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Engine Generator: 25S-8E1

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2. 3 39 3 4 12 Charge relay 3 39 3 4 13 Tachometer with hour meter 3 40 3 4 14 Fuel gauge 3 41 3 4 15 Sending unit 3 42 3 4 16 Oil fence level switch 3 43 3 4 17 Fuel air bleeding electromagnetic pump 3 44 3 4 18 Air filter differential pressure switch 3 44 3 4 19 Water temperature gauge 3 45 3 4 20 Water temperature sensor for ECU emergency stop and gauge 3 46 3 4 21 Oil pressure gauge 3 46 3 4 22 Oil pressure sensor for oil pressure gauge
3. RO T0 p Connector terminal arrangement No A1 0 5 Y W STARTER The following arrangement is seen from the side of the SWITCH ASSY connector inserting port pl J2fuanvarcna 2 F1 20 24 CN4 3 1 25P oe 1 25 B R o NITLLLLLLLLLLLLLLLTA 0 zz Ce PANEL LIGHT SW OFF D SR W CN1 51MAP2 IGKEYCN1 24 0 95R 0 85 R L STARTCN1 46 0 5 R W cw 4 49MAPQ ENGINE SIDE CN1 27 CN1 28UP B CN1 2 29 RIG CN4 9450 58 Y cy1 26 Down B CN1 S 428 1 STARTRCN1 14 0 5 B W 0 5 R G TO GENERATOR m 18 4 GLOWCN1 10L0 5B G P1 1 MENS UMAR CASE X0 STX SIGN CN1 43 838 SIGN CN POWER CN1 1 1 258 4 4 POWER CN1 3 258 POWER CN1 4 1 25B 71 a 1 25ENGINE STOP 17 4 1 33REG MODE DC DC CN1 53MEM CLEAR 4 BAROMETRIC 1 395 CN1 615V2 DIAGL CN1 6 f CN3 6 DIAGNOSTIC PRESS SENSOR CN1 71B ARO OILPL CN1 17 0 5 G R CN3 GLOWL CN1 11 0 9L YicN3 5 GLOW CN1 7 ew 0 5B r R R FILT ER 5 0 8 5 Y gem B x 5 UE 0 8 5W L 0 858 INLET AIR TEMP SENSOR NLICN1 58 150CAN H CN1 78 150CAN L TACHO CN1 8 TACHO PULSE 1 5201 6 irypNS 4PULSE LINN 19 15 01 G 5 CN3 12 AIR FILTER CN3 16 0 5W G CN3 17 0 5B P CN14 15 16 A130920E 5 4 5 Refer
4. 3 4 3 2 3 Voltage selector switch 3 5 3 2 4 AVR Automatic voltage regulator 3 7 3 2 5 Thermal relay 3 10 3 2 6 Current transformer CT 3 11 3 2 7 Ammeter 3 11 3 9 Electronic Control System of Engine 3 12 3 9 1 Electronic control fuel injection system Common rail type 3 12 3 3 2 EGR Exhaust gas recirculation control 3 14 3 3 3 Engine speed adjustment 3 15 3 9 4 Preheating control 3 15 3 3 5 Diesel oxidation catalyst DOC 3 16 Table of Contents
5. 1 10 1 7 Fuel PIPING 1 11 2 Overhauling 2 1 2 1 Cautions for Overhauling 2 1 2 1 1 Precautions before starting work 2 1 2 1 2 Disassembly and reassembly 2 1 22 Tightening 2 2 2 2 1 General tightening torque of bolts and nuts 2 2 2 2 2 Tightening torque for terminal plate 2 2 2 3 Disassembly Reassembly of Generator Main Unit and Connection of Generator Main Unit and Engine 2 3 2 3 1 Disassembly of generator main unit 2 9 2 3 2 Measuring center deviation and surface deviation 2 5 2 3 3 Assembly of engine flywh
6. 5 6 X For the details of operation and installation see Instruction Manual 1 Specification 1 1 Specifications Model SDG258 8E1 Brushless Star with Neutral Three Exciting system Armature connection ZigZag Phase number Single m Power factor an A a Ot 14 4 14 4 240 120 Rated output Rated output bo 5 Qo Current ISUZU 4LE2T 4 cycle water cooled direct injection turbo charged Number of cylinders 133 2 179 Total displacement cu in L Eie o0 le rrj Z a s E et ola E ct D 25 c ES 75 D lt lt 5 C lt Operating mass weight lbs kg 2 161 980 The capacity of oil fence gal L 26 100 Rated output hp kW 33 3 24 8 Revolution per minute rpm min 1 800 1 800 Lubricating oil capacity 9 75 10 4 ded adio 275 04 BEEN 80D26R 12V Fuel tank capacity 52 195 Overall length 677 1 690 S Overall width 31 800 2 Overall height 55 1 400 E Net dry mass weight 1 764 800 E m 1 Specification SDG458 8E1 Model Brushless Star with Neutral Three Exciting system Armature connection ZigZag Phase number Single m Power factor an A N gt gt QO Rated output V Rated output w A NIN 240 120
7. 4 9 4 6 Engine Trouble Diagnosis Function 4 14 4 6 1 Engine trouble diagnosis 4 14 4 6 2 How to delete diagnostic trouble code 4 16 4 6 3 List of diagnostic trouble codes DIC 4 17 4 6 4 Diagnostic service tool E IDSS 4 19 5 References 5 1 5 1 Generator s Winding Wires Resistance Value 5 1 5 2 Forced Excitation Method 5 1 5 3 Idling Revolution Per Minute 5 1 5 4 Generator Wiring Diagram 5 2 5 5 Engine Wiring Diagram 5 4 5 6 List of Consumable Parts and Electrical Appliances
8. Current ISUZU 4LE2X 4 cycle water cooled direct injection turbo charged intercooled Number of cylinders Engine Generator m rrj 5 2 5 5 E ct e E D o o s g 5 lt D D 3 lt Operating mass weight lbs kg 3 197 1 450 The capacity of oil fence gal L 37 140 Total displacement cu in L 133 2 179 Rated output hp kW 57 7 43 Revolution per minute rpm min 1 800 1 800 Lubricating oil capacity 3 1 11 7 2565 NEN 85D26R 12V Fuel tank capacity 106 400 Overall length 82 2 080 S Overall width 38 970 2 Overall height 61 1 560 f Net dry mass weight 2 425 1 100 E s UN 1 Specification pem 1 LLI Qe 2 A A O N T LV6OELV ANVI IV INJANOSTANI Ad311V8 NIVMO ANVIL IVIN3ANOSIAN3 18646 1915 1 K 5000 30 01108 OI 61 uum 4IV ONT 1002 7 Z 9M WNOMIAN 9772 IWIN 83 11 L3NN08 I 543 0 970 43 I V8 n 3NISN0 8 N 56 8000 00 090 Yad 8 28 1 JINI 1905 803 JN Id a B ESMINANLAY TANS 01
9. 4 3 4 2 2 Voltage is very high or it cannot be adjusted 4 4 4 2 3 Voltage fluctuates 4 4 4 2 4 Load cannot be operated 4 5 4 2 5 Voltage drops when load is applied 4 5 43 Emergency Switch Functions 4 6 4 3 1 Engine oil pressure drop is displayed in monitor and engine will stop 4 6 4 3 2 Engine water temperature rise is displayed in monitor and engine will stop 4 6 Table of Contents 4 4 Engine Troubleshooting 4 7 4 4 1 Anything abnormal is not shown but it sometimes stops without its cause shown 4 7 4 4 2 At start up starter rotates slowly 4 7 4 4 3 It will not speed up to rated speed 4 8 4 5 How to Check
10. 3 47 3 4 23 Engine oil pressure sensor for emergency stop 3 47 3 4 24 Ammeter for battery charge 3 47 3 5 Electronic Control Engine Component 3 48 3 5 1 Engine component location diagram 3 48 3 5 2 Various parts and sensors 3 49 4 Troubleshooting 4 1 4 1 Repairing Procedures 4 1 4 1 1 Safety caution 4 1 4 1 2 Caution during failure diagnosis 4 1 4 1 3 How to use the failure diagnosis 4 2 4 2 Generator Troubleshooting 4 3 4 2 1 No voltage is generated or voltage too low
11. Connector terminal arrangement 5 214142 1 Controller function 81 pins To the 20A fuse via main relay Starter cut relay coil Fuel pump relay coil Power supply Gru ng To the 20A fuse via main relay Starter cut relay coil Power supply Fuel pump relay coil Monitor lamp CN3 6 When engine fails it supplies power to CN3 6 terminal to terminal Diagnosis lamp make diagnosis lamp glow 3 Electric System Line Pin No color CN1 7 Br R CN1 8 CN1 9 CN1 10 B G Connection Function Monitor lamp CN3 2 terminal Boost temperature lamp Auto start unit CN5 2 terminal NIL Glow relay GR coil Monitor lamp CN3 5 No power exists during usual operation When boost temperature rises higher than specified one interior contact in ECM 1s ON and it connects ground to send power Thus boost temperature rise warning lamp glows Warning lamp lighting temperature 185 F 85 C It outputs engine speed Revolution ratio pulse type revolution per 4 pulses No power exists during usual operation When power is sent to CN1 24 terminal preheating starts When preheating interior contact in ECM is ON and it connects ground to send power Thus glow relay GR works to preheat ECM decides glow timing pre glow and after glow according to engine coolant temperature and it sends power to CN1 10 terminal each time to function glow relay
12. 13NYd IN3WRHISNI 831114 13013 1198 9811411 ALIAVHS 30 83IN32 96 5 c8 A E NECS i S 131100 SIV 9 11002 B 2 hj Y31113 J31VM H3A02 n 9 8 052 131100 i 3 25 a bo ce mdi 1 5 Specification 1 SDG45S 8E1 GELLELV ANVIL 1VIN3A08 LAN3 D e A eN 009 0511 OEEN Y371YY1 uod 60025 9 066 091057 S 310H 51 7 12g 901 8 2U 2 129 1384 NIVEG 10 3NI5N3 05 NIVEd S3IVANN OST 779 OFZ w G DL 1102 803 Ws a i ae 8 t3UNHnI3H 1304 804 abe i STIS ara UNY o 11 4 402 S310H B Quee ED ee CE n LLAS 40 831132 gt 1 VERON NOLIN 4015 JON3OHIW3 2 4 5 HEE gt a aonr m EHRE EST 5 e ve a mn 5 2 NL WWTIWSSI 114100 E core i lk m E3D03138 35VITOR duvoS ONY L3NNOS8 3HL NI HI ONT 100 13NYd LNAWNYLSN TS INT ONT 1002 841113 11014 11 8 9811311 89 40 H3IN32 55 016 1d EDO WI v 1002 089
13. 12V 3 4W Stator coil CA CR Rotor Chkaraelan arge lamp LA dd IH S AAAG LP TE SG14147E 3738 3 Electric System 3 4 9 Main Starter cut Fuel pump relay Part number 44346 08500 Rated voltage DC12V MM 6 Capacity of contact 20A lamp load point 25A others i 19 0 02 Er PC12043 1 3 4 10 Starter relay Part number 44346 16100 Rated voltage M E 1 obo olo 200A Rush current 3 4 ony 80A Braking current M p cR 12044 3 4 11 Glow relay Part number 44346 15700 Rated s d 2 1 obo oo 2 Coilresistance resistance i B WS mN 100A Rush current p 5 Jl pot 40A Braking current T PC12044 3 4 12 Charge relay Part number 44346 13200 Rated voltage ielo loj Gai Motor load ne Rated load AOA at steady state NS as ua dE pos Coil resistance PC12044 3 89 3 Electric System 3 4 13 Tachometer with hour meter Part number 36146 05901 20 3 TACHOFIETER 1m METER 101019101779 5612116 1 Specifications Operation voltage DC10 16V Operation temperature 4 F 140 20 60 Revolution ratio pulse type 2 revolutions per 1 pulse 2 List of functions BP j Grundng 010005050000 Alternator L terminal Input of hour meter function signal 15A fuse Power sup
14. ES aa K Water temperature sensor Camshaft angle CMP sensor Pressure limiter Suction control valve SCV Supply pump Fuel temperature sensor Engine oil pressure sensor Crankshaft angle CKP sensor Common rail pressure sensor O o s cb rnm 4 H a 0 ELM e 3 zw LA 3226 5 2 rt Te e CAES p Qi bc m nii E eet a Y i i s gt 11 SG14150 10 Intake manifold temperature IMT sensor 11 Injector 12 Boost temperature boost pressure sensor 13 EGR motor position sensor 14 Intake air temperature IAT sensor X Mounted to air filter intake air pipe 15 Barometric pressure sensor X Mounted to the inside the control panel 3 48 3 Electric System 3 5 2 Various parts and sensors Supply pump The supply pump pressurizes fuel using engine output and pressure feeds fuel to common rail The supply pump has suction control valve SCV fuel temperature FT sensor and feed pump Suction control valve SCV The suction control valve SCV is installed onto supply pump section and controls pressure feed of fuel discharge amount to common rail The engine control module ECM regulates period of electric conduction of suction control valve SCV to regulate the fuel discharge amount 3 49 Fuel temperature FT sensor Suction control valve S
15. LV3H UNV JgJIIV8 404 5410 V0c d 19 193934 V08 3 19V14d3238 d3AV 388 SVYHd 4 5 J NILYVLS 2 ILVNOIOV 0 31 14 INI 1002 ALIAVSMS S31N32 431113 MN31YA YSA09 MATS J3lVM YJA09 y 8 05 1 411 0 LSAVHXS LY LNd LNO JLIMS 44 133 25 39v1 10 A HOLIMS UNY 7 IdNVd INAWNYLSN gee 1 3 1 Specification SDG25S 8E1 c60 IV 007 EG 0 094 056 iis ole BBB po
16. No power exists during usual operation When engine speed rises up to emergency stop set speed interior contact in ECM is ON and it connects ground to send power Thus overspeed warning lamp glows Emergency stop set speed 2 070min 69Hz Suction control valve Monitor lamp CN3 13 terminal CN2 88 Y It detects common rail pressure fuel pressure It detects fuel pressure in common rail and it converts it Common rail pressure voltage signal and inputs it It is used for fuel injection sensor OUT terminal control Pressure detecting voltage signal is high when pressure is high and it is low when pressure is low It detects engine intake boost intake air temperature and pressure It is a sensor of the thermistor type the boost Boost temperature boost temperature sensor send the ECM measure the pressure sensor OUT temperature terminal It counts boost intake air pressure from detected voltage signal for fuel injection control Voltage 1s high when pressure 16 high and 1t 1s low when pressure 1s low CN2 90 W CN2 91 L oc 41484 8 8 3 22 3 Electric System Line Pin No nw Connection Function CN2 92 INT CN2 93 G W EGR motor posision sensor V terminal CN 2 94 G B EGR motor posision sensor U terminal CN2 95 Crank angle sensor VCC terminal CN2Z96 CN2 97 R B Suction control valve SCV CN2 98 W CAM angle sensor OUT terminal EGR motor
17. un dm Sa Sm 1 pem m Lr al ENB YY ELE a ie CP CA NN d i e 6P 5 16 oso c esc BOM SS boe Oen o LE p icc ES M NT 1 TO AUTO START UNIT gt gt gt l de COHERENTE UN RUE EUY aa TO BATTERY 52 d TO ENGINE HARNESS A130904 5614160 5 References 506455 8 1 Molded case circuit breaker three phase Molded case circuit breaker single phase Shunt coil A Ammeter 51 Thermal relay Automatic voltage regulator CN4 3P Hand trimmer voltage regulator TERMINAL PLATE MCB2 2 5 Ammeter change over switch CP Circuit protector SW1 Frequency selector switch 98 TEE Le AS RT 52225 F 4 SW id 5 e M tim 240V m 4 34 i s 1 VETERES S SEIS __ peso E d RH HHH Ci S i m INE IR i E Q T7 i ES Ut T Wio T12 LH PN A 78 Lx 1 2 5 E WAX pe IS Le E s EE Sept TO BATTERY C TQ ENGINE D A bo Rc 5 A131089 5614055 5 3 5 References 5 5 Engine Wiring Diagram
18. 3 4 Electrical Appliances of Engine 3 17 3 4 1 Controller ECM 3 17 3 4 2 Monitor lamp 4 3 26 3 4 3 Auto start UNIT 3 29 3 4 4 Sequencer 3 33 3 4 5 DC DC Converter DC POWER SUPPLY 3 35 3 4 6 Power relay 1 3 36 3 4 7 Power relay 2 3 37 3 4 8 Alternator 3 38 3 4 9 Main Starter cut Fuel pump relay 3 39 3 4 10 Starter relay 3 39 3 4 11 Glow relay
19. Y31114 YALVM YAAOD 8 059 141100 15 25 245 5 525 0 7 1 6 1 Specification 1 3 Internal Components 5 6 8 9 1011121314 15 16 17 4 0 15 Hg a dN TE 34 33 30 29 28 27 26 25 24 23 22 21 20 19 18 SG13111E SDG255 8E1 Description Fuel drain valve Engine oil drain valve Oil fence level switch Sending unit Ground terminal 22 DOC Diesel Oxidation Catalyst 24 8 Engine oil filler port 25 Selector valve of fuel pipe Engine oil filter 26 Fuel filter Air filter 27 Fuel pre filter Vacuator valve 28 Auxiliary receptacles 9 Eneine oil level gauge 9 Remote control terminal plate for d ia automatic operation battery charger 1 1 Supply pump 30 GEFCI receptacles 1 receptacles breaker and auxiliary 1 4 Reserve tank 31 receptacles breaker Emergency stop switch Radiator 33 Generator main unit Exhaust pipe 34 Battery I4 1 Specification 1 4 Instrument Panel m N o J OO co m STOP RUN L 4 START maa 19 18 17 16 15 14 13 12 11 5614164 SDG25S 8E1 1 Monitor lamps 11 Main circuit breaker 2
