23. Reset the communication mode for COM1 to “Modbus” (step 7 to 8);
24. In the IBIS Controller, set the Genset operation on Automatic.
IBIS-FM with Genset Module (854680) – IBIS FMT, Rover and ArcSAR
1. In the IBIS Controller, set the Genset operation on Manual and leave the AMF25 supplied;
6. Press Enter and change the communication mode from Modbus to direct;
PDC_2019_019 Rev. 1.0 Page 73

7. Now the procedure is slightly different depending by the system:

a. on the IBIS-FM: open the rear door of the PSU: unscrew the 6 bolts which fix the rear cover (Allen Key: 3
mm);
b. on the IBIS-Rover or ArcSAR: open the panel which allow the access to the back side of the Power Supply
Unit modules;
8. once removed the cover, locate the serial port on the back side of the Genset module;
10. On the Device Manager check which COM port is used by the RS232 cable. See an example below;
If you are using a laptop with no serial port, it’s necessary to use an USB-to-serial converter
connected to the RS232 female-to-fermale serial cable. Remember to install the drivers of USB-to-
Serial converter cable before using it.
PDC_2019_019 Rev. 1.0 Page 74

11. Start Lite Edit software on the computer;

12. Execute the command Connection → Open Direct;
13. Select the right COM port, as verified in the Device Manager previously;
14. Wait until the connection is activated;
command will enable the possibility to update the AMF25 configuration.
16. Execute the command Controller → Configuration → Select;
17. Select the new .ail configuration file;
18. Execute the command Write to Controller following the wizard;
19. At the tab asking Actual Software Configuration and setpoints will be replaced with the selected one! Do you want to
save actual archive?, click on No;
20. At the tab asking The Controller will be switched to Off mode. Do you want to continue?, click on Yes;
21. At the tab asking Do you want to overwrite the setpoints by values from the selected archive?, click on Yes;
22. At this point the AMF25 will be programmed with the new .ail file, don’t interact with the software until the end of
the programming;
PDC_2019_019 Rev. 1.0 Page 75

23. Once the new configuration file is written on the AMF25, the application will open some windows;
24. One of them is called Setpoints: activate this window;
25. Click on the Basic Settings group;
26. In the Gen-set Name field, delete the current value and write the name of the configuration file just uploaded (file
name only, without the .ail extension (e.g.: if you uploaded the file IDSv01_20111028.ail, in the Gen-set name field
you will write just IDSv01_20111028);
27. Press Enter on your computer keyboard in order to confirm this value;
28. It should be possible reading the current configuration file from the AMF25 (page → basic settings → genset name).
You can reduce the length of the name, indicating the date only;
29. On the Main Control page, switch the Control Mode from OFF to MAN, using the arrows as shown in the two images
below;
PDC_2019_019 Rev. 1.0 Page 76


31. At the tab asking Do you want to save the archive? click on No;
32. Remove the RS232 female to female and insert again the cover on the rear side of the AMF25 (or simply close the
back panel if you have an IBIS Rover);
33. In the IBIS Controller, set the Genset operation on Automatic.
Stand-alone dismounted AMF25
1. Copy the IL-NT-AMF25-1.5.1.AIL file into the folder C:\Users\Public\Public

Documents\ComAp\LiteEdit\Archives\Default of the computer;
2. Copy the IL-NT-AMF25-1.5.1.ilf and IL-NT-AMF25-1.5.1.mhx file into the folder C:\Users\Public\Public
Documents\ComAp\LiteEdit\App of the computer;
3. Plug the AMF25 to the external 24Vdc supplier (857997) with Supply cable AMF25 (858528) then plug the supply cable
AMF25 to the POWER socket on the AMF25;
8. Press Enter and change the communication mode from Modbus to direct;
9. Locate the serial port;
command will enable the possibility to update the AMF25 firmware and configuration;
14. Select the command Controller → Programming and Cloning → Programming;
15. Select on the list Firmware version 1.5.1 for AMF25 then follow the wizard to update the firmware;
PDC_2019_019 Rev. 1.0 Page 77


