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Engine Generator: 45S-8B1

1. B Black W White Lg Light green SDG100S 125S 8B1 3 RW Sky blue Wire of Red White Line Bue Orange V Viet SWITCH ASSY Me p eee G Gren Pink T Tan pu ou 4 ire size mm R Red EMERGENCY STOP 1 3 1258 125 l 25B R 10 es 2j AUTO NS 2W R 125R W 1 2 ce to _ MR1 22 E 0 15Y R um FR SWITCH ASSY vot v21 0757 8 125W G I 125R J uns a gr 9 75Y R MAIN HELAYA T L 5 0 75R Wy gt FUEL PUMP SW e al X 7 T 0 75R GT 74 25P wn gt an 1 5 777 ke 0 75 m V30 UP MR2 8 587 Y 34 SIGN STARTER MOTOR E Lew ENGINE SPEED SIGN ap lt SELECT SW E SPEED 35 MANUAL OR 60 ca a vso POWER SL ISR L 5R ex L__4_ auto on DLE ME M ENGINE STOP GLOW PLUG BAROMETRIC PRESS SENSOR ye V61 REG MODE LOAD ADVANCE
2. 506455 655 8 1 5609077 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 6 18 1 4 13 shooting 2 Measurement of insulation resistance of generator field Diode module 9 winding wire exciter armature winding wires SDG45S 65S 8B1 Generator field winding wire Disconnect the wires and leading to the rotary rectifier then measure the insulation resistance between the disconnected wires 0 and the shaft Exciter armature winding wires Disconnect the wires 9 three pieces and short circuit them then measure the insulation resistance between these wires and the shaft SDG100S 125S 150S 8B1 Generator field winding wire Disconnect the wires leading to the rotary rectifier then measure the insulation resistance between the disconnected wires and the shaft Exciter armature winding wires Disconnect the wires and short circuit them then measure the insulation resistance between these wires and the shaft 3 Measurement of insulation resistance of exciter field winding wire i O Disconnect the field connector J K in the control panel and measure the resistan
3. 4 9 Engine Trouble Diagnosis Function 4 17 References 5 1 Generator s Winding Wires Resistance Value 5 1 Forced Excitation Method 5 1 Generator Wiring Diagram 5 2 Engine Wiring Diagram 5 4 For maintenance of engine parts see Engine Workshop manual and Troubleshooting manual published by engine manufacturer 1 Specification 1 1 Specifications ee 727 mue OO Current 108 108 Model ISUZU BU 4JJ1T mm ame E H capacity of oil fence gal L 41 155 Generator neral Specifications 1 1 1 Specification 227 EE e 1 c L9 uic e es Current 152 152 Model ISUZU 4 1 4 1 wa
4. a 0812 a0 ote np 8 09 T L 7 T JAN m 34 ND TET 8 628 STILI RP V GOVT TD NENG NaN Tana 803 cal AA Lile s38 5j Wi LEE ag 85 E i 2 8 8 H NIRE TNT NN Y 009 my 007 713 4 LNGWOSLESNI NOLING 9015 A9N39333 4 MAINO J Te XADI 01 NIV ONTOS 1 15 1 1 3 Internal Components 1 2 3 4 5 6 7 8 9 SDG45S 65S 8B 1 n bo p l
5. IVINGRNISTAN3 r E2SDNIVNO 1304 gt gt uu gt gt E 98 09 ATAL MD gt e o 3108608 0 gt p 29 8 28 gi 2 2 AM 1304 303 9 Q3NNDE ND es 8 24 ES NT Tans G CXSNIVC ID NNI Nanay Tang 03 o 1 cH n RI 2 Ex ls lt y N ITI ONT TODO 9 Y L ALAVED 30 IND A ONY a 4 ar 16 ISVS Joo Y 5 Ww e mM gt 9 1 14 1 SDG150S 8B1 L veO0080V L3NNU8 JHL ND SXQUT WWI 813 9NIN3dU 053 19V1d3238 43713 7304 1866 9074 W3lV3H NV 14111984 403 SIIH IVINGANUSTAN3 S8IT COL 1 7304 NIVAC YNVL TWINAWNOSIANS 30 W31N32 128 SNIIDUO yun Ld LN HOLIMS 801937135 39VL IDA GA 159 NIVEC TWINAWNOSTANS E99NIVMT 7303 06 087 0
6. Control panel Voltage selector switch Output terminals Air filter Reserve tank Engine oil filler port Engine Engine oil filter Radiator 13 14 15 16 17 18 A080581 10 Generator main unit 11 Battery 12 Air bleeding electromagnetic pump 13 Fuel pre filter 14 Fuel filter 15 Selector valve of fuel pipe 16 Intercooler 17 Fuel tank 18 Exhaust muffler Instrument 11 marked are provided on the other side 1 5061005 1255 1505 8 1 5 6 7 8 po T 9 10 11 A070314 SDG150S 8B1 1 Control panel 2 Voltage selector switch 3 Air filter 4 Engine 5 Generator main unit 6 Output terminals 7 Fuel tank 8 Battery 9 Radiator 10 Intercooler 11 Exhaust muffler 1 12