20. padded by wooden block at the bearing side face Generator main unit frame The generator main unit separated from engine should be kept firm with the rotor in the stator fastened by wire or rope to prevent them from moving Then start this job Wooden block 5613056 2 4 2 Overhauling 2 3 2 Measuring center deviation and surface deviation Measure them with a dial gauge pressed to the flywheel 1 Measuring the center deviation turn the rotor with the dial gauge pressed to the circumference of the coupling flange If the biggest value measured on the same circumference exceeds 0 008in 0 2mm it is necessary to repair it 2 Measuring the side run out turn the rotor with the dial gauge pressed vertically to the coupling flange If the biggest value measured on the same diameter exceeds 0 008in 0 2mm it is necessary to repair it Magnet chuck Flywheel side run out Housing center deviation Engine M Flywheel Dial gauge 5606059 2 5 2 Overhauling 2 3 3 Assembly of engine flywheel and generator coupling rotor IMPORTANT The mounting holes not equally spaced along the circumference Therefore position the holes in advance so as to match the coupling counterpart by turning and adjusting the engine flywheel Use guide bolts while centering to mount the assembly Tighten the bolts to the specified torque 1 Mounting engine F
21. 14 3psi 0 098MPa SMC ____ It outputs engine speed 2 revolutions per 1 pulse Grounding terminal for tachometer engine speed detection In order to show engine speed pulse signal outputted from CN3 16 terminal to tachometer pulse signal at minus side is necessary and so diode is added at ground circuit and ground level of tachometer 1s raised 1 2V higher 3 28 3 Electric System 3 4 3 Auto start unit Part number 46760 73710 1 List of functions To the 10A fuse via emergency stop switch No 2 terminal Air filter differential pressure indicator Manual Auto selector switch CN4 3 terminal Oil fence level switch 5614146 Power supply When pressing emergency stop switch also during manual operation main relay becomes OFF and power supply of controller ECM and power supply of automatic start unit ASU become OFF Then it will be brought to emergency stop No power exists during usual operation Air filter differential pressure rises ON When air filter differential pressure indicator is for 10 seconds interior contact of terminal is switched ON and warning lamp glows Function differential pressure More than 0 9psi 6 2kPa Power supply for remote start stop switch With CN5 4 terminal power supply input remote start stop switch external output terminal plate A1 A2 terminals is XO relay works No power exists during usual operat
22. Starter relay coil SY ECM CN1 50 terminal It outputs start stall signal No power exists during usual operation When automatically starting interior contact of PLC unit Y2 terminal is ON and it outputs start signal to starter relay When starter works and X07 contact is ON by generation signal PLC unit judges that starting 1s completed but when X7 contact is not ON even after cranking is tried 10 seconds it stops 8 seconds and cranking operation will be repeated 10 seconds When engine will not start even after this operation is tried three times make the interior contact of PLC unit Y4 terminal ON and output start stall signal to monitor panel and then overcrank warning lamp goes on No power exists during usual operation When oil fence level switch is 1nterior contact of PLC unit Y5 terminal is ON and oil fence water level rise warning lamp glows It outputs engine speed 2 revolutions per 1 pulse Engine speed 1 revolution per 4 pulses inputted from ECM is converted for tachometer 2 revolutions per 1 pulse and outputted Power supply for engine starting when automatically starting When remote start stop switch is ON XO relay works to supply power to PLC unit XO terminal and 2 seconds later interior contact of Y1 terminal is ON Engine power supply is outputted from CN7 7 terminal Outputted power from CN7 7 is to activate MR1 relay and supply power to ECM for sta
23. Any problem in load or cable v pa such as short circuit or loose connections NO 4 Troubleshooting Load capacity too high Adjust If 1t cannot be adjusted at all please refer to troubleshooting 4 2 1 No voltage is generated or voltage too low Turn on Immediately the circuit breaks automatically Check load Fault 1n circuit breaker MCB contact or voltage selector switch Retighten and correct Check cable used for load Please refer to the sentence 4 2 1 No voltage 1s generated or voltage too low Reduce load capacity to suit generator capacity Or use a higher kVA generator that suits load capacity Engine output insufficient Repair Refer to Engine repair manual 4 Troubleshooting 4 3 Emergency Switch Functions 4 3 1 Short Check engine oil quantity ee Proper Faulty Check oil filter Normal Engine oil pressure drop is displayed in monitor and engine will stop I I gt Replenish or replace I Sec Ee murum Filter clogging I gt Replace it I Lower than 14 3psi 0 098 Check engine oil pressure Higher than 14 3psi 0 0908M Pa Check cable connection to Faulty engine oil pressure sensor Normal Check water quantity and Shortage quality in radiator Normal Faulty Check belt tension Normal Higher than Check ambient temperature 104 F
24. Instantaneous characteristic is set at the best point So it is not necessary to adjust it Adjustment is prohibited Notch position of time constant adjustment volume 0 10 X Position of notching The top of volume resistance is marked arrow at the one of the variable cross holes for showing the set up position 378 3 Electric System Over excitation protection A circuit protector CP is installed on the side of the circuit breaker board for prevention of AVR from being damaged by the over excitation current caused due to wrong wiring and disconnection to detective inlet terminal of AVR If this device functions the black push button at the top of CP 16 kept pressed up In order to reset it push the black button on after getting rid of the cause of the excessive exciting current flow IDEC NRF110 us X After tripping you should not switch on again before the bimetal gets cooled approx 60 seconds and more required to be cooled G12105E 3 9 3 Electric System 3 2 5 Thermal relay Part number 46928 01500 Terminals for main circuit Test lever Setting dial Push Test lever Automatic manual re set selector lever Contact structure 1 L1 3 L2 SfL3 97 95 instrument circuit Upper part B contact normally close Lower part contact normally open Thermal relay LLL UE LS LT un 2 1 4 T2 GTS 96 96 SG12022E 1 Thermal relay
25. 40 C Lower than 104 F 40 C Check clogging of radiator and intercooler Intercooler equipped only SDG45 Normal Check water temperature Clogging Faulty Sensor Normal Check cable connection to Faulty water temperature sensor Refer to Engine repair manual T 6l Pare Ao xS ty VU Vui v END er BET 1 Looseness of cable gt Repair connection or separated E es a A 1 Defective oil pressure Basie sensor 2 p Looseness of belt defective belt I gt Adjust or replace l I Lower ambient temperature down to less than 104 F 40 C Ue Ram iP roS ET EHE 1 Defecti t Detective water kake temperature sensor i 1 1 Looseness of cable m gt Repair connection or separated 4 Troubleshooting 4 4 Engine Troubleshooting 4 41 Anything abnormal is not shown but it sometimes stops without its cause shown Excluding the cases of faulty contact of starter switch and fuse broken Check cable connection to Disconnected Y m D i monitor lamp Faulty cable connection gt Repair I Normal Fault Faulty controller ECM or Check if controller ECM au
26. 54 DC 0 5A Maximum primary contact Less than 100m Q resistance excluding lead line Fluid level in oil fence when warning lamp glows L 11 50 Level switch is ON Fluid level in oil fence in above table shows the value calculated not actually measured 3 48 3 Electric System 3 4 17 Fuel air bleeding electromagnetic pump Part number 43650 02600 With filter type Part number of filter ISUZU part number 898071 4010 5612075 1 Specifications Rated voltage 1 5 Max Discharge volume More than 0 3gal min 1 3L min 3 4 18 Air filter differential pressure switch Part number 32148 03000 Operating pressure 0 9psi 6 2kPa A Contact SC10016 3744 3 Electric System 3 4 19 Water temperature gauge Part number 36145 06800 1 List of functions Function B Grounding Y W Power supply for lighting Detector for water temperature Power supply 2 Temperature and resistance value of sensor Temperature F Resistance value Q 120 49 marked reference value 3 Lamp specifications 3 45 5606040 3 Electric System 3 4 20 Water temperature sensor for ECU emergency stop and gauge ISUZU part number 898023 7170 Signal GND SER dE t ON in case of more than etting temperature 212 F 100 Water temperature gauge Tightening torque SG14149E p en 15lb ft 203 m 3 4 21 Oil pressure gauge Part nu
27. 9 7T 12T Indication does and indication example not appear n some cases Hexagon headed bolt Socket bolt Hexagon headed bolt Nominal diameter feni amm uu 98 Applied sections Onn For specified sections and frame IMPORTANT Generally the abovementioned tightening torques should be followed but in some points different torque is specified So use the tightening torque without fail Make sure to remove rust and dust before tightening 2280 41 2 2 2 Tightening torque for terminal plate Should be tighten terminal of thermal relay other electric equipment etc according to following Nem 9 8 100 torque 1 5 15 2 9 30 17 2 175 34 850 2 2 2 Overhauling 2 3 Disassembly Reassembly of Generator Main Unit and Connection of Generator Main Unit and Engine 2 3 1 Disassembly of generator main unit IMPORTANT The generator main unit is unilaterally mounted and the clearance is small so it must be handled with extreme care to avoid the possibility of damage to the rotor or stator Use hoisting equipment of sufficient capacity when it is necessary to lift up the engine and the generator main unit 1 Lifting weight Unit lbs kg SDG255 8E1 SDG458 8E1 Weight of generator 293 133 main unit Weight of engine 420 190 D Generator main unit 2 Engine 3 Bolts for coupling of the engine flyw
28. EGR temperature by the mixture of fresh air thus 1t contributes to reduction of NOx Furthermore the adoption of a check valve for EGR system controls reverse flow of EGR gas and it allows gas flow in one direction only Thus EGR amount is increased EGR function ECM 1s to operate EGR motor according to such engine conditions as engine RPM and engine load and to control EGR valve lift Valve lift 1s detected by EGR position sensor Intake air Exhaust 5614140 1 EGR cooler 4 EGR valve 2 Outlet port of coolant 5 ECM 3 Inlet port of coolant 6 Boost pressure boost temperature sensor 3 14 3 Electric System 3 3 3 Engine speed adjustment It is possible to adjust the rated speed and operates the frequency adjustment switch during Operation Frequency adjustment switch UP While you are pushing UP side engine speed rises and it can raise engine speed The upper limit of the rotation speed adjustment 2 080min DOWN While you are pushing DOWN side engine speed drops and it can lower engine speed but it can not be lowered lower than the lowest idling speed The lower limit of the rotation speed adjustment 1 000min Control when key switch is OFF Engine speed which is adjusted by frequency adjustment switch is memorized in ECM and on next start engine runs at engine speed adjusted when key switch 1s OFF 3 3 4 Preheating control QOS Quick On Start system The ECM determines t
29. LL 0 9Br R cNa 2 BOOST TEMP prom 0 5G W cN3 7 WATER TEMP ECM AIR FILTER OVHL CNI 16 0 85B OVRL CN2 88 05 CN3 13 OVER SPEED OIL FENCE m 0 85B DIAG SW TACHO 8 TACHO PULSE I TURNS 4PULSE 0 9 1 8 ON1 52 DIAG CN7 125R Y QO S5R L vit og sty lt lt 1 050 05L W 41 Q5B L Iz 0 5B L 5 CN3 1609W 6 0 5L 0 5L CN3 1 7 0 5B P 6 05RAI Q 5R B 9 ut J 5614145 3 26 3 Electric System List of functions 2 CN31 B Grounding ECM CN1 7 terminal Boost temperature Br R Oil fence CN3 3 CN3 4 CN3 5 CN2 6 LIB ECM CN1 6 terminal Diagnosis lamp ECM CN1 52 terminal Diagnosis switch ECM CN1 11 terminal Glow lamp ECM CN1 16 terminal Water temperature Engine speed CN3 8 L Auto start unit CN7 5 terminal Auto start unit CN7 6 terminal Function No power exists during usual operation When boost temperature intake air pressure rises higher than set temperature interior contact in ECM is and boost temperature intake air pressure rise warning lamp glows Warning lamp lighting temperature 185 F 85 C No power exists during usual operation When oil fence level switch is ON interior contact of auto start unit Y5 terminal is switched ON and warning lamp glows Warning lamp lighting capacity See 3 4 16 When engine s
30. be read by connecting diagnostic service tool Diagnostic trouble code DTC list refer to 4 6 3 and diagnostic service tool refer to 4 6 4 6 Necessary measures for the results of diagnosis trouble For the detailed countermeasures refer to Engine repair manual published by engine manufacturer If diagnostic service tool is fitted it is possible to read diagnostic trouble code DTC by diagnostic service tool operation Take special care in handling fuel system and so refer to the following cautions Fuel pipes gt Never use such pipes as used high pressure pipes of 1 2 3 fuel system and injector pipes Make sure to replace used ones by new ones Never change pressure limiter and common rail pressure sensor only If they are 1n trouble change 1t 5614034 as an assembly and all fuel pipes 1 Pressure limiter 2 Common rail 3 Common rail pressure sensor Cautions about maintenance of fuel system All the parts of fuel system and holes clearances as fuel passage are precision machined so that entrance of foreign matters affects so badly them to cause damages to fuel passage Therefore you should take special care to prevent them to enter fuel system Before preparing maintenance work wash your hands and never use working gloves for this job f you remove high pressure pipes in fuel system make sure to replace them by new ones If you re use them it could damage sealing face and
31. cause fuel leakage Make sure to replace spare parts such as gasket and O ring by new ones 4 15 4 Troubleshooting 4 6 2 How to delete diagnostic trouble code DTC 1 Deletion of diagnostic trouble code DTC When diagnostic trouble code DTC is memorized in engine control module ECM in case of system trouble Even after troubled parts have been repaired memory of diagnostic trouble code DTO will not be deleted in this case It is necessary to compulsorily delete this memory according to the following procedures 2 Memory clear D Switch ON starter switch Fault diagnosis lamp goes out after lighting for 3 seconds for the lamp bulb check out 2 Continue pressing diagnosis switch Keep pressing until section 6 3 To ground green line color No 5 terminal of 6 pole connector of the left corner of the control panel inside 6 Green 4 SG13103E 50614159 Left corner portion inside control panel 4 Wait for more than 3 seconds in the grounding 5 Remove the jumper wire that was grounded 60 Switch OFF diagnosis switch Turn off 7 Switch OFF starter switch Wait for more than 10 seconds Confirm of memory clear Switch ON starter switch Fault diagnosis lamp goes out after lighting for 3 seconds for the lamp bulb check out 9 Continue pressing diagnosis switch Fault diagnosis lamp will be bling below if it is memory clear While you pressing diagnosis switch diagnosis