18. Reset the communication mode for COM1 to Modbus (step 7 to 8).
PDC_2019_019 Rev. 1.0 Page 78

8.4. SET GENSET RUNNING HOURS

These procedures describe how to reset the Running Hours (RunHrs) of the AMF25. AMF25 Genset Controller operation.
Procedures are different if the AMF25 is installed on the old Control Panel box, in the new PSU Genset Module or as
standalone AMF25 dismounted from the Genset Module
REQUIRED FILES (provided by IDS GeoRadar)
IL-NT-AMF25-1.5.1.ail IL-NT-AMF25-1.5.1.ilf IL-NT-AMF25-1.5.1.mhx
PROCEDUREs
Power Supply Module (AS03230_A) with Genset module (AS03148_A)

1. Copy the Firmware file "IL-NT-AMF25-1.5.1.AIL" into the folder C:\Users\Public\Public
Documents\ComAp\LiteEdit\Archives\Default of the computer.
2. Copy the Firmware files "IL-NT-AMF25-1.5.1.ilf" and "IL-NT-AMF25-1.5.1.mhx" into the folder C:\Users\Public\Public
Documents\ComAp\LiteEdit\App of the computer.
3. In the IBIS Controller, set the Genset operation on Manual. Leave the AMF25 supplied;
8. Press Enter and change the communication mode from “modbus” to “direct”;
9. Open the door of the AMF25 Box and locate the serial port
11. Start Lite Edit software v. 4.6.5 on the computer;
command will enable the possibility to modify AMF25 parameters.
14. Select the command Controller → Set Statistics → select Run Hours and modify the value (e.g. 0.0 in case the genset
has been replaced) and click Set button;
18. In the IBIS Controller, set the Genset operation on Automatic and check Running hours value modified.
PDC_2019_019 Rev. 1.0 Page 79

Power Supply Unit (AS05295_A) with Genset Module (AS03148_A)

Documents\ComAp\LiteEdit\Archives\Default of the computer.
Documents\ComAp\LiteEdit\App of the computer.
3. In the IBIS Controller, set the Genset operation on Manual. Leave the AMF25 supplied: the Genset Module has to be
turned on;
8. Press Enter and change the communication mode from “Modbus” to “direct”;
9. Open the rear door of the PSU: unscrew the 6 bolts which fix the rear cover (Allen Key: 3 mm);
10. Once removed the cover, locate the serial port
PDC_2019_019 Rev. 1.0 Page 80

Stand-alone dismounted AMF25 (bench operation)

Documents\ComAp\LiteEdit\Archives\Default of the computer
Documents\ComAp\LiteEdit\App of the computer
3. Plug the AMF25 to the external 24VDC supplier (AS03573_A) with Supply cable AMF25 (AS04337_A) then plug the
supply cable AMF25 to the POWER socket on the AMF25
8. Press Enter and change the communication mode from “Modbus” to “direct”;
9. Locate the serial port
PDC_2019_019 Rev. 1.0 Page 81

8.5. REPLACEMENT of a VOYAGER4010
This procedure describes how to replace a Voyager4010 generator in the IBIS-Rover/IBIS-ArcSAR Power Supply Unit (PSU);
1. Turn off all the Isolation Points of the IBIS system: one is on the PSU Control Module; the others are on the Supply
Unit front side; turn off also Genset RCD from Circuit Breaker panel;
2. Access the batteries compartment placed next to the generator sliding panel. With an Allen key, unscrew the two
screws and open the panel pulling the top side downwards
3. Pull out the batteries drawer, unscrewing the security bolt;
4. Disconnect the blue and red connectors to isolate Genset Battery.
5. With an Allen key, unscrew all the fasteners that are holding the roof cover above the Genset compartment, together,
if present, with the solar panel;
6. Lift the roof cover and if the solar panels are present, disconnect the two cable connectors, pressing the wings where
indicated;
PDC_2019_019 Rev. 1.0 Page 82

7. Remove carefully the roof cover: in this way you have a full view and access to the top and rear side of the Voyager
generator;
8. Remove the Genset front panel, just below the generator sliding panel;
9. With an Allen key, disconnect the exhaust pipe tube unscrewing only the two lateral bolts.
10. If present, disconnect the fuel pump bleeding button, placed just above the AC Breaker switch;
a. With a Philips screwdriver, remove the two fixing screws of the transparent protection board;
PDC_2019_019 Rev. 1.0 Page 83

b. Remove the protection: two wires are still plugged to the generator frame;
c. Unplug the wire that is connected to the generator electrical board;
d. With a racket with a 13 mm head, remove the bolt of the battery cables and remove the other wire coming
to the fuel pump bleeding button. Now the support of the black button should be completely free;
11. Now it is necessary to disconnect the wiring that enters into the generator from its left side:
PDC_2019_019 Rev. 1.0 Page 84