7. SG09001E 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 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 5605050 Unit in mm re Dmm Dee egens 8B1 8B1 8B1 8B1 8B1 Shroud inner diameter b Top gap Q 04709 Bottom gap 0 0 7108 Side gap 9 059059 2 Overhauling 2 3 6 Changing the bearings in the generator main unit IMPORTANT Use guide bolts to avoid the danger of dropping the bearing shield 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 is 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 temperature and humidity So always make sure to check for any abnormal noise of the bearings and also to check for any abnormal rise of temperature Should it bec
8. 2 16 Suction Control Valve SCV Replacement Procedure 2 18 Electrical Parts 3 1 Installation Positions of Electrical Appliances 3 1 Electrical Parts of Generator 3 4 Electronic Control System of Engine 3 13 Electrical Parts of Engine 3 17 Electronic Control Engine Component 3 49 Troubleshooting e e o e rre n rrr un MTM 4 1 Repairing Procedures 4 1 Generator Troubleshooting 4 3 Emergency Switch Functions 4 6 Engine Troubleshooting 4 7 How to Check
9. 13 14 15 16 17 18 070315 5061505 8 1 12 Engine oil filter 16 Fuel filter 13 Reserve tank 17 Air bleeding electromagnetic pump 14 Engine oil filler port 18 Fuel pre filter 15 Engine oil level gauge 2 Overhauling 2 1 Cautions for Overhauling 2 1 1 Precautions before starting work 1 Work to be performed It is very important to always plan in advance what facilities tools instruments materials oil etc 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 is 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 e 2 tester insulation resistance gauge etc 2 Tools 3 Torque wrenches D Jigs and specialized tools Solder and soldering iron Sealing tape Molybdenum sulfide tube type Lithium base grease Diesel oil cleaning solvent Cleaning cloths 1 Literatures such
10. A A section coupling details frame 5605046 2 5 2 Overhauling 1 Procedures of disassembly 1 2 3 0 1 Da Remove cables from battery terminal Remove brackets or fittings for muffler air filter and etc equipped on the bonnet Remove top cover and dismantle such parts on the bonnet so that generator main unit can be pulled out Remove cables and pipes Remove mounting bolts of generator main unit and engine Remove engine cooling fan guard and fan shroud If necessary remove radiator radiator hoses fuel tank and battery Insert an angle timber under the engine housing for inclining the engine Separate engine housing and generator stator 10 Separate engine flywheel and generator rotor 5606071 insulation film is damaged by contact of stator and rotor during disassembly of generator main 2 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 padded by wooden block at the bearing side face 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 unit perform varnish drying treatment to such portion Generator coupling this time sta
11. 26 e fg 2 U 1 d 5609020 E Power supply This detects engine speed pulse conversion air filter clogging and water level rise in oil fence No power exists during usual operation Air filter differential pressure rises ON When air filter differential pressure indicator is ON for 10 seconds interior contact of Y3 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 CN6 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 operation Fluid level in oil fence rises ON When oil fence level switch is ON for 10 seconds interior contact of Y5 terminal is switched ON and warning lamp glows Warning lamp lighting capacity More than 1 3 of blank capacity 3 31 3 Electrical Parts y Line Pin No Connection Function color Remote start stop switch connector terminal With CN6 4 terminal power supply input remote start stop switch is ON XO relay works Thus the relay is switched power is sent to PLC unit via DC12V DC24V
12. 660 2711717 NSRISN nd ul WU NINS3L LAd LAD HJLIAS AOLOITIS 39VL IDA iNGW BISNI 58000 30 ve ISS 55 eL Lx1840L1 A21 Ad3LIVE 30 031020 AIVE 15 In qun sv AIMA 319 ADD 128 NIVAC 1 10 1 SDG100S 8B1 V Lv0080V 1 NV 1831198 amp 4 SIH USE 43038 003199143238 GIL 903 22 8 06 she 076 RR Iw 08 TVINGANUSTAN3 LINNEA HL ND CUZ SITE 304 Tad 0002 sede e SA07 WYJ ADA SNINGdU NIYAT NVI TIWINGANISTAN3 09 09 54000 40 MOLIOR LIN NIV WNIWASL LAdLO HOLIMS 40193735 399 908 HOLIAS Alv ONTO TANYA INSNNSLSNI yun 08 GA 128 IVLNGRNDSTAN 8 29 304 414 8 52 7384 804 C E 71384 1 11 eI JINI aly AHAVA 40 YILNI ALIAVAD 40 3108 NOLIN