32. compression Repair the trouble and get rid of the cause Pressure drop Check engine compression Normal Maladjustment of other parts of the engine valve i Repair the trouble and get i timing valve clearance rid of its cause others I e X For the detailed countermeasures refer to Engine repair manual published by engine manufacturer 4 8 4 Troubleshooting 4 5 How to Check A Checking for disconnection of voltage adjusting resistor hand trimmer Turn the knob right and left and check if the resistance changes It is normal if the resistance value is within the following ranges Resistance value several 2kQ The resistance decreases when the knob 1s turned in the direction of The resistance increases when the knob 1s turned 1n the direction of B Also make sure resistance varies smoothly G12035 1 B Measurement of generator winding wire resistance The standard resistance value of each wire includes the generator s winding wire resistance value Please refer to the sentence 5 1 Generator s Winding Wires Resistance Value 1 Generator armature winding wires 4 Exciter field winding wire zw L1 L2 3 HU J K I T1 T7 T7 E T10 T10 EF D1ode module Diode lleccmloezcee
33. even after the 2 supply pump strainer joint bolt built in type has been cleaned it should be replaced NOTE Supply pump strainer not part of the decomposition please do not remove the strainer of internal order 130889 Joint bolt tightening torque 2 5 Air Bleeding If the unit runs out of fuel bleed the air according to the following procedures Procedure gt D Turn the MANUAL AUTO selector switch to Priming pump MANUAL position 2 Place starter switch to OPERATION position to keep electromagnet pump functioning 3 Loosen air bleeding plug enough to move priming 7 Air bleeding pump till fuel comes out plug 4 Close air bleeding plug and move priming pump more often than 10 times till fuel is filled in fuel Element filter 5 After waiting about 1 minute loosen air bleeding NULL plug to bleed air from fuel filter C gt Repeat the above procedures till air does not come out from air bleeding plug at least more often than three times 7 Perform warming up operation for 3 minutes after engine starts A A130905 When this machine 1s not in use or operation the MANUAL AUTO selector switch should be kept OFF 2 13 2 Overhauling 2 6 Engine Maintenance Standards SDG258 8E1 SDG458 8E1 ISUZU ISUZU BZ 4LE2TAGD 02 BP 4LE2XAGD 02 M12 lb ft lst time 65 88 900 2nd time 65 88 900 3rd time 60 an
34. for contamination or discoloration However do not wash rubber parts with diesel oil 5 Be careful not to damage disassembled parts they are precision built 6 Replace consumables such as oil seals O rings filters oil etc with new items when reassembling parts 0 Apply a coating of clean grease to O rings when installing them in the machine When reassembling parts place each part in the order of assembly and take care that no parts are missing or misassembled When reassembling an assembled part set part be sure to replace it as an assembly Contamination or rusting may occur due to dust or humidity if parts are left in disassembled or partly disassembled condition for a long time Therefore be careful to prevent dust or rust from affecting parts 1f you have to leave the repair incomplete for a long period of time 1 Check tightening torque and clearance when assembling parts 2 Check the direction of rotation speed and oil leakage after assembly 9 Before starting the machine after disassembly run it at low idle to check for unusual noises etc to prevent engine or generator damage 2 1 2 Overhauling 2 2 Tightening Torque 2 2 1 General tightening torque of bolts and nuts Fasten all the bolts and nuts with the specified tightening torque when assembling iC d Low or medium carbon steel bolt High strength steel bolt SS400B etc SCM435 etc Strength classification 4 6 6 8 4T 6T 8 8 12
35. is possible to change frequency with combination of CN1 49 CN1 50 and CN1 51 terminal switching This unit 18 set to 60Hz constant operation with this terminal directly connected to 15A fuse It gets start signal from auto start unit CN7 9 terminal in Auto start unit CN7 9 5 order to perform idling for protection of turbo during 10 terminal seconds after it starts Operation mode frequency switching input terminal ON 60Hz constant It is possible to change frequency with combination of CN1 49 CN1 50 and CN1 51 terminal switching This unit is set to 60Hz constant operation with this terminal directly connected to 15A fuse CN1 50 R B Tool E IDSS No 12 When engine stops with starter switch ON and terminal diagnosis lamp is ON make diagnosis switch ON or Y B Monitor lamp CN3 4 connect CN1 52 terminal directly to ground Then terminal diagnosis lamp begins to blink Blinking pattern shows Diagnosis switch present and past engine troubles Resetting terminal of past trouble memory External input connector When terminal is ON between option connector No 5 No 5 terminal option and No 2 ground terminals past trouble memory is 1 53 G NL CN1 54 CN1 55 CN1 56 CN1 57 L W E IDSS OD Diagnostic service tool connection terminal B W Shield line Barometric pressure sensor SG terminal inlet Grounding air t
36. power supply timing of suction control valve SCV It inputs crankshaft position CKP signal CKP signal 16 caused when convex portion of flywheel passes through sensor position ECM judges cylinder according to CKP signal and 1t decides crank angle and counts fuel injection control and engine speed This control is performed based on CKP signal but in case crankshaft angle CKP sensor is in trouble it is performed based on camshaft position CMP signal detected by CN2 98 terminal 3 28 3 Electric System Line 1 nw Connection Function CN2 108 B W Shield line Grounding Crank angle sensor GND CN2 109 terminal Grounding Water temperature sensor motor W CN2 110 W L CN2110 we terminal Same as CN2 103 terminal C N2 111 W R EGR DC motor U terminal CN2112 CN2 113 R W E control valve Same as CN2 105 terminal NIL __ CN2116 R Injector and 3 Injector 4 Injector 2 Injector 1 Injector 3 Injector 1 and 4 Power supply OFF for ECM Power in ECM is not yet OFF 10 seconds after starter Starter ES switch is OFF In case that it is necessary to switch OFF power supply by clear memory it is necessary that you should wait longer than 10 seconds after switching OFF Starter switch OFF starter switch of power supply 10 sec SG14166E 3724 3 Electric System 3 Characteristics of water temperature glowing time K
37. set value Rated current Detected current at rated operation CTratio 100 5 150 5A Wound rolls Rolls of 2 rolls cables through CT Set value Tripping of over current is set to be reset automatically 3 10 3 Electric System 3 2 6 Current transformer CT 5612026 a SDG25S 8E1 SDG45S 8E1 46923 04700 46923 04500 Specification 5VA 100 5A 5VA 150 5A CW 5L Number of turns Nothing abnormal is found on its appearance Maintenance Measurement of insulation resistance checks More than 2 000MQ shall exist between secondary coil and mounting bracket 3 2 7 Ammeter Terminal cap S MMA thread Zero adjuster G12027E SDG25S 8E1 SDG45S 8E1 Part number 46154 16000 46154 14500 P 0 50A 50 5A O 75A 75 5A Specification 0 100A class 2 5 0 150A class 2 5 ACF 6 LM 3 Electric System 3 3 Electronic Control System of Engine Excerpted from ISUZU Engine repair manual The engine control system 1s electronic control system which maintains optimum combustion status of engine all the time according to operating conditions It consists of the following components D Electronic control fuel injection system Common rail type EGR Exhaust gas recirculation control 3 Idle speed control The engine control system also has the following system control functions other than engine control 4 QOS Quick On Start system 5 Engine speed signal output 0 Self diagnosis functi
38. the index of explanation For details see 4 5 How to Check 4 2 4 Troubleshooting 4 2 Generator Troubleshooting 4 2 1 No voltage is generated or voltage too low Check the frequency meter Lower No speed and confirm that engine Raise the speed to the increases Refer to Enei speed during no load B specified value watching 2 operation corresponds to the frequency meter the following values We No load speed About 60Hz 1 800min Check the AC output voltage OK Check the terminal voltage OK meter of output terminals L1 L2 of the voltage meter and L3 None or low The Ex stator connectors NO Disconnected J K are connected Connect again correctly properly Conductivity in AVR resistor NO Defective resistor hand hand trimmer trimmer OK If magnetized forcibly how Voltage normal Residual magnetism does does the voltage change not exist any more 0 or lower Fault in rotary rectifier wiring board Repair winding wire in generator Winding wire broken in generator or insulation poor YES C 4 3 4 Troubleshooting 4 2 2 Voltage is very high or it cannot be adjusted Speed should be about NO Higher Adjust the speed to the 1 800min for 60Hz during specified speed with the no load operation YES Check resistance in AVR resistor hand trimmer YES The AVR connectors J K NO Disconnected are co
39. well experienced you can find out the cause easily during the process of confirmation 4 But easy understanding could cause unexpected failure So check and judge it according to the following procedures D Check the easiest thing or portion first 2 Investigate the most possible cause 3 Check the other things connected to the trouble 4 Check for the possibility of any other troubles 5 Start proper and careful investigation on this trouble 6 Prevention of repeated occurrence of similar trouble Even if you have repaired the trouble unless you get rid of the fundamental cause of the trouble it will repeatedly occur Therefore perform full investigation of the trouble and it is absolutely necessary to remove the basis of the trouble 4 4 Troubleshooting 4 1 3 How to use the failure diagnosis Possible UU UU Tees ee ee ee eB eB Be o eB ee eS Impossible Abnormal LILI eB Normal DIn the troubleshooting column something abnormal is mentioned in lined parenthesis 2 In the troubleshooting column the cause of the said trouble is mentioned in dotted parenthesis m In the troubleshooting column the countermeasures or treatment are mentioned in the double lined parenthesis Ld 4 under each column means
40. you will need to use the exact locations and methods of performing inspection adjustment or disassembly and the key points of any repair work to be performed 2 Care not to spill oil Use a pan to collect used engine oil when changing the oil or attaching or detaching an oil line If a large volume of oil 1s expected to flow out make sure to drain any accumulated oil from the engine oil pan in advance 3 Care when detaching parts When disassembling a complicated part put a matching mark to indicate the position of detached parts for future reference Make sure that the negative cable is detached from the battery terminals before starting repair work 4 Tools to be prepared D Measuring instruments 4 Jigs and specialized tools e g tester insulation resistance gauge etc 5 Solder and soldering iron 2 Tools 6 Cleaning cloths 3 Torque wrenches D Literatures such as manuals etc 2 1 2 Disassembly and reassembly D Wash dirt dust and grime off vinyl tube and fuel hose before removing it and take necessary steps to cover or tape the openings of vinyl tubes or fuel hoses to prevent any dirt from entering them Perform disassembly work in a dust free location whenever possible When disassembling parts wash their outer surface and place them on a clean sheet of paper or cloth taking care not to contaminate or damage them ON Wash disassembled parts with diesel oil cleaning solvent after checking
41. 3 Electric System SDG45S 8E1 Part number 46917 05300 5614136 oystem of contacts arrangement 36 36 1 180 277 240 139V 240 120V Q fo GEN NES NENNEN Sx pto 9 E o 10 PN on fl C 1 15 9 QN 5 18 19 r 5 20 lt lt LLL 2 22 c __ NENNEN 5 y y 26 3 o __ 5 28 29 c o 4L 3 c 114 3 c y 31 3 c Ld 5 36 3 c LU 38 3 dq Lo a 380 5 42 Tu es sc d 15 c 1 2 4 5614137 376 3 Electric System 3 2 4 AVR Automatic voltage regulator Part number 46950 02901 if 4 Adjustment of voltage Time constant ADJ Adjustment of time constant Adjustment of stability Adjustment of V Hz characteristics Over excitation protection circuit protector Generator cable T10 AVR power supply Frequency selector switch 50Hz Connect to hand trimmer Variable resistor 2k 2W 60Hz Terminal No 54 and 55 connected Frequency selector switch 60Hz Connect to hand trimmer Frequency selector switch 50Hz Terminal No 54 and 55 open open circuit AVR over excitation protection circuit protector RN 2 2 AVR over excitation protection circuit protector 3 7 3 Electric System AVR is adjusted and set prior to delivery from factory Accordingly it is not necessary to
42. 36159 02101 Oil fence level switch 46813 08100 43650 02600 electromagnetic pump ISUZU part No 898068 2750 Air filter indicator 32148 03000 Oil pressure gauge 36143 03600 Tachometer with hour meter 36159 03000 mloleimarolore 21 15 5 2 2 a 5 8 alg 13 5 2 52 T 3 D n 2 5 6 5 References SDG25S 8E1 SDG45S 8E1 Oil pressure sensor 44365 00300 des for oil pressure gauge ISUZU part No 898027 4560 Water temperature gauge 36145 06800 ISUZU part No 898023 7170 ISUZU part No 892146 8300 Barometric pressure sensor 44328 21500 i ISUZU part No 897217 7780 Ammeter for battery charge 46154 15300 Emergency stop switch 44336 03001 ISUZU part No 894402 5000 There is a case that the part number is changed such as modification Please refer to the parts catalog part number of the latest 5 7 This text book contains the most recent information available at the time of printing and the contents of the list are based on information in effect at that time and are subject to change without notice HOKUETSU INDUSTRIES CO LTD STH FLOOR SHINJUKU SAN EI BLDG 22 2 NISHI SHINJUKU 1 CHOME SHINJUKU KU TOKYO 160 0023 JAPAN TEL 81 3 3348 7281 FAX 81 3 3348 7289 Copyright C 2013 HOKUETSU INDUSTRIES CO LTD AIl Rights Reserved NSG 0060 PRINTED IN JAPAN Sep 2014 AIRMAN HOKUETSU INDUSTRIES CO LTD