a. Disconnect the 9-pin connector that is at the end of the cable coming from the Power Supply Unit (GENC00);
b. Disconnect the 4 cables (two red ones and two black one) coming from the battery;
c. Disconnect the cables on the left of the mammoth connector, those are the ends of the AC cable going to
the Power Supply Unit (AC0G03);
PDC_2019_019 Rev. 1.0 Page 85

d. If the generator is equipped with a Wait-to-start glow, there is an additional cable coming out from the
motor and reaching a box placed just below the system Power Supply Unit (just follow that cable path).
Open that box and disconnect the glow cable in order to let the generator free of be lifted;
12. For safety purpose, put some isolation tape on the wire ends;
13. Remove the wirings you disconnect from the shell of the generator, letting them pass out of the hole on the left side
of the generator frame;
14. If present remove the white plastic cover below the AC Breaker switch (red button) using a flat screwdriver.
15. Drain out all the fuel from the tank opening the valve of the black tube using a tank.
PDC_2019_019 Rev. 1.0 Page 86

16. Take note of the order of the fuel pipes: one is the INLET and the other one is the OUTLET; you may put some tape for
better recognize them;
17. With a flat screwdriver, unscrew the hose clamps that fix the fuel tubes:
18. Hold the two ends of each pipe and separate them: the connection may be a bit hard so you may detach them
vigorously;
19. With a screwdriver, open the back panel of the Voyager generator;
20. There are four locking nuts fixing the Voyager generator to its metallic housing, two are placed on the front side (first
four images below), the others are placed on the rear side (last two images below): remove those nuts with a racket;
PDC_2019_019 Rev. 1.0 Page 87

21. There are two sockets where you can knot belts or hooks: using a crane with hook or a forklift lift the generator from
its position and remove it from the system;
PDC_2019_019 Rev. 1.0 Page 88

22. With the same forklift or crane, lift the new Voyager generator and insert it in the generator housing, paying attention
to align the generator base holes with the supports mounted on the damping pads;
23. Fasten again the nuts on the four threaded support studs, in order to fix the generator to the damping pads;
24. Reconnect first the exhaust pipe (see below), then the fuel tubes, paying attention to the order (INLET – OUTLET),
cables and connectors and finally fix the four pedestal supports screw.
PDC_2019_019 Rev. 1.0 Page 89

25. Reconnect the fuel tubes, paying attention to the order (INLET – OUTLET[RP1]),
26. Reconnect the wirings to the left side of the generator;
27. Reconnect and mount the bleeding fuel pump button;
28. Fix the four pedestal supports screws;
29. Follow the Generator first setup guide on IBIS Rover User Guide: fill the fuel tank and check for the proper oil level: fill
it if need refill with SAE 15W40 oil.
30. Check if the red switch placed under the black button is ON position
31. Drain air from the fuel circuit: push the black button to activate a pump primer. Wait until hearing a bleeding sound
from fuel filter.
PDC_2019_019 Rev. 1.0 Page 90

32. Reconnect Genset battery then turn ON all the isolation points switches and RCD Genset Switch, then turn SYSTEM
and AC INPUT switches ON.
33. Test the Generator from the AMF25 (manual start): turn on the GENSET switch on the PSU Control Module: the AMF25
control panel will be switched on; - on the AMF25 control panel, push the green button START in the display a
countdown will be shown: wait the end of it; once the countdown is ended, push the button I/O (close the GCB) on
the right: check if orange Battery LED light up.
34. Test the Generator from Controller (Manual mode): open Last acquisition session, go on Supply Control panel, check
if POWER Generator is enabled (ON) from Settings menu, switch on Manual Mode and click on START ENGINE. After
the countdown the genset has to start (Running) and output power has to be around 600W with System Battery Status
Charging and orange Battery LED light up.
35. Re-mount generator frontal panel and the cover roof on the top of the Power Unit.
PDC_2019_019 Rev. 1.0 Page 91