13. p A olololo 0 Fr 5 12 11 10 00 1 O Od c0 t Starter relay SY Glow relay GR Main relay MR2 Safety relay SR Fuel pump relay FR Magnetic switch MR1 Automatic operation unit Automatic voltage regulator AVR Three phase circuit breaker Thermal relay 3 2 SG09003 11 Terminal plate 12 Controller ECM 13 Intake air temperature sensor 14 Barometric pressure sensor 15 Fuse 15A 16 Fuse 20A 17 Fuse 10A 18 Fuse 60A 19 Current transformer 20 Voltage selector switch X The voltage selector switch is provided on the output terminal plate of the right bonnet 3 Electrical Parts 18 17 16 15 14 SDG150S 8B1 1 2345 6 7 8 z mE 999 91 00 2 OO Qt goes 13 12 Starter relay SY Glow relay GR Fuel pump relay FR Main relay MR2
14. 480 msec or more has elapsed after key switch ON Key switch input power supply volt age is higher than 9 V Main supply voltage is 9 V or more Main relay power supply voltage is 9 V or more 4 2 relay power RUN SUB pulse does not change for 20 msec or more When charge cir bank 1 volt age inside ECU is low When charge cir cuit bank 2 volt age inside ECU is low 6 Nearly simulta neous to fault simulta neousto fault occur rence Operationality is not affected Back up No back up action Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart DTC descrip tion 4 Troubleshooting to be detected Preconditions when DTC is set DTC set condition Fault judg ment period Behavior when trou ble occurs Diag nosis lamp from failure P1173 ee ae Starter cut telay fault Check engine lamp fault No pump pres sure feed fuel leakage Pressure lim iter open Boost tempera ture sensor fault low volt age fault Boost tempera ture sensor fault high volt age fault Overheat Injection nozzle common 1 drive system fa
15. Camshaft gear crankshaft gear installing angle is out of phase or damage in gear Intake air temperature sensor fault Short circuit in sensor or harness low voltage fault Starter cut relay fault Starter cut relay fault sensar fauli Open short circuit deterioration of sensor or harness high voltage fault presure Open short circuit breakage of sensor or harness low voltage fault Boost pressure sensor fault high voltage fault Short circuit in sensor or harness Chaves circuit fault band ECU charge circuit 1 fault internal burnout open circuit etc Chasse civem fault Gank ECU charge circuit 2 fault internal burnout open circuit etc A D conversion fault A D conversion fault EGR position fault Brushless Open short circuit breakage of sensor or harness specification Trouble open circuit or valve engage stuck drive motor side CPU fault 52 CPU monitoring IC fault Sub CPU fault Engine coolant temperature sensor fault voltage fault Open short circuit breakage of sensor or harness 2 2 4 4 EGR valve control fault Engine coolant temperature sensor Short circuit in sensor or harness fault low voltage fault 14 15 16 19 2 3 32 34 36 4 5 51 52 Q 9 e E c 418 4 Troubleshooting Blinking pattern 53 54 mel o E S Voltage fault in power supply 1 Voltage fault in 5V power supply 2 Voltage fault i
16. Wire size mm2 ACC SELECT SW EMERGENCY STOP 3 MANUAL 125R S 125R A 125p 5275 7 Be m m 2W R 125R V 1775 1 mer 0 TSR7W cx 0 5 1 MRI S 0 75Y R lt ECM S 10A TTR MAPO IGKEY V24 ep EE 0 75R W START VAR E ISYZR 0 758 ET SWITCH ASSY V51 MAP2 MAINR v21 1 0 125W G 7771 1258 2 MAINR v4 0 25Y R MAIN RELAY EXT _ S 0 75R W VIXIDIMNE LL ee 2 OR pPs B v2 LO TSR G 1175 a AY 8 V30 UP v5 HR G STARTER MOTOR 15 SY V31 DWN CASE V81 MR2 2 SIGN V43 mE A SIGN V62 4 POWER V1 Bener 60 5 5 50 1 POWER V3 BW Fa POWER 7 ISR GLOW PLUG ENGINE STOP V47 LTR a UBI UE REGMODE eee re OPTION Pn LOAD ADVANCE V45 777 MEM CLEAR V32 0 75R W V72 IAT POWER SUPPLY 0 75B G 0 75R W GLOW V10 FOR GLOW RELAY 0 75B W 2 V18 CAN H 0 75B W 0 75R G En 1 Tyee CAN L STARTR V44 SAFETY RELAY MONITOR LAMP 0 758 0 CN1 17P TOOL 0 75Y B ee oe eto 1 FUEL PUMP RELAY E DIAGL V6 0 7578 DIAGNOSTIC zi i 0 5 OL PRESS LOWL LOW Eisw BOOSTL V7 BOOST TEMP