43. 5 15 P0336 14 P0340 P0380 45 P0404 44 P0409 294 P0521 294 P0522 294 P0523 35 P0563 53 0601 154 P0602 153 P0604 51 P0606 njector Circuit Cylinder 2 njector Circuit Cylinder 3 njector Circuit Cylinder 4 ngine Coolant Over Temperrature Condition ngine Overspeed Condition urbocharger Boost Sensor Circuit Low urbocharger Boost Sensor Circuit High rankshaft Position Sensor CKP Circuit rankshaft Position Sensor CKP Circuit Range Performance amshaft Position Sensor CMP Circuit low Plug Circuit xhaust Gas Recirculation EGR 1 Control Circuit Range Performance xhaust Gas Recirculation EGR 1 Sensor Circuit ngine Oil Pressure Sensor Performance il Pressure Sensor Circuit Low Input il Pressure Sensor Circuit High Input ystem Voltage High nternal Control Module Memory Check Sum Error ontrol Module Programming Error nternal Control Module Random Access Memory RAM CM PCM Processor CO CO C O m 4 17 4 Troubleshooting 2 2 2 2 3836 PO6OB Internal Control Module A D Processing Performance 0409 P0615 Starter Relay Circuit BB P0641 ensor Reference Voltage 1 Circuit S P0651 Sensor Reference Voltage 2 Circuit E E P0685 CM PCM Power Relay Control Circuit Open P0687 CM PCM Power Relay Control Circuit high P0697 lt Reference Voltage Circuit PO6AF EDU Injector Custom IC 56 NUN 19 E 55 56 a NN EM 77 7727 Posar EDUiecerCusomicC
44. A LL UC AR E ue up M ow tu ue dar Ao WUCOE AR Ra P EXC 2 2 22 CES UD ELEC PES DAR ae RE a Me dl Am ML C 354 eg NONE LTEM rods 2 2 0 MU NE t Xr A rer rr ES n AIRMAN SERVICE MANUAL ENGINE GENERATOR H8 SGp9uS 139 SG790S 30IAH3S HOKUETSU INDUSTRIES CO LTD Preface This service manual explains about the cautions for maintenance jobs and is to serve a guide for the electric system and troubleshooting for service personnel Fundamental matters and other things already mentioned in the Instruction Manual and the Parts Catalogue are omitted to avoid duplication Therefore for the operation and handling of this unit we request you to refer to the instruction manual and caution plates and further for the structure and components of the unit please refer to the Parts Catalogue separately to be supplied with the unit If you should find any description which does not coincide with the instruction manual and parts catalog we request you to make sure to start the job after clarifying it service personnel is required to safely take quick and proper countermeasures as well as to use correct technology of maintenance in case of field services and periodical maintenance
45. CV Feed pump 5609040 Suction control valve SCV 5609042 3 Electric System Fuel temperature FT sensor The fuel temperature FT sensor is installed onto the supply pump and the thermistor changes the resistance according to the temperature The resistance is low when the fuel temperature 1s high and is high when the temperature is low The ECM energizes the voltage 5V SG09054 to the fuel temperature FT sensor through pull up resistance and calculates fuel temperature based on change of voltage to use for various controls such as supply pump control etc If the resistance is low temperature is high the voltage becomes low if the resistance is high temperature is low the voltage becomes high Removal Do not replace the fuel temperature FT sensor If it is faulty replace it as supply pump assembly Common rail Pox O The common rail receives fuel from supply pump holds a the common rail fuel pressure and distributes fuel to each cylinder The common rail has common rall Common rail S pressure sensor and pressure limiter pressure sensor M Common rail Note For common rail replacement procedure refer to Tie Engine section 1n the service manual limiter 5614151 The common rail pressure sensor is installed onto common rail detects fuel pressure 1n common rail converts the pressure into the volt
46. GR No power exists during usual operation When preheating interior contact in ECM is ON and it ee eee terminal Glow lamp connects ground to send power Thus glow lamp glows When it starts automatically it makes glow lamp glow CNii3 CN1 14 B W CN1 1 CN1 16 G W CN1 17 G R Starter cut relay SR coil Monitor lamp CN3 7 terminal Water temperature lamp Monitor lamp CN3 14 terminal Oil pressure lamp Tool E IDSS No 3 No power when starting After starting engine speed rises and exceeds 750min interior contact in ECM 1s ON and it connects ground to send power Thus starter cut relay SR functions to cut power to starter motor No power exists during usual operation When engine coolant temperature rises up to emergency stop level interior contact in ECM is ON and it connects ground to send power Thus engine coolant temperature rise emergency stop lamp glows Emergency stop lamp lighting temperature 212 F 100 C No power exists during usual operation When engine oil pressure drops down to emergency stop level interior contact in ECM is ON and it connects ground to send power Thus engine oil pressure drop emergency stop lamp glows Emergency stop lamp lighting pressure 14 3psi 0 098M Pa Tool connection terminal CAN communication CN1 18 B W With connection of diagnostic service tool it is possible to terminal diagnose eng
47. I 10A davoga HJIIMS ONV JANYd LNAWNYISNT es N V gt em 007 008 062 gt G 009 1 4 Specification 1 SDG45S 8E1 9 LLIEIV IWINAWNOG Ad3l11VvV8 AN 3 1 6501 4NVI 13d CORO 00 gr DNI 1002 NI Vdd ANVL I VIN3 ANO8IAN3 0 4004 40 WOLLOd OL 80 E l 2 u 2 cw Le eee 41 CSE ANVI TVLINSWOUTAN BE 971 D Jo s w 5 90 4311 81 HO 600 t9 6 t9 86 S310H 51 8 24 7 124 Nivad 1303 NIVEG 110 3NISN3 el M YSLVM SC 6c 8 28 131NT 1304 903 eme eem 8 t JNHni3H 1304 804 v J gt EJIV3H ONY alle _ Ad31IVS 804 S310H A uem ee NE ALTAYUD 30 U31N32 eomm NOLIN 4015 AON3OUJN3 X Ie oj 6 md ka LELELII lle ll anya 1051502 5 EE 2 1 IndlfO HOIIMS 83124115 39 110 dqHVOS 211 5 L3NNOS JHL NI
48. It is important that service personnel should have proper and sufficient knowledge about the structure and function of the unit and should be well familiar with such technique mentioned in them Regarding the part numbers mentioned in this manual we request you to refer to the Parts catalogue separately supplied together with the unit because the parts numbers in this manual are sometimes changed Copies of this service manual are intended to be distributed to limited numbers of our customers The unauthorized reproduction or distribution of this service manual is prohibited Table of Contents 1 Specification 1 1 1 1 Specifications 1 1 1 2 Outline Drawing 1 3 1 3 Internal Components 1 7 1 4 Instrument Panel 1 8 1 5 Protection Device 1 9 1 6 Terminal
49. Ltczcecieezc Varistor Voltage selection switch position 480 277V G14043E 1 Measurement of generator armature winding wires resistance Remove all wires leading to the control panel terminal from the generator and measure the resistance between the wires on the generator side Please explain how to check with voltage selector switch circuit T1terminal T4 terminal T terminal T10 terminal T2 terminal 5 terminal T8terminal T11 terminal T3 terminal T6 terminal T9terminal T12 terminal 4 9 4 Troubleshooting 2 Measurement of generator field winding wire resistance Disconnect the wires D leading to the rotary Rotary rectifier rectifier then measure the resistance between the wires um LAG 3 Measurement of exciter armature winding wires resistance O A Disconnect the wires 3 three wires at center of diode 9 Le 1 module leading to the rotary rectifier and measure the i Varistor resistance between the wires 5614006 Diode module G12120 4 Measurement of exciter field winding wire resistance Disconnect 4P connector in the control panel and measure the resistance at the connector on the generator side Between J amp K terminal G12121 4 10 4 Troubleshooting C Measurement of insulation resistance of generator winding wires Measurement is performed with a 500V megger Th
50. Tachometer with hour meter 12 Voltage selector switch 3 Fuel gauge 13 Current selector switch 4 Voltmeter 14 Voltage adjuster 5 Engine water temperature gauge 15 Engine diagnosis switch 6 Panel light 16 Panel light switch 7 Engine oil pressure gauge 17 Frequency adjuster switch 8 Ammeter 18 Manual automatic selector switch 9 Ammeter for battery charge 19 Starter switch 10 Frequency meter 1 8 1 Specification 1 5 Protection Device For prevention of troubles during operation this machine is provided with various protection devices When the engine stops due to function of the protection devices and circuit breaker trips get rid of the causes of trouble referring to the trouble shooting clause and then restart operation List of protection devices This machine is equipped with the following devices the table Repair and make necessary treatment in accordance with the item Three phase Lamp display Engine Monitor Functions stops When engine oil pressure drops it functions Operating pressure lower than 14 3psi 0 098 circuit breaker trips Item Engine oil pressure drop begins to function Function rotation Under operation at 60Hz 2 070min 69Hz When air filter 1s clogged and it becomes necessary to clean or replace 1t it functions When boost temperature rises higher than 185 F 85 C monitor lamp goes on In case of abnormal rise of engin
51. adjust it unless the machine equipped with a new AVR functions abnormally If upon test operation there is any trouble such as voltage hunting adjust it according to the following procedures Adjustment of AVR 1 Start engine and adjust the frequency to 60Hz at no load operation 2 Turn the voltage adjuster hand trimmer on the instrument panel fully to the right to the maximum position 3 Under this condition turn the voltage adjuster of AVR in the control panel using a driver so that the upper value of voltage may meet the value mentioned in the following table 4 The driver slot of voltage adjusting volume of AVR should be coated with silicon caulking paste and fully sealed Adjustment of stability It is possible to adjust the response speed of generator output voltage at no load operation by the adjusting volume knob of stability 1 Turning the volume knob of stability adjustment clockwise reduces the response speed and voltage overshoot value becomes a little in the direction of stability 2 Turning it counterclockwise raises the speed and voltage shooting value becomes bigger in the direction of instability Notch position of stability adjustment volume STAB ADJ 3 10 Adjustment of V Hz characteristics As the V Hz characteristics are set at the best position any adjustment 1s not required Notch position of V Hz characteristics adjustment volume V F ADJ 8 10 Adjustment of time constant
52. age signal and sends it to ECM Voltage becomes higher as pressure becomes higher and lower as one dose lower ECM calculates the actual common rail pressure fuel pressure based on the voltage signal sent from sensors and uses it for fuel injection control etc Removal Do not replace the common rail pressure sensor If it is damaged replace it as common rail assembly Pressure limiter The pressure limiter operates to release the pressure in common rail when the pressure becomes extremely high Removal Do not replace the pressure limiter If it is damaged replace it as common rail assembly 3750 3 Electric System Injector The injector is installed onto cylinder head section and is conrtolled by ECM to inject fuel The ECM raises the voltage for operating injectors internally energizes to injector and regulates period of electric conduction of injector to control fuel injection amount and injection timing The injector replacement rewrite the ID code 1s required to ECM 1 ID code Correction value 2 QR code Product control number 5614152 Crankshaft angle sensor The crankshaft angle CKP sensor is installed onto cylinder block and produces the CKP signal when the sensor rotor passes the sensor The ECM distinguishes the cylinders by the CMP signal input from camshaft angle CMP sensor determines the crank angle and uses it to contorl fuel injection and ca
53. al and performs fuel injection amount correction high altitude correction etc by barometric pressure 5609069 Intake air temperature IAT sensor The intake air temperature IAT sensor is installed onto the intake air pipe and detects the temperature of intake air for optimum fuel injection control SG09070 8 12 b ft 10 8 16 3N m 3 52 3 Electric System EGR motor position sensor It is installed in EGR valve and detects the valve lift ite 1 amount of EGR Note Do not disassemble the EGR motor position sensor If it is faulty replace it as EGR valve assembly 5609072 Boost temperature boost pressure sensor This sensor detects boost pressure and boost temperature Boost pressure sensor changes pressure to voltage signal and it sends the signal to ECM Voltage becomes higher as pressure becomes higher and lower as one dose lower ECM calculates the boost intake air pressure based on the voltage signal sent from sensors and uses it for fuel injection control etc Boost temperature sensor 1s of thermistor type to measure temperature and to send it to ECM Installation 44lb in 5 5614156 3 58 3 Electric System Intake manifold temperature IMT sensor This sensor is installed on the intake manifold to o measure intake air temperature The sensor is t
54. ap shot displa Trouble Shooting Manual Actuator test Injector balanceinc ECM history data download x njector ID Code Actuator test Common Rail System Rail Pressure Control The ECM replacement ID code rewite of injector injector Balancinc and ECM history data download in ection Limin Multi Injection Stop Injector Forced Drive Device Control Glow Plug Rela EGR Control ECM Reflash ECM Reflash VGS Turbocharger Injector Replacement Not applicable Replace ECM DPD regeneration Not applicable Factory setting SG14161 2 Appearance 1 E IDSS 1 2 USB cable N 3 AC adapter 4 Data link cable Connection to the actual unit X Diagnostic service tool connector 16 poles is provided at the left corner in the control panel Refer to photograph of 4 6 2 5613099 4 19 5 References 5 1 Generator s Winding Wires Resistance Value At the temperature of 68 F 20 C 0 360 Voltage selection switch T1 T2 T1 T2 position 480 277 T2 T3 T2 T3 T3 T1 T3 T1 Generator armature winding wires Generator field winding wire Exciter armature winding wires Exciter field winding wire Auxiliary winding wires 5 2 Forced Excitation Method 1 Run the generator at the rated r p m 2 Disconnect the field connector in the control panel and apply the battery voltage to the exciter winding wire J and terminal of battery K and terminal of