ALARM/ERROR CODE
Here below the complete list of the ALARM/ERROR CODE:
ALARM CODE ON READ_IBIS_LOG WHEN THE
ALARM CODE ALARM NAME
ALARM IS STILL ACTIVE
243 543 RPM
265 565 Gen Freq
266 566 Gen V L1-N
267 567 Gen V L2-N
268 568 Gen V L3-N
269 569 Gen V L1-L2
270 570 Gen V L2-L3
271 571 Gen V L3-L1
275 575 Mains V L1-N
278 578 Mains V L1-L2
279 579 Mains V L2-L3
280 580 Mains V L3-L1
281 581 Mains Freq
302 602 Battery Volts
304 604 Oil Pressure
305 605 Engine Temp
306 606 Fuel Level
308 608 GCB Feedback
309 609 MCB Feedback
310 610 Emergency Stop
314 614 MainsFailBlock
327 627 IOM AI1
328 628 IOM AI2
329 629 IOM AI3
330 630 IOM AI4
332 632 IOM BI1 Alarm
397 697 ECU YellowLamp
398 698 ECU RedLamp
399 699 ECU WaitToStrt
407 707 res
408 708 ActCallCH1Fail
409 709 ActCallCH2Fail
410 710 Low BackupBatt
411 711 Wrn Batt Volt
412 712 Sd Gen L1 >V
413 713 Sd Gen L1 <V
414 714 Sd Gen L2 >V
415 715 Sd Gen L2 <V
416 716 Sd Gen L3 >V
417 717 Sd Gen L3<V
418 718 Sd Gen V Unbal
419 719 GenParamsFail
420 720 Sd >Freq
PDC_2019_019 Rev. 1.0 Page 92

421 721 Sd <Freq

422 722 Wrn >Freq
423 723 Wrn <Freq
424 724 Sd Amps Unbal
425 725 Mains L1 >V
426 726 Mains L1 <V
427 727 Mains L2 >V
428 728 Mains L2<V
429 729 Mains L3 >V
430 730 Mains L3<V
431 731 Mains V Unbal
432 732 Mains > Freq
433 733 Mains < Freq
434 734 Sd Overload
435 735 Sd Overspeed
436 736 Sd Under Speed
437 737 GCB Fail
438 738 MCB Fail
439 739 Sd Start Fail
440 740 Gen CCW Rot
441 741 Mains CCW Rot
442 742 Emergency Stop
443 743 Wrn WaterTmpLo
444 744 ChargeAltFail
445 745 Sd IOM Fail
446 746 Sd Override
447 747 SdRPMMeasFail
448 748 Sd BatteryFlat
449 749 WrnMaintenance
450 750 Sd Short Crct
451 751 Sd Amps IDMT
452 752 Sd Stop Fail
453 753 Wrn RA Fail
454 754 Wrn ECU Alarm
455 755 Wrn ECU Comm
456 756 DPF RengenInhib
457 757 Regener Needed
458 758 RegenerNeeded!
459 759 HEST Lamp
PDC_2019_019 Rev. 1.0 Page 93

SUPPLY LOG FILES

Here below a scheme with all parameters of the genset as listed in the log-file (<*supply*.txt>):
SUPPLY LOG FILES (some older controller version provide less parameters in the logs)
NAME (LOG NAME (READ IBIS UNITS DESCRIPTION

FILE) LOG)
ExcelTime - time stamp execl format
Time - time stamp text fomat
Vb IBIS Battery [V] IBIS battery voltage [V] (voltage inside PSC)
AvVb IBIS AvBattery [V] average IBIS battery voltage [V]
Iout I_Out [A] battery current [A] (negative if batteries are charging; positive if batteries are
supplying the system)
Isun I_Sun [A] current from solar panels [A]
Iwnd I_Win [A] current from solar panels [A]
PscStatus PSC mode 0: Manual;
1: Automatic;
PSC status 1: Genset On For Low Genset Battery);
2: Genset On For Low IBIS Battery;
4: Genset Stopped For Low Fuel Level;
8: is Going Standby;
15: Not connected;
GensetPout Genset P_out [W] power provided by genset [W] (positive value when genset is on and batteries are
charging)
GenAvPout Genset AvPout [W] average power provided by genset [W] (positive value when genset is on and
batteries are charging)
GenVb Genset Battery [V] genset battery voltage [V]
RPM Genset RPM [RPM] genset rounds per minute (normally around 3000 when genset is on)
Fuel Genset Fuel Level [%] genset fuel level [%] (total capacity is 10 liters)
normally ranging from "0" to "100". ("200" in case of a wrong AMF25 reading)
FuelAvg Genset AvFuel [%] genset average fuel level [%] (total capacity is 10 liters):
Level if PSC in automatic mode it is normally ranging between "0" and "100". ("150" if
PSC average value is not available)
If PSC in manual mode it is always "200"
FuelAlarmCode Genset Fuel [%] 0 (0x00): No error;
Alarm 1 (0x01): Low Fuel Warning;
16 (0x10): Low Fuel Alarm;
32 (0x20): Fuel invalid value
RunHours Genset Run [h] genset hours of activity
Hours
SwitchStatus Genset Switch 4: GCB is open;
Status 5: GCB is closed
(GCB is by deafault open. It is automatically closed by PSC after a genset start.
PSC opens it just before stopping the genset)
GensetStatus Genset State -1: Genset communication timeout;
0: Genset off;
1: Genset stopping;
2: Genset starting;
3: Genset running;
Alarm 1 Genset Alarm1 Each alarm is stored as "XXX Y" in the log file:
Alarm 2 Genset Alarm2 XXX: represent the alarm code (between 243 and 459)
Y: "1" if the alarm is still active; "0" if the alarm is not active anymore
Alarm 3 Genset Alarm3 IBIS_READ_LOG will add "300" to actual alarm code if the alarm is still active. See
Alarm 4 Genset Alarm3 GENSET ALARM LIST for more details
PDC_2019_019 Rev. 1.0 Page 94