17. d 1 MTS 3 Exciter armature winding wires 2 Generator field winding wire ae 4 Varistor Voltage selection switch position 480 277V 5610012 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 terminal 4 terminal T7 terminal T10 terminal T2 terminal T5 terminal 8 terminal T11 terminal T3 terminal 6 terminal T9 terminal T12 terminal 4 9 4 Troubleshooting 2 Measurement of generator field winding wire resistance Diodethodule Disconnect the wires D and 2 leading to the rotary rectifier then measure the resistance between the wires 3 Measurement of exciter armature winding wires resistance Disconnect the wires 2 three wires at center of diode module leading to the rotary rectifier and measure the resistance between the wires 4 Measurement of exciter field winding wire resistance Disconnect 9P connector in the control panel and measure the resistance at the connector on the generator side Female connector J K Between J amp K terminal 5606020 4 10 4 Troubleshooting 5061005 1255 1505 8 1 1 Generator armature winding wires 4 Exciter field winding wire AN VN
18. 4 B __ Grounding 3 Lamp specifications Lamp specifications SDG458 1258 8B1 SDG1508 8B1 3 40 3 Electrical Parts 3 4 7 Sending unit SDG45S 65S 8B1 HOKUETSU part number 36159 03000 SDG100S 125S 150S 8B1 HOKUETSU part number 36159 00600 Grounding black Unit red white Unit in mm 11 7 297 SG09027E Sending unit of SDG45S 65S 8B1 Resistance Remaining fuel L Pointer position vale SDG45S 506659 5061005 5061255 SDG1508 8B1 8B1 8B1 8B1 8B1 10 3 39 10 3 39 19 3 73 19 3 73 21 4 81 54 4 206 54 4 206 93 0 352 93 0 352 103 6 392 96 4 365 96 4 365 180 0 680 180 0 680 200 0 756 Above fuel residual volume are based on calculated values 3 41 3 Electrical Parts 3 4 8 fence level switch SDG45S 65S 8B1 HOKUETSU part number 46813 08100 SDG100S 125S 150S 8B1 HOKUETSU part number 46813 08000 Black Black B 61 8 IN Kj D OFF 1 Open close position Connection terminal B A ID of float 09 Fluid level ON ni y SG09028bE 1 Specifications Bg 5 506455 SDG65S SDG100S 8001258 SDG150S 8 8 8 8 8 Maximum working current Maximum working current AC 0
19. INS Suction control valve SCV It detects camshaft position CMP signal CMP signal is caused when cam position of GEM aisle camshaft passes camshaft position 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 between E107 p99 terminal E106 terminals but in case crankshaft position CKP sensor is in trouble it is performed based on camshaft camaat position CMP signal _ CMP signal E100 B W Shieldline Grounding o O Common rail pressure sensor SG terminal E101 TET EGR motor position sensor rounding grounding terminal No power exists during usual operation When engine speed rises up to emergency stop set speed interior contact in ECM is ON and E102 Y Monitor lamp CN1 13 terminal it connects ground to sends power Thus overspeed warning lamp glows Emergency stop set speed 2070min 69Hz EGR DC motor V terminal Same as E110 amp E111 terminal __ _ 65 O When power stays fuel is sent to common rail by pressure E105 R W Suction control valve SCV Fuel injection volume to common rail is controlled by control of power supply timing of suction control valve SCV It detects crankshaft position CKP signal CKP signal is caused when convex portio
20. ag i x d lt 1 i 1 H i f BL ne x gt 4 7 NE lt 1 g Pod m S e T D EN E gt FN E 6 gli i iSi gt Oc 42 1 gt 12 2 5 ANY 2 75609005 5 3 5 References 5 4 Engine Wiring Diagram AE ARRS B Black W White Lg Light green SDG45S 65S 8B1 2 RW L Bue 0 Orange V Violt Wire of Red White Line STARTER SW SWITCH ASSY n 2 G Green Pink T Tan Wire size mm2 ACT 2 R Red Gr Gray EMERGENCY STOP 1 1 BT Manuau 1258 5 1 258 125 eR torr SR 2R B j 125R W 1 2 dl MERE TREE 5 0 5Y R lt ECM tA a 0 5R W 0 85R W TZR V43 6 0 8587 FR SWITCH ASSY ___________ yap SUPPLY v21 Q5Y R MR2 058 1258 Ge 125W G 5 2 4958 _ 4 0 5 MAIN RE