55. ating TT 4 E 1210 seconds 8 seconds 10 seconds 8 seconds 10 seconds Overcrank warning lamp G13072E 3 82 3 Electric System 3 4 4 Sequencer PLC Programmable Logic Controller Part number 46879 65300 qe T g E i 4 COMETA beer 25 m MITSUBISHI a 210 mesec 2 v DIM Lees ies gt 5 T R ooo Pin No ARII SG13073 1 List of functions Connection Function DC DC converter V DC24V a output terminal relay No 6 terminal PLC terminal XO relay No 5 terminal relay automatic remote starting function PLC X3 terminal and ECM 02 PLC X2 terminal Air filter differential pressure When differential pressure indicator functions it indicator makes i
56. battery SG14058 3 Magnetize for 1 to 2 seconds then remove the wires and check if voltage 1s generated Note Thickness of lead wires between battery terminal and connector should be the same thickness as exciter field winding wires J and K wires It is dangerous that the wire may be overheating they are too small 1n thickness Generated voltage from forced excitation at 480 277V V Voltage generated V at the temperature of 104 F 40 C SDG258 8E1 SDG458 8E1 Battery 12V Battery 12V 330 970 The generating voltage is only for reference because it will change due to the ambient temperature 5 3 Idling Revolution Per Minute It is set to the figure in the table by engine governor Revolution per minute 1 000 ol 5 References 5 4 Generator Wiring Diagram SDG25S 8E1 three phase single phase _TERMINAL PLATE 51 M 3 d CBS CBA 3 98 E 2 8 Voltage Selector SVV i Voltage Winding Connection RECEPTACLE ssf AS PANEL R T 3 Phase 4 Wire Star exerce nes n 8Phase480 277V 4 34 T EN G 35 T4 3 36 T D 5 4 10 N20 T12 SUN BEEN 9 2 L O O 4 2 AVR 2 1 1615 9 10 1213 LAA AN IN AAAA 45 CN1 6P
57. capacity it makes warning lamp warning lamp PLC terminal PLC COM terminal 1 15A fuse When engine starts automatically interior contact BY1 i BY1 of PLC unit is made ON for 10 seconds to 0 perform idling operation for protection of turbo 2 It transmits preheating completion signal to PLC p Monitor lamp glow lamp X6 terminal through SD1 diode from glow lamp circuit Check the timing of cranking diode 3734 3 Electric System 3 4 5 DC DC Converter DC POWER SUPPLY Part number 46872 01300 OUTPUT V NC V DC24V 0 3A INPUT V V GR DC12V 1 2A Pin No 5613074 V P3 PLC terminal It DC24 power to PLC PLC terminal Grounding EAE PLC YO terminal It supplies DC12V power to DC DC o ov N Grounding N JPLC COM terminal 3 85 3 Electric System 3 4 6 Power relay 1 Part number 46177 08500 X7 relay AC220V Part number 46177 08300 STX relay DC12V m i bk eei PLC terminal It sends generation signal to PLC X7 terminal from X7 i Control panel T9 terminal Power supply XLI X7 relay coil Control panel T7 terminal Power supply for X7 relay coil 2 List of tuncion STX relay Starter relay No ernal When it detects preheating completion at PLC X6 terminal it makes starter
58. e water temperature 1t functions Operating temperature 212 F 100 C This lamp goes on when operator fails to start engine during automatic operation mode When more condensate fuel engine oil and coolant than 1 3 of capacity 1n the oil fence 1s accumulated monitor lamp lights Excessive rotation Clogging of air filter When engine rotates excessively it 4 Boost temperature rises 42 Water temperature rises Overcrank O1l fence Overcurrent or short circuit Engine troubles When the monitor lamp lights in the oil fence immediately drain it For the capacity of the oil fence refer to 1 1 Specifications To protect environment do not drain it directly into rivers When starter switch 1s ON the monitor lamp glows and goes off after preheating 1s performed In case of overload or short circuit accident 1t functions Refer to 4 6 Engine Trouble Diagnosis Function a 179 1 Specification 1 6 Terminal The unit is equipped with three phase output terminals ground terminal GFCI receptacles and auxiliary receptacles mentioned in the following table SDG255 8E1 SDG458 8E1 Item Bolt size and length Quantity Bolt size and length Quantity L1 L2 L3 terminal L1 L2 L3 terminal 8 1 25 M14 X P2 0 Three phase output terminals N terminal M8 x P1 25 M14 X P2 0 1 M8X P1 25 M14X P2 0 1 3 Onipnt
59. e of blinking pattern Flash code 1 2 1 2 9 Case of code 123 Sig vg vag AI 0 9 4 05 O 9 A A A A f 4 1 v v g paw VV VV V Vd VV O code 6 poa y O3 225 e 3 2 e yO poa pos 3 poa ON 0 6 0 6 0 6 seca Sec 2 Sec 4 Sec 24 oc Cse aa OFF SG09079 2E Long interval blinking approx 1 2 seconds Short interval blinking approx 0 3 seconds 4 14 4 Troubleshooting 2 Display of diagnostic trouble code DTC by diagnosis lamp Only when diagnostic trouble code DTC occurs during engine operation diagnosis lamp is ON During engine stop diagnostic trouble code DTC displays both present and past diagnostic trouble code DTO by diagnosis lamp blinking pattern 3 In case that past diagnostic trouble code DTC is memorized It displays three times memorized flash code In case that more than two flash codes are memorized it displays them three times each numerical order After they are displayed one round they are displayed in numerical order again This display continues while diagnosis switch is being pressed 4 In case that no diagnostic trouble code DTC is memorized While you pressing diagnosis switch diagnosis lamp repeat continuously the lighting 0 3 seconds 2 4 seconds off 5 Reading diagnostic trouble code DTC by diagnostic service tool Diagnostic trouble code DTC can
60. e situation is considered to be satisfactory if the measurement produces a result of 1MQ or more while a result of less than that value indicates failure 1 Measurement of insulation resistance of generator armature winding wires Disconnect all wires leading from the generator to the control panel terminals and short circuit them then measure the insulation resistance between the wires and the generator body Method of periodic inspection gt Procedure o GROUND D Remove the load side cable from the output terminal board 2 Remove the ground cable of the terminal N and terminal GROUND Bonnet 040180 1 131009 3 Remove the AVR connector 1 inside the generator control panel 4 Switch ON the three phase breaker 2 and then measure each insulation resistance between the terminals L1 L2 L3 terminal and bonnet 5 Insulation resistance when measured with 500V megger tester must be above 1M Q 0 After finishing the measurement of insulation resistance re connect the ground cable of the terminal N and terminal GROUND WARNING After making sure that the insulation resistance of the generator is higher than 1 9 be sure to re connect the cable of the terminal N and termi
61. e than 100k Tester range X k Cooling fan Dumper plate Diode module WM v 7 i 4 Oe primm Exil qq ny UE E FERE a imum N VE 777 d TMM 222 Varistor SG12120 Rotor ass y Generator field winding wire Exciter armature winding wires SG14008 Diode module rg Diode J Pa E z S l S Exciter armature winding wires 5 K SG09107 1 4 13 4 Troubleshooting 4 6 Engine Trouble Diagnosis Function With regard to this electronic governor engine Common rail electronic control fuel injection engine engine controller ECM is equipped with trouble diagnosis function 4 6 1 Engine trouble diagnosis 1 Check and confirmation of trouble When engine fails diagnosis lamp 1 on monitor panel lights For the details of the trouble press diagnosis switch 2 and then it displays trouble conditions with blinking pattern flash code Pr gt ocedure 08 D Turn starter switch to RUN position Fault diagnosis lamp 1 goes out after lighting for 3 seconds for the lamp bulb check out 2 Continue pressing diagnosis switch 2 LL START OFF MANUAL AUTO 3 When engine is in trouble it displays trouble conditions with blinking patterns of the diagnosis lamp 1 while diagnosis switch is pressed A130961 Exampl
62. eel and generator coupling rotor 2 6 2 3 4 Assembly of flywheel housing and generator main unit frame stator 2 7 2 3 5 Mounting of generator main unit and engine on frame 2 8 2 3 6 Changing the bearing in the generator main unit 2 11 2 3 Replacement of rotary rectifier wiring board 2 12 2 4 Check and Cleaning of the Supply Pump Strainer 2 13 2 5 Air Bleeding 2 13 2 6 Engine Maintenance Standards 2 14 3 Electric System 3 1 3 1 Location of Electrical Appliances 3 1 3 2 Electrical Appliances of Generator 3 2 3 2 1 Rotary rectifier 4 3 2 3 2 2 AS Ammeter change over switch
63. emperature sensor Barometric pressure seor VO Power supply for barometric pressure sensor DC5V CN1 58 CN1 59 CN1 60 CN1 61 3720 3 Electric System color Wie B Gunn SS CN1 63 INIL ovre Boost temperature boost It detects intake air temperature and pressure in intake CN1 65 B R pressure sensor manifold __ a NL It detects manifold air temperature of unit under operation In order to optimize fuel injection control with ECM it detects manifold air temperature at unit in use In front of engine air intake device Manifold air temperature CN1 68 W R Sensor CN1 69 It detects engine oil pressure Pressure detecting voltage signal 1s high when pressure is high and it is low when pressure is low It detects barometric pressure Barometric pressure It counts barometric pressure from voltage signal and it Oil pressure sensor OUT terminal CN1 71 W sensor OUT terminal corrects fuel injection volume high altitude compensation It detects 1ntake air temperature of unit under operation Intake air temperature In order to optimize fuel injection control with ECM it sensor detects intake air temperature at unit in use In front of CN1 72 Lg engine air intake device CN1 7 CN1 74 CN1 75 CN1 76 CN1 77 Tool E IDSS No 14 terminal terminal G d sensor Power supply for engine
64. ences ENGINE HARNESS 0 75 B R 22 129 CN 0 0 ENS 1 NS ed celo o 73 uw Cc C9 m c Un CN2 CN2 Spb LENE VCC 0 1 0 5 CN9 19 0 5R CAM ANGLE our 05T CN9 05 05W SENSOR ENT 0 5B CN2 0 75B WL CN9 06 MEME 0 5 B W laa COMMON RAIL SCC 638r ECN3 13 PRESS SENSOR T 1 rr SHIELD LINE 0 75L CN11 01 CN2 sce CNL 04 EGR MOTOR yp 0750M CN11 03 POSITION SENSOR wi 0750 CN11 02 CN11 05 SHIELD LINE CN2 eW LEN 0 5R CRANK ANGLE UT E 0 56 r B CN9 02 fw SENSOR CNBLLML L 0 5W B CN9 01 0 5B 311 0 75B CN9 02 0 5 B W T 0 75Y G L CN12 01 FUEL TEMP PA c e CN2 0 75G CN12 05 0 5R B 355 WATER TEMP v7 0 75W BT 0012 04 CN 2 984 i 0 75R CN12 06 0 5W B CN2 CN2 CN2 1110 8 5W R CN11 08 103 0 8 5W B CN11 07 119 0 85W L CN11 06 12111 25W 1 25W CN10 01 CN 10 05 1 25W CN 10 02 TE CN10 06 CN10 03 ots 1 25R CN10 04 118 CN10 08 05 0 8 5 RW 113 0 8 5 R W CN 12 02 0 858 B 0 8 5 R B CN 12 03 27 ENGINE HARNESS 0 7 5W R U DC MOTOR 0 7 5W L W 1 25 B W 1 25R 1 25B 1 25 L R 0 7 5 R W 0 7 5 R B A130921 5 References 5 6 List of Consumable Parts and Elect
65. ey OFF ON Pre Glow After Glow gt Pre glow time sec After glow time sec Glow lamp time sec D e o 8 0 6 0 4 0 2 0 0 0 When starter switch is ON glow relay functions for a certain time in accordance with engine water temperature After engine starts glow relay functions for a certain time in accordance with engine water temperature Pre glow time Water temperature C After glow time Water temperature C Glow lamp time Water temperature C G14143E 3 25 3 Electric System 3 4 2 Monitor lamp Part number 46870 47901 LED3 OIL PRESSURE LED8 OVERSPEED LEDS AIR FILTERE LED BOOST TEMPERATURE DIAGNOSIS 2 PE zm T1 CAU m mo F TEMPE C x OVER M gt N CONTAI 17161514 1312 1110 C rz mma gm 4o EX 32 9 8765 4321 CN3 SG14144 1 External schematic diagram PLC J Kx N a J gt COMO COMI C4 lt COM2 LINA LSV S OLAV lt cn S lt lt o o fen is no lt MONITOR LAMP SR W cN3 10 DIAGL GNI 6 0 9L B cN3 6 DIAGNOSTIC OILPL CNI 17 UN CN3 14 OIL PRESS GLOWL CNI 11L e 057 cN3 5 GLOW BOOSTL CNI 7
66. ft the engine mounted onto the generator main unit leaving the shims in the four places after adjustment 0 Remove the assembly level plates and place the cushion rubbers in their respective places on the frame Insert or place adjusting shims on the cushion rubbers of both engine and generator main unit 7 Place the engine with the generator main unit on the cushion rubbers and fasten it with nuts Make sure to coat the bolts with anti corrosion agent Metal Clear which are tightened for cushion rubbers 8 points consisting of upper side 4 pieces and under side 4 pieces E Engine generator C L Bracket Cushion rubber Engine mounting Frame position SG13058E X Before installing cushion rubbers place assembly level plate on the position of generator main unit and engine connection and then adjust the clearance between engine mounting bracket and assembly level plate Assembling level plates size Unit in mm 1 4 84 1 4 84 Assembly level plate SG13088E 2 9 2 Overhauling 2 Check the gap between the cooling fan and fan shroud IMPORTANT Maintain an adequate gap in both the vertical and horizontal directions f the fan is mounted incorrectly so that it leans toward one side wall of the shroud leading to a smaller gap in one direction the fan may produce abnormal noise due to rubbing against the shroud during starting or stopping and may also overheat Gap size U
67. gle tighten M8 Ath time 21 29 300 0 0157 0 4 normal temperature Valve clearance 0 0157 0 4 normal temperature Fiingorder ____ 1 8 4 2 Injection timing BTDC Electronic control Nozzle injection pressure psi MPa Compression si MPa 442 3 04 i Rotation speed 200rpm 200min Tightening torque of head bolts kgf Temperature for oF 180 82 start of release temperature Valve lift in mm 0 37 9 5 3 Electric System 3 1 Location of Electrical Appliances 16 1 18 19 20 VIEW A 1 2 4 6 d 8 9 Fuse 10A Fuse 15A Fuse 20A Auto start unit Thermal relay Frequency selector switch Current transformers Three phase circuit breaker Voltage selector switch m Automatic voltage regulator AVR 1 m Terminal plate SDG258 8E1 VIEW B 5614133 Fuse 60A Engine controller ECM MR1 relay Glow relay Barometric pressure sensor Starter relay Fuel pump relay Starter cut relay MR2 relay Circuit protector CP 3 Electric System 3 2 Electrical Appliances of Generator 3 2 1 Rotary rectifier Rotary rectifier wiring board is connected to the varistor for the protection of rectifier while direct current is supplied to the generator field windings by three phase full wave rectification Cooling fan Dumper plate imm An Y Ed S mme Ro
68. he period required for glow pre glow after glow and operates the glow relay and QOS indicator lamp QOS system allows to make the starting at cold weather easier and reduce white smoke and noise at starting When turning the key switch to ON the ECM detects the engine coolant temperature by signal from engine coolant temperature ECT sensor and changes the period for glow so that the proper starting conditions can be achieved all the time Also after glow function allows to stabilize idling immediately after starting 3 15 3 Electric System 3 3 5 Diesel oxidation catalyst DOC Performing resolved into water and carbon dioxide by a chemical change in the catalyst HC hydrocarbons in the exhaust gas CO carbon monoxide DOC is an exhaust muffler of the oxidation catalyst combination No maintenance of cleaning items or exchanged Exhaust IN DOC drain 5614141 3 16 3 Electric System 3 4 Electrical Appliances of Engine 3 4 1 Controller ECM SDG25S 8E1 Part number 44390 04200 SDG45S 8E1 Part number 44390 04300 ald A L 116 cy 1 CN2 40 pins 32 38 1 24 20 1 4 ns 40 9118 117 116 115 14113 12111 1019 817 6 106 107 108 109 110 111 112 113 41140 98 99 117 1118 37 JE 62 91 91925312495 o6 7 811 977811117678 74 ro 72111 709 en 87186 e5 84168 67 68 89 8 33 35 1