TRB Gen Overall Troubleshooting

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OVERALL TROUBLESHOOTING and REPLACEMENT PART’S PROCEDUREs

GENSET - OVERALL TROUBLESHOOTING

Product: IBIS-FM, FMT, Rover, ArcSAR

Tool IDS Georadar code Image

RS232 female to female 861962

24Vdc Supplier 857997

Supply cable AMF25 858528

PDC_2019_019 Rev. 1.0 Page 1

USB to Serial converter 861954

PDC_2019_019 Rev. 1.0 Page 2

PDC_2019_019 Rev. 1.0 Page 3

FIG. 1 – RIGHT LATERAL PANEL ..................................................................................................................................................... 11

PDC_2019_019 Rev. 1.0 Page 4

FIG. 60 – VOYAGER4010 – BATTERY CHARGER REGULATOR (POSITION)............................................................................................... 49

PDC_2019_019 Rev. 1.0 Page 5

1.1. STANDARD INFORMATION NEEDED FOR TROUBLESHOOTING ACTIONS

• Conditions when problem occurred:

o At start (no problems during the last run);

o Resumed to work after long time.

• Weather conditions (mainly temperature, at least hot/cold weather);

PDC_2019_019 Rev. 1.0 Page 6

Try to turn ON the

Try to turn ON the engine with

The problem is in YES

Verify the engine (oil, gasoil, air filters) –

Try to start the

Try to start the

Let it works for 10 minutes, then turn OFF the

Fix the nut, verify 12Vdc on the EV

The problem can be:

PDC_2019_019 Rev. 1.0 Page 8

PDC_2019_019 Rev. 1.0 Page 9

TANK SWITCH OFF NA -

For more information, details and support:

MASE GENERATORS SPA

PDC_2019_019 Rev. 1.0 Page 10

1) Purely mechanical (Air, Fuel/Oil circuit);

HOW TO ACCESS THE ENGINE

Follow these procedures to access to the engine:

Fig. 1 – Right lateral panel

Fig. 2 – Black (upper) and red (lower) frontal panels

PDC_2019_019 Rev. 1.0 Page 11

Fig. 3 – Left lateral panel

Fig. 4 – Genset PD50S - “Normal mode” configuration

Model: Voyager 4010

PDC_2019_019 Rev. 1.0 Page 12

Fig. 5 – Genset RCD

Fig. 6 – Genset rotating panel

PDC_2019_019 Rev. 1.0 Page 13

Unless otherwise indicated (Model: PD50S or

PURELY MECHANICAL OPERATIONS

This section describes purely mechanical interventions, such as:

2) Check for and resolution of:

PDC_2019_019 Rev. 1.0 Page 14

5.1. MOTOR OIL AND OIL FILTER

5.1.1. GENERAL INFORMATION

• API (American Petroleum Institute) services categories CD or higher;

Fig. 7 – Oil chart

WARNING! SUDDEN MOVEMENT HAZARD!

5.1.2. ENGINE OIL REFILLING AND OIL FILTER REPLACEMENT

PDC_2019_019 Rev. 1.0 Page 15

Fig. 8 – Engine oil refilling/Oil filter replacement

4) Place a recipient under the engine to collect wasted oil;