21. from failure ble occurs period Black smoke emitted Back up Same to boost pressure and boost temperature sen sor fault Engine stopped Back up Engine stopped and can not restart To clear the trouble displayed on the monitor of the machine one more ignition cycle may be needed after the following ignition cycle 1 Even if the diagnostic trouble code DTC has restored normally the diagnosis lamp and back up mode are not restored in the ignition cycle that the diagnostic trouble code DTC is detected After turning the key switch OFF diagnostic trouble code DTC diagnosis is performed when the vehicle starts again If it 16 judged as normal everything will be recovered to normal from the next ignition cycle 1 Diagnostic trouble code DTC is detected 2 Repair and inspection 3 Returned to normal 9 When the diagnostic trouble code DTC has recovered to normal condition in the ignition cycle that the diagnostic trouble code DTC is detected the diagnosis lamp and back up mode will also be recovered 1 Diagnostic trouble code DTC is detected 2 Returned to normal 4 29 00 switch and Engine OFF run ON lamp posset temet 5609103 po Key Switch and Engine OFF run ON beh oven eeu o z Diag lamp OFF ON Back up mod
22. Battery 12V Battery 24V SDG45S 8B1 450 The generating voltage is only for reference because it will change due to the ambient temperature 5 1 5 References 5 3 Generator Wiring Diagram three phase 4 EE s s 9066 case circuit breaker single phase SHC Shuntcoil 1 illumination lamp NS ND EN A Current transformer F 1 4 9 4 6 6 3 3 2 36 5 6 Voltage selector sw 6 7 4 1 2 5 10 32 809008109 1 0 0 50 50 YY CNP i 7181123 4 5 XL tole t tinis ajz DF I Von Oe WAY CNS 6P m Pha 516 4 4 4 Switch Board Assy S pr bbe eed Ut TI0A UI VI AlE3 JI K 1 auto start bod unit To Battery pues mp cessi E ED TIER Sn E E CUT EC aos ere s eem E Monitor A C Generator lamp Tug Xo E WI RU IPIE EN UP I Dx cg EM DII UIS Single Phase 2or 3 Wire Parallel Zig Zag Single Phase
23. SENSOR F2 0 75G Y deni eue lee eee 5 9 E95 5V4 E111 0 75W R 8 U E91 BPRESS 0 75W B EGR 2 103 E109 5VRT4 DC MOTOR EBM3 110 V74 THBST 125W E1 E106 CRANK NJI 119 2151 107 CRANK E108 5104 E117 EG CYL 3 V80 5V3 NUS ENL 0 75G R E9 CYL amp 2 V67 OILPRESS V79 5VRT3 Fen THW COM2 E116 IER ES WE Bibs 0 751 7 TE E83 THL UE Eq 0 75L R E6 CYL amp 6 0 75G B E101 O TNT E99 SP CAMHAL 98 IF CAMHAL E100 5105 SCVH1 E105 0 75R W E87 5V5 SCVH1 RAW SCV E82 PFUEL 5 1 Ego 072 E90 PFUEL SCVLO E97 258 E101 5 5 E94 1 E93 EBMPOS2 E92 053 ECM SG09014 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 00000000 0000000000 00 000 8TH FLOCR SH N SAN El BLOG 22 2 N SH SH N UU 1 HOE SH N TOKYO 160 0023 J TEL 81 3 3348 7281 FAX 81 3 3348 7289 URL htt p ww ai rnan co j p Gopyri ght 2010 5 ES 00 LTD Rights Reserved N5G 0043 PRI N J 2010 10 Trademark of American Soybean Association HOKUETSU INDUSTRIES CO LTD
24. Temporarily tighten the two suction control valve SCV installing bolts Note Temporarily tighten the two bolts evenly by hand until the suction control valve SCV contacts the pump housing completely 5609052 4 Fully tighten the suction control valve SCV installing bolts to the specified torque 5 18 01 6 9 10 8N m 70 110kgf cm Note After tightening the two bolts tighten again the bolt tightened firstly 5609053 2 Connect the suction control valve SCV connector 3 Wipe off the fuel which was leaked at replacement work Start the engine and make sure there is no fuel leaked from the installation part of the suction control valve SCV 2 20 3 Electrical Parts 3 1 19 18 17 Installation Positions of Electrical Appliances SDG45S 65S 8B1 0 IO TA WY Barometric pressure sensor Intake air temperature sensor Sta