69. heel and the generator coupling p h Bolts for connection of the engine flywheel housing and the generator main unit frame 5 Fan guard Fan guard should be fitted at the angle shown for avoidance of its contact with DOC diesel oxidation catalyst G14130E 2 3 2 Overhauling 2 Procedures of disassembly D Remove cables from battery terminal 2 Remove brackets or fittings for muffler air filter and etc equipped on the bonnet 3 Remove top cover and dismantle such parts on the bonnet so that generator main unit can be pulled out 4 Remove cables and pipes 5 Remove mounting bolts of generator main unit and engine 0 Remove engine cooling fan guard and fan shroud 7 If necessary remove radiator radiator hoses fuel tank and battery Insert an angle timber under the engine housing for inclining the engine 9 Separate engine housing and generator stator Separate engine flywheel and generator rotor 5613055 If insulation film is damaged by contact of stator and rotor during disassembly of generator main unit perform varnish drying treatment to such portion 3 Demounting stator and rotor at the same time from engine When demounting stator and rotor of generator main unit at the same time from engine place the generator main unit with the engine coupling face upward and pull out the rotor At this time stabilize the generator main unit frame
70. hekSum POBAF EDU Injector Custom IC Communicaton ne 227 P1098 Fuel Rail Pressure FRP P1097 Boost Temperature Sensor CircuitLow 213 P1098 Boost Temperature Sensor Circuit High 34 P1261 Fuel injector Group 1 Supply Voltage Giron 34 P1262 Fuel injector Group 2 Supply Voltage Girst 4s P1404 Exhaust Gas Recirculation EGR 1 Closed Position Performance s 6 Wicrmematiue 00707 s P1606 SWiCtimemarCommunestonUmefaue i E 158 m NM re 7 M T NEN 156 P2228 Barometric Pressure P2229 BaromeriePressureeCieutHigh ea uos cANBusMafundion 4 18 4 Troubleshooting 4 6 4 Diagnostic service tool E IDSS E IDSS Engine Isuzu Diagnostic Service System Using E IDSS it is possible to diagnose electrical failure of engine control system and check the system by reading diagnostic troubles codes DTC and referring to troubleshooting manual and retelling injection ID code download history of ECM and checking and confirming engine various control values Permit to use E IDSS 16 required and certified by engine manufacturer User ID and password are required 1 E IDSS of the function Diagnostic CAN Diag nostics Trouble Code Data Displa CAN Contoroller area network Real time displa Sn
71. hermistor type The resistance the sensor changes as the temperature changes 22222222221 Installation SG14157 m x 15lb ft 203 Water temperature sensor Refer to 3 4 20 Engine oil pressure sensor Refer to 3 4 23 3 54 4 Troubleshooting 4 1 Repairing Procedures When performing failure diagnosis pay special attention to the followings observing general cautions 4 1 1 Safety caution 1 Removing such cap and or plug for receiver tank fuel tanks and pipes where pressure is loaded stop the machine and relieve all the interior pressure Install measuring instruments connected firmly 2 When doing the job with co worker s together make sure to give signal to the other person s and do not allow other persons to come near to the job site 3 Take care not to touch hot portions and not to be involved in turning portions 4 1 2 Caution during failure diagnosis 1 Do not make haste to disassemble the unit If the unit 1s disassembled urgently D You may disassemble the other portions which are not related with the trouble 2 The cause of trouble may be missing The unnecessary reparations require more spare parts and man hours and reparation costs will increase more What is worse you will lose reliance or trust from clients operators and users Therefore it is absolutely necessary to investigate the trouble more careful
72. ine control system and to check system CN1 19 00 0 0 0 0 poo 00000 CN1 20 3 Electric System Line 1 no Connection Function When power 1s sent to CN1 24 terminal 1t works main relay MR2 Thus main relay MR2 is switched and CN1 21 Y R Main relay MR2 coil when power is supplied to CN1 2 and CN1 5 terminal voltage is applied to fuel pump relay FR to operate the pump 2 22 CN123 R W 15A fuse Switch ON starter switch to input ACC signal Preheating starts External input terminal for engine emergency stop When option connector is placed ON between No 3 and No 4 terminals engine is brought to emergency stop No power exists during usual operation When frequency adjuster switch is placed DOWN it is switched ON Engine speed goes down Engine speed fall limit Down to low idle speed No power exists during usual operation When placing frequency adjuster switch UP or DOWN Frequency adjuster it is switched ON Combination of CN1 26 and CN1 28 terminal switching makes engine speed UP and DOWN No power exists during usual operation When frequency adjuster switch is placed it is switched ON Engine speed goes up CN1 24 External input connector No 3 terminal option CN1 25 B R Frequency adjuster DOWN B Y CN1 27 G
73. ion Fluid level in oil fence rises ON When oil fence level switch 1s ON for 10 seconds interior contact of Y5 terminal is switched ON and warning lamp glows Warning lamp lighting capacity More than 1 8 of blank capacity 3 29 Y 3 Electric System Line Connection Function color Remote start stop switch Via external output terminal plate A1 terminal Generator unit T7 terminal Generator unit T9 terminal Remote start stop switch connector terminal With auto start unit ASU CN6 4 terminal power supply input remote start stop switch is ON XO relay works Thus the relay 1s switched power 1s sent to PLC unit via DC12V DC24V converter And XO relay works and voltage 16 applied to PLC unit XO terminal Then 2 seconds later interior contact of Y1 terminal 1s ON and preheating starts Then when X6 terminal detects preheating finished interior contact of Y2 terminal is ON and starter motor begins cranking and start engine l Stop Remote start stop switch 1s OFF to make XO relay switch OFF but power is supplied to PLC unit itself for 10 seconds with power input from CN5 1 terminal Then after engine performs cooling operation for 10 seconds interior contact between COMO YO terminals is OFF and engine is brought to stop In case pushing emergency stop button When pushing emergency stop button on operation panel power supply of auto start unit CN5 1 terminal 1s shut down
74. ker and single phase receptacle on the control panel 4 Turn the operating selector switch to position on the control panel The unit will be under stand by and start once the start signal is sensed 3 Function When start signal activates stand by conditions it starts the generator engine after preheating When stop signal activates 1t continues 10 seconds cooling down operation to stop engine and the machine 1s placed again stand by conditions Voltage Time Starting ue Check 2seconds 2seconds 10 seconds Stop Start signal Start command Engine starts Voltage assured stop signal Stop signal Stand by 5613071 In order to start generator unit surely cranking operation is repeated after it stops for 8 seconds in case that engine will not start even after cranking operation for 10 seconds In case the engine will not start even after cranking operation 1s repeated three times trouble signal goes on showing difficulty starting Incase that the lamp OVERCRANK goes on switch off power supply once pressing the button EMERGENCY STOP Then after releasing the button EMERGENCY STOP get rid of the cause of trouble why engine would not start Try no load operation 5 to 10 minutes once a week Start signal ON 2 seconds Power supply 2 seconds 2 seconds lt 2 seconds Preheating TEL Preheating Fyr Prehe
75. l Overcrank Auto start unit CN7 3 terminal Air filter ECM CN2 88 terminal Overspeed ECM CN1 17 terminal Oil pressure Tachometer Engine speed detection terminal Tachometer Grounding terminal for engine speed detection It inputs start stall signal No power exists during usual operation Upon auto start interior contact of auto start unit Y2 terminal is ON When it outputs start signal to starter relay X3 terminal detects engine start speed more than 750 min The engine start will not start even after three times trial interior contact of auto start unit Y4 terminal is ON and output start stall signal to monitor lamp CN3 11 No power exists during usual operation When air filter differential pressure indicator 18 ON for 10 seconds interior contact of auto start unit terminal is ON and air filter clogging warning lamp glows No power exists during usual operation When engine speed rises up to emergency stop set speed interior contact of ECM CN2 88 terminal is ON and it connects ground to send power Thus overspeed warning lamp glows Emergency stop set speed 2 070min 69Hz No power exists during usual operation When engine oil pressure drops down to emergency stop set pressure interior contact of ECM CN1 17 terminal is ON and it connects ground to send power Thus engine oil pressure drop emergency stop warning lamp glows Emergency stop lamp lighting pressure
76. lamp repeat continuously the lighting 0 3 seconds 2 4 seconds off D Switch OFF diagnosis switch Turn off 12 Switch OFF starter switch 3 While connecting the diagnostic service tool E IDSS can be delete by the tool 4 16 4 Troubleshooting 4 6 3 List of diagnostic trouble codes DTC Flash code is code that indicates the fault condition blinking pattern of lamp failure diagnosis diagnosis lamp DTC is a code that can be read by connecting the diagnostic service tool E IDSS LL Excerpted from ISUZU Engine repair manual X Engine failure Engine stop item Flash code DTC DTC description E rankshaft Position Camshaft Position Correlation uel Rail System Pressure Too Low 16 225 0016 0087 151 P0089 Fuel Pressure Regulator Performance 247 P0091 247 P0092 227 P0093 Fuel System Leak Detected 214 214 22 22 23 23 211 P0097 P0098 P0112 P0113 P0117 P0118 P0182 ntake Manifold Temperature IMT Sensor Circuit Low ntake Manifold Temperature IMT Sensor Circuit High ntake Air Temperature Sensor Circuit Low ntake Air Temperature Sensor Circuit High ngine Coolant Temperature Sensor Circuit Low ngine Coolant Temperature Sensor Circuit High uel Temperature Sensor Circuit Low 211 P0183 Fuel Temperature Sensor Circuit High 245 P0192 245 P0193 271 P0201 Injector Circuit Cylinder 1 2 2 P0202 273 P0203 2 4 P0204 542 0217 543 0219 2 0237 2 0238 15 P033
77. lculate the engine speed These contorls are performed usually based on signal However it 15 done based signal if p the crankshaft angle CKP sensor is faulty Removal Disconnect the connector and remove the 0 4in 10mm 9 mounting bolt and sensor 5614153 Installation 44 b in 5 m 1 Sensor rotor 2 CKP sensor 3 Rotating direction 83 51 3 Electric System Camshaft angle CMP sensor The camshaft angle CMP sensor is installed onto the gear case cover of engine front and produces the CMP signal when the cam portion of camshaft passes the sensor The ECM distinguishes the cylinders by the CMP signal input from camshaft angle CMP sensor determines the crank angle and uses it to contorl fuel injection and calculate the engine speed These contorls are performed usually based on CKP signal However it is done based on CMP signal if the crankshaft angle CKP sensor is faulty Removal Disconnect the connector and remove the 0 4in 10mm mounting bolt and sensor SG14154 Installation Apply a coat of engine oil to the O ring p em 44 b in 5 1 CMP sensor 2 Protrusions 3 Timing chain sprocket 4 Rotating direction Barometric pressure sensor The barometric pressure sensor is installed into the control panel and converts the barometric pressure into voltage signal The ECM calculates barometric pressure by voltage sign
78. les When any diode is judged to be in disorder d during the inspection 1 1s necessary to replace eee a diode module Diode module d E gt a a a a D o is amp is E cc m m a am Forward direction Forward direction Reverse direction Reverse direction resistance resistance resistance resistance SG08004 1E Testing method of resistance of diode module Direction Tester lead pole Tester Direction Tester lead pole value Sod de Red lead Black lead f diod Red lead Black lead D wire wire 7 pL wre wie Forward less than Reverse more than direction LB 100 direction OV OW 3 8 3 Electric System 3 2 2 AS Ammeter change over switch Part number 46913 01000 OFF L3 L1 L2 5613061 5606068 374 3 Electric System 3 2 3 Voltage selector switch SDG25S 8E1 Part number 46917 00800 JL EE OIOI PEERS Ed d dau d ld 5614134 oystem of contacts arrangement 3 3 19 480 211V 250 139V 240 120 o 3 og de 180 22 eee 5 p A Gic d TL je 26 N re MA s 520221202 2 ae 5614135 lt a
79. lty Faulty controller ECM or ee eee functions well cable connection X Please locate engine defective portion referring to 4 6 Engine Trouble Diagnosis Function For the details of engine error please take necessary measure in accordance with Engine repair manual by engine maker 4 4 2 At start up starter rotates slowly x Check battery voltage and Faulty Battery specific gravity too Re charge and or supply specific gravity low or electrolyte shortage water replace Normal Volt more than 12V Gravity more than 1 26 Check battery cable Normal When starter switch is placed at the START position the battery is not normal if B terminal voltage decreases by 10V 4 7 4 Troubleshooting 4 4 3 It will not speed up to rated speed Filter clogging i Check air filter Faulty air filter Clean or replace it Supply pump strainer Replace strainer clogging Normal Check fuel filter and Filter clogging i Fuel filter and pre filter pre filter faulty Normal ica e air bleeding electromagnetic pump Replace filter Check how fuel transported Faulty filter clogging Repair pipes and bleed or if any air mixed Fuel pipes faulty alr Normal Peery ac Got fee OV te eke VASA peg ete 1 Check supply pump and Faulty Faulty supply pump or injector pope Normal 1 1 Faulty