25. more DTC P1630 P1633 P0117 or P0118 is not detected During operation o input Pressure limiter is opened Boost tempera ture sensor volt age is less than 0 1 V Approx 5 sec Approx 4 sec Operationality is not affected Back up No back up action Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Operationality is not affected Back up Boost temperature default setting 30 C 86 F ON 1 Boost tempera ture sensor volt age is more than 4 94 V Coolant tempera ture is more than 105 C 221 F Approx 5 sec Open short cir cuit in injector common 1 side electrical wir ing EDU out put part fault Main relay power supply voltage is 9 V or more 70 rpm or more None of the follow ing DTC sets are detected DTC P0611 P1261 and P0201 DTC P0611 P1261 and P0204 4 27 No injector 1 4 monitor input signal exists Operationality is not affected Back up Boost temperature default setting 30 C 86 F Operationality is not affected Back up No back up action Engine stopped Back up Engine stopped and can not restart 4 Troubleshooting DTC Flash DTC descrip Item to be Preconditions when code tion detected DTC is set P1262 159 Injection nozzle Open short ci
26. 2 0 150 0 V60 MEM CLEAR INLET AR TEMP SENSOR GLOW 0 75R W GLOW RELAY POWER SUPPLY TECH 0 75B W 0 75R G z x 0 58 W vig SAFETY RELAY 0 758 0 vaa 0 758 0 75R G MONITOR LAMP S TOOL 1 075Y7B V5 FUEL PUMP RELAY 2779 5 E 0151 9 158 0750 8 71 OIL PRESS i MONITOR TAME 015 GLOW zR l4 E d 0 T5G W WATER TEMP a gt z OVER SPEED 2 SIGNAL OF b ee rp AIR FILTER HOUR METER __ 01 FENCE _ 0 TAL W OVER CRANK 1 0 5W L 0 75B L a ee OIL FENCE we n ARFLTER 0 15Y G e WITH HOUR METER el 2 2TURNS 1PULSE 0 75W G 0754775 ae a rik 0 75B P 0 75B P L7 aoa 1 em 5205005 E PEREL A 4 Al cc Me EE E E E a E ae 2S 7 oe 2 e S ss L C oh of of sy ic rn 1 9 vi l o pg M MXNSTX AE P s Gm 5 x0 EERE E EE sy sl al 5 P o 1258 0 0 SIX gt 2 xor xz heal X0 X2 X3 X4 X5 7 coMolvo coMi v1 2 2 Iya vs DIE IN 4 10758 Ch 42 24 P2 P 4 m gt At 0 75Y W WALA er 8 D sod Um E ON STARTT Teen 10 want 2 5 o 40 001 ce an es ns case age Bas hn RON J sanoi TO GENERATOR 5 6 5 Refe
27. 3 5 13 Camshaft position CMP sensor The camshaft position CMP sensor is installed onto the rear of cylinder head 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 position CMP sensor determines the crank angle and uses it to contorl fuel injection and calculate the engine speed These contorls are performed usually based signal However it is done based on CMP signal if the crankshaft position CKP sensor is faulty SG09065 Removal Disconnect the connector and remove the 0 39in 10mm mounting bolt and sensor Installation Apply a coat of engine oil to the O ring 5 81 41 69 18lb in 7 8 2N m 80 20kgf cm 5609066 3 5 14 Engine oil pressure sensor The engine oil pressure sensor is installed near the starter motor of the cylinder block it detects engine oil pressure converts the pressure into the voltage signal and sends it to ECM Voltage becomes higher as pressure becomes higher and lower as one does lower G09067 Removal Disconnect the connector and remove it with 1 06in 27mm wrench Installation 2015 8 41N m 420kgf cm 5609068 3 55 3 Electrical Parts 3 5 15 Barometric pressure sensor The barometric pressure sensor is installed onto
28. 4 17 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 DTC by diagnosis lamp blinking pattern flash code 3 In case that past diagnostic trouble code DTC is memorized It displays three times memorized trouble code In case that more than two trouble codes are memorized it displays them three times each in numerical order After they are displayed in 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 Code 1 which shows code display start is repeatedly displayed 5 Reading diagnostic trouble code DTC by scan tool Tech2 It is possible to read diagnostic trouble code DTC using scan tool 6 List of blinking patterns Flash codes Results of trouble diagnosis Item to be detected pattern Cam sensor fault no signal Open circuit in sensor wiring Cain sensor tault tena faul Broken tooth unnecessary signal mixed such as short circuit with other wiring Crank sensor fault no signal Open circuit in sensor wiring faute Gignal adio Broken tooth unnecessary signal mixed such as short circuit with other wiring
29. 480 277 240 139 H 5 System of contacts arrangement SDG45S 65S 8B 1 3 3 1 480 277V 240 139 240 120V 5606017 8 S 5606016 5061005 1255 1505 8 1 3 3 1 480 277V 240 139V 240 120V 5606018 3 Electrical Parts 3 2 4 AVR Automatic voltage regulator DST 100 2FA4 5606019 1 0 0 0 AVR CONNECTOR eS o 7772 7 71 HE Re Variable resistor SW n rimmer Orange NIL 5 NES E isset No 4 of connector 6 connector 6P and No 4 connector 6P short circuited ak E Eo 2 Generator cable No 4 py supply Generator cable No 3 Detect generator output voltage between generator cable No 3 and E3 27 Generator cable J Field winding of exciter Generator cable K Field winding of exciter 6 NIL PC Generator cable U Auxiliary winding 8 Gray Generator cable Auxiliary winding NIL Generator cable 3 9 3 Electrical Parts AVR is adjusted and set prior to delivery from factory Accordingly it is not necessary to adjust it unless the machine equipped with a new AVR functions abnormally If upon test operation ther
30. J K Varistor Diode 3 Exciter armature winding wires 2 Generator field winding wire Voltage selection switch position 480 277V 6 15 1 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 terminal 4 terminal T7 terminal 10 terminal T2 terminal 5 terminal 8 terminal T11 terminal T3 terminal 6 terminal T9 terminal T12 terminal 4 11 4 Troubleshooting 2 Measurement of generator field winding wire resistance Disconnect the wires leading to the rotary rectifier then measure the resistance between the wires 6 15 2 3 Measurement of exciter armature winding wires resistance Disconnect the wires leading to the rotary rectifier and measure the resistance between the wires 4 Measurement of exciter field winding wire resistance Disconnect 9P connector in the control panel and measure the resistance at the connector on the generator side Female connector Between J amp K terminal SG06020 4 12 4 Troubleshooting Measurement of Insulation Resistance of Generator Winding Wires Measurement is performed with a 500V megger The situation is considered to be satisfactory if the measuremen
31. So be careful not to make mistake in polarization For the details see 3 2 1 Rotary rectifier and 4 5 D Checking Rotary Rectifier and Varistor 7 Diode module silicon rectifier should be tightened according to tightening torque mentioned in above table using torque wrench Diode module silicon rectifier should be connected by soldering iron 9 Rotary rectifier should be removed in reverse order to installation procedures 2 15 2 Overhauling 2 4 Engine Maintenance Standards petet 11 SDG45S Shi ISUZU BU 4JJ1TYGD 04 Tightening torque of head bolts N s e 51 7 70 1 715 0 006 0 15 normal temperature j Engine model Valve clearance 0 006 0 15 normal temperature Firingorder CT 1 3 4 2 Injection timing BTDO pi MPa 000 0000 psi MPa 43500 Rotation speed 200zpm 200min 9 Temperature for oF 185 85 start of release Thermostat oF C 198 92 temperature Valve lift 0 39 10 ple ees s 500655 8 1 Engine model ooo ISUZU BJ 43J1XYGD 04 lb ft Tightening torque of head bolts N m kef em 51 7 70 1 715 0 006 0 15 normal temperature Valve clearance 0 006 0 15 normal temperature Firing order 13 42 Injection timing BTDC __ Electronic control O _ psi MPa 435 3 0 Rotation speed 200rpm GO0min D Temperature for oF 185 85 start of release Thermostat Pull open F C 198 92 temperatur
32. Standard pressure psi MPa 0 600 41 113 8 0 78 Standard resistance value 2 3 4 14 Others 1 Engine oil pressure switch for emergency stop Accessory for engine 5609033 OFF case of less than 15 0 1 2 Engine water temperature switch for emergency stop Accessory for engine 5606078 OFF case of more than 221 F 1050 3 47 3 Electrical Parts 3 4 15 Ammeter for battery charging SDG45S 125S 8B1 HOKUETSU part number 46154 15300 SDG150S 8B1 HOKUETSU part number 46154 15500 Power source for lighting Gos Alternator Wiring diagram SG06043E Power supply voltage specifications SDG458 1258 8B1 SDG1508 8B1 3 48 3 Electrical Parts 3 5 Electronic Control Engine Component 3 5 1 Engine component location diagram Engine coolant temperature ECT sensor Overheating switch Common rail pressure sensor Engine oil pressure sensor Crankshaft position CKP sensor Camshaft position CMP sensor EGR valve 5609036 8 Suction control valve SCV 9 Fuel temperature FT sensor 10 Boost temperature sensor 11 Boost pressure sensor 12 Injector 13 Glow plug 3 49 3 Electrical Parts 3 5 2 Supply pump Fuel temperature FT sensor The supply pump pressurizes fuel using engine output and pressure feeds fuel to common rail The supply pump has suction control val