80. ly in advance and to follow the required procedures for failure diagnosis 2 Ask the clients about the trouble in details In order to prevent misunderstanding and incorrect judgment about the trouble it 1s necessary to ask users or operators about the following questions D Is there any other disorder than the trouble he has informed 2 Anything abnormal occurred before this trouble 3 Did this trouble happen unexpectedly Or the unit had been operated in bad conditions before 4 When and how did this trouble occur 5 Had he repaired the unit before this trouble occurred 0 Did he not experience similar trouble before 3 Inspection items before starting diagnosis Sometimes such trouble may be caused owing to routine mishandling of the unit Before starting failure diagnosis check the following items D engine runs short of engine oil or its oil is not dirty 2 Check each cable connection for any disconnection 3 Check the other portions for any damage 4 Confirmation of trouble Discuss with user s and or operator s sufficiently about the trouble As a result judge whether their judgment is based on the numerical comparison or sentimental basis Make him them understand well the reparation or correction you have finished Then check and confirm by yourself the cause of the trouble Note Never proceed any investigation or measurement which may cause further greater damage 5 Procedures of diagnosis When you become
81. lywheel housing Mount the engine on the vibration isolator rubbers at the frame side of engine Put angle wooden block under the engine housing and incline the engine a little SG06072 2 Install rotor D Hang the center of the rotor with jute rope and bring 224 it near to the flywheel Hd 2 Match the rotor coupling plate to the engine flywheel and then combine them tightening the coupling Ulp d connecting bolts C pe The coupling connecting bolts shall be high tensile A bolts or more Use 2 guide bolts for this job 5606073 3 Size of guide bolt M s 7 L 5605047 Unit in mm SCRE 800455881 M8 x 1 2530 M10 1 5735 Quantity PB Ib ft N m 18 4 25 0 255 36 1 49 0 500 2 6 2 Overhauling 2 3 4 Assembly of flywheel housing and generator main unit frame stator IMPORTANT Handle the stator with care after fastening the engine flywheel and generator coupling to avoid damage to either the rotor or stator Tighten the connections to the specified torque For connection of flywheel housing and generator main unit frame stator coat anti corrosion agent METAL CLEAR on the connecting faces to prevent rust and corrosion 1 Install the stator D Remove casing from stator 2 Carefully push into the stator preventing the stator and rotor from rubbing each other 3 Install the flywheel housing a
82. mber 36143 03600 TM 5 Grounding naire Connector for lighting eRe 5613081 1 Indicated pressure and resistance value Indicated pressure psi T 60 0 41 113 8 0 78 Resistance value Q 12 3 2 List of functions PinNo Linecoor Connection _ Funcin 15A fuse Power supply Detector for oil pressure B Grounding Panel light switch Power supply for lamps B Grounding 3 Lamp specifications 3 46 3 Electric System 3 4 22 Oil pressure sensor for oil pressure gauge Part number 44365 00300 M5XPO0 5 R1 8 ERU Sensor should be screwed in in the direction as shown in the figure SG14057E 1 Standard pressure and standard resistance value Standard pressure psi MPa 0 4 60 0 41 113 8 0 78 Standard resistance value Q 12 3 3 4 23 Engine oil pressure sensor for emergency stop ISUZU part number 898027 4560 Qoia C OFF in case of less than da 14 3psi 0 098 Tightening torque poem 301 41N m GND Signal Power 3 4 24 Ammeter for battery charge Part number 46154 15300 YAN Power source for lighting Alternator B terminal Power supply voltage DC12V Wiring diagram G13082E 3 47 3 Electric System 3 5 Electronic Control Engine Component Excerpted from ISUZU Engine repair manual 3 5 1 Engine component location diagram ga TWO EE MD 7
83. nal GROUND just as it was originally connected If it is left disconnected the grounding becomes imperfect so that it could cause electric shock 5614158 4 11 4 Troubleshooting 2 Measurement of insulation resistance of generator field winding wire Disconnect the wires D and leading to the rotary BOSE TO Ue rectifier then measure the insulation resistance between the disconnected wires D and the shaft 3 Measurement of insulation resistance of exciter armature winding wires Disconnect the wires 3 three pieces and short Varistor circuit them then measure the insulation resistance 5914006 between these wires and the shaft Diode module G12120 4 Measurement of insulation resistance of exciter field winding wire Disconnect 4P connector in the control panel and measure the resistance at the connector on the generator side 5614045 Between J terminal amp body 4 12 4 Troubleshooting D Checking rotary rectifier and varistor 1 How to check rotary rectifier diode module How to judge whether rotary rectifier diode module is in good order or in disorder For the details see 3 2 1 Rotary rectifier 2 How to check varistor Disconnect the wires D and 9 leading to the rotary rectifire Measure the resistance between the terminals of the varister 5 5 It is good if the measured resistance is mor
84. nd the stator tightening the connecting bolts bolts should be high tensile 7T or more 4 Remove the angle wooden block from under the flywheel housing and place the generator main unit and engine horizontally 5 Install the casing to the stator 5613057 2 Tightening torque of generator main unit frame stator connecting bolts See 4 of 2 3 1 Bolts M10 1 5 30 Quantity 12 8 IN m 18 4 25 0 260 2 7 2 Overhauling 2 3 5 Mounting of generator main unit and engine on frame IMPORTANT Perform centering carefully to avoid deviation in the horizontal leveling caused by distortion of the frame or inaccurate mounting of the generator main unit and engine Running the machine without accurate centering may cause abnormal vibrations D Generator main unit 2 Engine 3 Bracket 4 Bolt 5 Shim 6 Cushion rubber 0 Nut 5614131 2 8 2 Overhauling 1 Centering method D Mount the brackets on the engine secured to the generator main unit Use only genuine fastening bolts 2 Place four assembly level plates on the points for mounting the engine and the generator main unit onto the frame 3 Place the generator main unit with the engine mounted onto it on the assembly level plates on the frame 4 Use shims for adjustment if joint gaps are found at any of the four places where the brackets and assembly level plates are to be fixed 5 Li
85. nit in mm Fan outer diameter a 16 9 430 Shroud inner diameter b 18 1 460 Top gap Bottom gap d 0 71 18 Side gap e 0 59 15 SG05050 3 Retighten the bolts at the lifting portions as shown in the figure When assembling the bonnet after having mounted the generator unit and engine retighten the bolts for lifting the bonnet for sure Torque of bolt 1 SDG25S 5016 683 m SDG45S 110Ib ft 1503 m Coat the tips of the bolts marked with sealant ThreeBond 1212 as shown in the figure to prevent rain water from entering inside the bonnet 5612089 Coat the circumference of the bolt tip with sealant ThreeBond 1212 5 6455 8 1 5612088 2 10 2 Overhauling 2 3 6 Changing the bearing in the generator main unit IMPORTANT Use guide bolts to avoid the danger of dropping the bearing shield casing and to prevent the rotor and stator from rubbing against each other Use the guide bolts used to mount the generator main unit Do not hit the bearing outer race when installing or the bearing may be damaged The generator main unit 16 equipped with fully sealed bearing It is not necessary to supply grease But the machine life 4 years or 15 000 20 000 hours of operation may change depending upon the conditions such as vibration ambient temperatu
86. nnected properly NO Is AC voltage at AVR input 0 or lower terminal T7 T9 proper 4 2 3 Voltage fluctuates Is there any unbalance between single phase load phases Are revolutions stabilized at 1 800min 1 YES Any faulty connection found YES Looseness found in control panel NO Check whether stability of AMR is correctly adjusted or not YES NO YES Disconnect each connection between generator and control panel And when magnetized forcibly the generated voltage among phases is balanced 4 4 frequency adjuster knob Not adjustable Refer to Engine repair manual Defective resistor hand trimmer Repair Repair Use single phase load by balancing it among phases or increase generator capacity Repair adjust engine Repair Readjust Fault in generator winding wire Repair Fault in AVR 4 2 4 Load cannot be operated Generated voltage and frequency are normal YES Circuit breaker MCB is ON YES Specified voltage found at YES load NO When circuit breaker MCB is on is specified voltage found among output terminals L1 L2 L3 and N YES Any looseness in output terminals L1 L2 L3 and N connection 4 2 5 Voltage drops when load is applied When the load is applied Normal how is generator rpm Drop Check whether load starting kVA exceeds rated output of generator
87. nterior contact of PLC Y3 terminal close gt lt Cheek When oil fence level switch functions it makes interior contact of PLC Y5 terminal close Diode TP It transfers preheating completion signal to PLC X6 terminal from glow lamp circuit Check the timing anode side of cranking MP seus Noter It decides whether it 18 to be continued or stopped by detecting generation signal Six edlay Nod terminal Power supply for STX relay coil starter relay function STX relay No 4 terminal Power supply for starter relay SY X04 X05 X06 X07 P1 ge 00 DC DC converter DC12V Power supply for DC DC converter 12V When remote auto start signal is inputted it closes LOO uae XO relay and starts auto start 1 COMO PI terminal Power supply for starter relay SY P1 STX relay No 1 terminal Power supply for STX relay coil starter relay function 4 Starter switch ACC terminal Power supply for PLC unit PLC BY0 terminal ES ES 3 88 3 Electric System 09 STX relay No 5 terminal Power supply for STX relay coil starter relay function HERD MOR OT When air filter gets clogged warning lamp glows warning lamp Monitor lamp overcrank warning lamp In case of start stall it makes warning lamp glow When condensates in oil fence accumulate more than Monitor lamp oil fence apt Y05 1 3 of condensate
88. oil pressure sensor DC5V terminal CN1 78 W L Diagnostic service tool connection CN1 80 CN1 81 3 Electric System 2 Controller function 40 pins Pin No Connection Function color It detects common rail pressure fuel pressure It detects fuel pressure 1n common rail and it converts 1t Common rail pressure voltage signal and inputs it It is used for fuel injection sensor OUT terminal control Pressure detecting voltage signal 16 high when pressure is high and it is low when pressure is low It detects fuel temperature Fuel temperature sensor changes resistance value according to change of internal thermistor temperature ECM detects voltage which changes according to temperature change and it counts fuel temperature and CN2 83 Y G Fuel temperature sensor uses it for control of supply pump Voltage is low when fuel temperature is high and resistance is little and it is high when fuel temperature is low and resistance is large Resistance of thermistor is little when temperature is high and it is large when temperature is low It detects engine water temperature Water temperature sensor It detects voltage which changes according to resistance and then it counts engine water temperature o INI 12 terminal sensor VCC terminal Power supply for left sensors DC5V EGR motor position sensor power supply terminal CN2 84 R B
89. on 7 CAN Controller Area Network communication 3 3 1 Electronic control fuel injection system Common rail type ECM engine control module detects such information as engine RPM engine load etc signals from various sensors Base on the information ECM sends electrical signal to supply pump and injectors to properly control fuel injection of each cylinder and injection time this system A a rere canter n prae 5614139 1 Electromagnetic pump 6 Pressure limiter 10 CKP sensor 2 Fuel filter 7 Injector 11 CMP sensor 3 Supply pump 8 ECM 12 Fuel tank 4 Fuel pressure sensor 9 Various sensors accelerator 13 Pre fuel filter 5 Common rail boost and water temperature etc 3 12 3 Electric System 1 Fuel system Fuel is supplied to supply pump from fuel tank and then sent to common rail after it 1s pressurized by pressure pump At the time fuel volume supplied to common rail 1s controlled by suction control valve SCV 2 Injection pressure control Injection pressure is controlled by controlling the fuel pressure in the common rail The appropriate pressure in the common rail is calculated based on the engine revolution speed and fuel injected amount and proper fuel amount is injected by the control of the supply pump and it is sent to the common rail with pressure and being controlled 3 Injection time control This control 1s conducted by calculati
90. on of fuel injection timing mainly based on engine revolution speed and injection amount as a substitute of timer and control of injectors 4 Injection rate control In order to improve combustion in cylinders at first a little fuel is injected pre injection to ignite and then once ignited fuel is injected 2nd time main injection Control of injection timing and injection volume is performed by controlling injectors 5 Maximum fuel injection amount This is calculated by adjustment of initial starting injection amount in accordance with water temperature and limitation of this maximum injection amount by boost pressure and also control of fuel injection amount at high altitude by barometric pressure 6 Inter cylinder correction This is not used for this model 3 18 3 Electric System 3 3 2 EGR Exhaust gas recirculation control EGR system works by recirculating a portion of an engine exhaust gas back into the intake chamber and lowers injection temperature also controlling occurrence of nitrogen oxide by mixing inert gas into intake air EGR amount 16 controlled by opening closing function of the EGR valve provided between exhaust manifold and intake chamber It is decided by engine revolution speed and engine load factor and controlled by the function of EGR valve High temperature EGR gas is cooled by EGR cooler provided in the passage of EGR gas and also the combustion temperature is made further lower than usual
91. ply for tachometer Panel light switch Power supply for lighting Monitor lamp CN3 16 terminal Detection of engine revolutions 3 Lamp specifications DCi2V 3 40 3 Electric System 3 4 14 Fuel gauge Part number 36158 00500 SG09051 1 Position of meter pointer 27 Remaining fuel gal L 95 2 List of functions Panel light switch Power supply for lamps Sending unit Detector for remaining fuel 15A fuse 3 Lamp specifications DCi2V 34W 3 41 3 Electric System 3 4 15 Sending unit SDG25S 8E1 Part number 36159 02101 SDG45S 8E1 Part number 36159 03000 Grounding black Unit red white Unit in mm Upper stage SDG25S 8E1 Lower stage SDG45S 8E 1 2 6 66 2 2 1 52 6 1 155 6 8 172 8 9 227 11 7 297 G14148E SDG255 8E1 Position of meter pointer for resistance value R ining fuel Igal L Pointer position Resistance value Q emaining fuel gal L SDG25S 8E1 SDG458 8E1 110 9 0 34 10 0 38 32 5 24 0 91 53 6 203 3 42 5 161 95 1 360 3742 3 Electric System 3 4 16 Oil fence level switch Part number 46813 08100 Unit in mm Black Black 0 59 15 G1 8 Distance between parallel sides of a hexagon 14 LO ON OFF Open close position Connection terminal 5 83 148 6 85 174 Fluid level G13037E 1 Specifications AC 0
92. posision sensor W terminal B W Shield line CAM angle sensor GND terminal Common rail pressure sensor GND terminal EGR motor position sensor GND terminal N2 10 NIL CN2 103 N2 10 NIL Suction control valve SCV N2 10 NIL W terminal Q Q Q Z Z Z 9 n n gt N W B EGR DC motor V terminal Crank angle sensor OUT It detects valve lift of EGR exhaust gas re circulation valve Power supply for crank angle sensor DC5V It inputs camshaft position CMP signal CMP signal is caused when cam position of camshaft passes camshaft angle CMP sensor ECM judges cylinder according to CMP signal and it decides crank angle and counts fuel injection control and engine speed This control is performed based on crankshaft position signal detected by CN2 107 terminal but in case crankshaft angle CKP sensor is in trouble it is performed based on camshaft position CMP signal Same as CN2 93 and CN2 94 terminal Grounding It operates EGR DC motor and it controls valve lift of EGR valve ECM decides EGR gas volume based on engine speed and engine load ratio fuel injection volume and it operates EGR valve by EGR DC motor and also it controls EGR gas volume to be mixed in engine intake air When power stays on fuel 1s sent to common rail by pressure Fuel injection volume to common rail 1s controlled by control of
93. re and humidity So always make sure to check for any abnormal noise of the bearing and also to check for any abnormal rise of temperature Should 1t become necessary to replace the bearing follow the under mentioned procedures Replacement of bearing D Remove bearing shield casing 2 Pull out the bearing from the shaft using bearing removing tools gear puller 3 Clean the surface of the shaft and check for any damages 4 Prepare a new bearing and check it by turning it by hand before installing it 5 Bearing is installed by using a bearing heater or a bearing push in tool The heating temperature of bearing shall be between 100 C and 118 C but never over 120 C 0 Set guide bolts to the generator main unit frame 7 Push in the bearing shield casing hitting it with a plastic hammer evenly Bearing installer Casing Guide bolt lt G14165E SG05052E 2 Overhauling 2 3 Replacement of rotary rectifier wiring board IMPORTANT Shorten time to keep soldering iron touch on diode module Degrease such surfaces where thread looseness is prevented by thread locking fluid t is impossible to replace diode module and varistor only because it is built in rotary rectifier D Rotary rectifier wiring board 2 Diode module 3 Varistor 5614006 5612097 Tightening s torque 9 ThreeBond No 1360 1 Tightening torque S380VT80 M3 Screw TND20V 471KB Vari
94. relay function P XO relay No 3 terminal Power supply of STX relay and MX relay PLC COMO terminal PLC common power supply DC12V d Power supply for MX relay coil preheat function PLC terminal PLC common power supply DC12V PLC Y2 terminal Power supply for STX relay coil starter relay function 3 86 3 Electric System 3 4 7 Power relay 2 Part number 46177 08400 relay DC12V rri 5613076 Connection Function Cathode side of 0 relay No 4 terminal Power supply for 12V input to DC DC SD2 diode converter Anode side of SD2 MX relay No 3 terminal Power supply for 12V input to DC DC converter diode When generation signal 1s being transmitted to X7 relay it closes X7 relay contact and switches OFF starter relay power supply to stop starter hier it COM X7 relay No 4 terminal Manual Auto selector switch Power supply of XO relay coil is inputted from No 3 terminal selector switch No 3 terminal It prevents ACC circuit of DC DC converter Cathode side of SD2 diode input power from throwing power When contact between remote control terminal Remote control terminal plate cob Al and A2 is ON A1 terminal is grounded AD terminal and relay functions 9791 3 Electric System 3 4 8 Alternator ISUZU part number 897228 3181 Terminal R IG Me Terminal L
95. rical Appliances Item SDG25S 8E1 SDG45S 8E1 Element Filter Belt mr 41290 01600 ____ ISUZU part No 899075 6710 nm 37438 07500 Engine oil filter cartridge ISUZU part No 894456 7412 ISUZU part No 898075 6761 32100 40700 Air filter element 32143 11700 43540 08700 Fuel filter ASS Y ISUZU part No 898236 9900 Fuel filter cartridge ISUZU part No 898240 2800 43540 08600 FUE pre Mer Asa T ISUZU part No 898236 9910 gt d gt n U lt Fuel pre filter cartridge ISUZU part No 898240 2790 ISUZU part No 898071 4010 electromagnetic pump filter D o 5 ISUZU part No 109630 0830 x 3 ISUZU part No 109630 0850 x 3 Belt ISUZU part No 898049 0340 ISUZU part No 898095 3350 eae ISUZU part No 898071 4040 electromagnetic pump filter 4 Engine supply pump strainer ISUZU part No 898074 9550 o D 2 amp 5 AID A o Q D D e D D o o 5 lt lt 3 53 44390 04200 44390 04300 ISUZU part No 898227 1080 ISUZU part No 898227 1081 46870 47901 46760 73710 46879 65300 46872 01300 46177 08500 Power relay STX 46177 08300 Power relay X0 46177 08400 Main starter cut fuel pump 44346 08500 x 3 relay 44346 16100 44346 15700 44346 13200 36146 05901 36158 00500
96. rting preheating It outputs start signal when automatically starting When ASU CN7 1 terminal V11 terminal detects end of preheating PLC unit Y2 terminal interior contact is ON to activate STX relay and it outputs start signal to starter relay SY from ASU CN7 8 terminal Starter works and cranking operation continues 10 seconds When generation signal is inputted to ASU CN6 7 and CN6 8 terminals during the time it makes Y2 terminal interior contact OFF to cut power supply and then cranking operation stops When generation signal is not inputted to ASU CN6 7 and CN6 8 even after cranking operation is tried 10 seconds it stops 8 seconds and cranking operation is repeated is tried and this operation 18 repeated three times When generation signal is not inputted to ASU CN6 7 and CN6 8 terminals start stall warning is outputted When engine starts automatically interior contact BY1 of PLC unit is made ON for 10 seconds to perform idling operation for protection of turbo 3 91 3 Electric System 2 Operating procedure This explains how the unit equipped with automatic power transfer is automatically started D Start the generator unit under the procedure of manual operation and adjust the frequency and voltage rating 2 Turn the starter switch to STOP position and stop the engine 3 Turn the circuit breaker of output terminal ON after the generator unit stopped when you use the circuit brea
97. stor Substrate diode module and varistor are installed is equipped at the side of the core of exciter generator armature Replacement procedures of rotary rectifier D Remove bearing shield casing 2 Pull out bearings from the shaft using bearing removing tools gear puller 3 Record positions of cable connection of the rotary rectifier 4 Remove rotary rectifier disconnecting cables fitted to the rotary rectifier 5 Install new rotary rectifier Tighten rotary rectifier to the specified torque using a torque wrench 7 The connections of rotary rectifier 5 point should be soldered Soldering work should not be performed for a long time because they are of semiconductor One point should be done in five seconds as aim 2 12 2 Overhauling 2 4 Check and Cleaning of the Supply Pump Strainer Procedure Loosen the supply pump strainer 1 joint bolt built in type and remove it Then after washing it in diesel oil blow dust and dirt off with high pressure air Please be replaced whenever this gasket 2 and 9 In case the conditions of lowered engine power and engine stop will not be improved
98. terminal hole diameter D ex _ 18 Single phase 120V CHCl reventacles Xi 120V 20A Socket 120V 20A Socket A Single phase 240 120V 240 120V 50A Socket 240 120V 50A Socket 3 Auxiliary receptacles 2 X1 GFCI AC power will be available independently of the position of voltage selector switch X2 Auxiliary AC power will be available only when the voltage selector switch is turned to 240 120V GFCI receptacle breakers 2 Auxiliary receptacle breakers X 2 N GROUND gt O L2 L3 6 Three phase output terminal plate 5613060 Output terminal hole A130846 GFCIreceptacles Auxiliary receptacles 120V 20AMPS 240 120V 50AMPS G12036 1E SDG25S 8E1 GFCI AUX A040271 A040270 1 0 1 10 1 Specification 1 7 Fuel Piping Fuel tank Pre filter 10m E C 09 RNC 77 y E 116 E SE 18 1 TE i i 09 09 a 09 Jm H Li Fuel filter 10 um L j Ltt HJ 0 Mal IE E H iei Selector valve Electric pump with filter External fuel supply tank G14129E 2 Overhauling 2 1 Cautions for Overhauling 2 1 1 Precautions before starting work 1 Work to be performed It 16 very important to always plan advance what facilities tools instruments materials oil etc
99. to stop immediately It detects generator unit T7 T9 generating power When engine automatically starts no power exists on X7 relay coil And in case no voltage is applied to X7 relay interior contact of PLC unit Y1 Y2 terminal is OFF and to stop engine start and to cancel auto re start function S Line Connection Function color ECM CN1 11 terminal To the charge relay via 15A fuse Monitor lamp CN3 12 terminal Air filter clogging warning lamp It detects preheating finish when starting While preheating interior contact of ECM CNI1 11 terminal is ON and then power flows When OFF preheating is completed When engine starts charge relay 1 becomes ON and interior contact BY1 of PLC unit becomes ON Then power is supplied to ECM CN1 50 terminal and idling operation is performed for 10 seconds No power exists during usual operation When air filter differential pressure indicator 1s for 10 seconds interior contact of Y3 terminal is ON and air filter clogging warning lamp glows 3 80 3 Electric System CN7 4 CN7 5 CN7 6 CN7 7 CN7 8 CN7 9 Connection Function Monitor lamp CN3 11 terminal Overcrank warning lamp Monitor lamp CN3 3 terminal Oil fence water level rise warning lamp Tachometer Via monitor lamp CN3 8 terminal Starter switch ACC terminal relay coil Starter switch C terminal
100. tops with starter switch ON and diagnosis lamp is ON make diagnosis switch ON or connect ECM CN1 52 terminal directly to ground Then diagnosis lamp begins to blink and present and past engine troubles are shown No power exists during usual operation When glowing interior contact of CN1 11 terminal is ON and it connects ground to send power Thus glow lamp glows No power exists during usual operation When engine is in disorder interior contact of ECM CN1 6 terminal is ON and it connects ground to send power Thus diagnosis lamp of monitor glows When diagnosis lamp glows it stops engine once With starter switch ON push diagnosis switch to supply power to ECM CN1 52 terminal Then diagnosis lamp begins to blink and present and past engine troubles are shown No power exists during usual operation When engine water temperature rises up to emergency stop set temperature interior contact of ECM CN1 16 terminal is and it connects ground to send power Thus engine water temperature rise emergency stop lamp glows Emergency stop lamp lighting temperature 212 F 100 It detects engine speed It detects engine speed converted to tachometer 2 revolutions per 1 pulse CN39 IN 444422 CN3 10 15A fuse Power supply for monitor lamp 3 Electric System CN3 11 CN3 12 CN3 13 CN3 14 CN3 15 CN3 16 W G CN3 17 B P Connection Function Auto start unit CN7 4 termina
101. tor ass y 5 212101 1 Rotary rectifier Generator field winding wire Exciter armature winding wires 5614008 D Diode module Varistor 3 Rotary rectifier wiring board 4 Exciter armature core 5 Rotor shaft Diode module A Diode Generator field winding wire Varistor SG09107 1 3 2 3 Electric System How to check whether diode module functions correctly or not If excessive voltage 1s applied to diode module or if excessive current flows interior diode will be damaged If diode module damaged generator does not generate electricity In order to check whether diode module is good order or not it 1s necessary to check resistance according to the following procedures Procedure D Remove casing of genera AC Diode module E eoe Diode 2 Record positions of cable connection of the rotary rectifier Then disconnect all cables connected to the diode module 3 Availing of resistance measurement range of the tester measure forward direction Exciter armature winding wires resistance and reverse direction resistance of each diode When forward direction Generator field winding wire resistance 1s found less than 100 and reverse direction resistance more than 100k the diode is in good order When diode 1s found electric current flowing in both forward and reverse directions the Disconnect diode is judged to be in disorder cab
102. y R CN1 28 Br W Frequency adjuster UP CN1 29 CN1 30 CN1 31 CN1 32 Operation mode switching input terminal No power exists during usual operation When power External input connector supply of ECM is ON and terminal between option No 1 terminal option connector No 1 and No 4 terminal is placed ON operation mode is switched to Regulation operation oo o Tool 055 No 11 CN1 33 W B CN1 34 CN1 35 CN1 36 CN1 37 W B Tool connection terminal CAN communication RO EIS SS No 7 With connection of diagnostic service tool it is possible to CN1 38 Br G 99 s diagnose engine control system and to check system terminal CN139 B W Shield line When power is sent to CN1 24 terminal 1t works main relay MR2 Thus main relay MR2 is switched and CN1 40 Y R Main relay MR2 coil when power is supplied to CN1 2 and CN1 5 terminal voltage is applied to fuel pump relay FR to operate the pump 3 19 3 Electric System Connection Function color CN1 41 Boost temperature boost emia pressure sensor Boost temperature boost R W pressure sensor VCC Power supply for boost temperature boost pressure terminal sensor DC5V 1 46 Auto start unit CN7 8 Inputting start signal terminal CN14 o CN14 Operation mode frequency switching input terminal ON 60Hz constant It

Engine Generator: 25S-8E1

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