33. Thus diagnosis lamp of monitor glows When diagnosis lamp glows it stops engine once With starter switch push diagnosis switch to supply power to ECM V52 terminal Then diagnosis lamp begins to blink and present and past engine troubles are shown No power exists during usual operation When engine coolant temperature rises up to emergency stop set temperature interior contact of EMC V15 terminal is ON and it connects ground to sends power Thus engine water temperature rise emergency stop lamp glows Emergency stop lamp lighting temperature 221 F 105 C It detects engine speed It detects engine speed converted to tachometer 2 revolutions per 1 pulse 3 36 3 Electrical Parts Line Connection Function color 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 terminal detects engine start speed more than 750 min CN1 11 L W Auto start unit CN7 4 terminal At this time when start speed is not inputted within 5 seconds and automatic cranking comes to end without success Repeat auto start and in case that engine 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 panel CN1 11 No power exists during
34. direction 100 direction 3 5 3 Electrical Parts 5061005 1255 1505 8 1 D Silicon rectifier Varistor 9 Conductive plate D Insulating plate 5 Lead wire alternator Lead wire exciter AS 016 e e anode How to check whether silicon rectifier diode element functions correctly or not Check the silicon rectifier diode element according to the resistance range of circuit meter When the anode side of good silicon rectifiers are connected to the circuit 4 and cathode side to the circuit gt the gauge shows infinite and anode side to gt and cathode side to the gauge shows several 10 Q lt Kside gt Normal part lt Kside gt Defective part Resistance value Resistance value Resistance value 0 Several 100 5609078 Note The rotary rectifier is equipped with 3 sets of silicon rectifiers of forward direct polarity at the K side and 8 of reverse direction polarity at the J side So take care not to make a mistake in the polarities 3 6 3 Electrical Parts 3 2 2 AS Ammeter change over switch Diagram AS for SDG100S 125S 150S L1 L2 L3 2CT L1 L3 OFF OFF Diagram Interior cable connection for SDG100S 125S 150S Diagram Interior cable connection for SDG45S 65S 8 7 5609015 5606069 5606068 3 Electrical Parts 3 2 3 Voltage selector switch As PA cm cm
35. e gt OHVL V15 WATER TEMP PRESS Tair PEACE OVRL E102 OVER SPEED SENSOR TACHO V8 AIR FILTER OVER CRANK FIBI OIL FENCE e QTY G gt FT UY 0 75W C 0 75B P _ _ 0 75 gt 1 Ex e un un in 2 m 5 5 2 gt gt 5 D MEL _ __ c d 5 B 1 1 BATTERY 95D31x 2 RO l 0 1 amp TO e RE M Z s a a s 3 5 zr 5 2 9 f 125 7 T9 DC DC Sl S S S S gt xpo xm a s 1 in ea ie a mum a fame nd A iiu PORA aie ete iz al z4 COM X0 X2 X3 X4 XS X6 X lvo cowi vi va dys 3 A1 0 75Y W NE START FE nes NIO pc N2 T 0 3 22 n ee TE J SG09013 GENERATOR 5 8 5 References 0 75R W 0 75L BOOST PRESS D16 SENSOR OUT BOOST TEMP SENSOR CRANK ANGLE SENSOR OIL PRESS SENSOR 0 75B Y 0 75R B WATER TEMP SENSOR 0 75Y G FUEL TEMP SENSOR CAM ANGLE SENSOR COMMON RAIL PRESS SENSOR i FA 0 75G B EGR MOTOR POSITION z 0 750
36. not detected Engine is running Key switch input power supply volt age is higher than 8 V but lower than 16 V Key switch input voltage is 9 V or more 4 25 Cam signal exists but no crank sig nal Number of pulse for crank signal is mismatched Crank signal exists but no cam signal Number of pulse for cam signal is mismatched No glow monitor Signal exists against glow relay drive instruction relay Glow lamp drive instruction signal is unmatched with glow lamp moni tor signal When trouble occurs 14 out of 21 ples Output lowering white smoke sion intense engine vibration possible Engine stall possi ble restart is possi ble when cam sensor is normal Back up Control based on cam when cam sen sor is normal When trouble occurs 14 out of 21 ples When trouble occurs 7 out of amp sam ples When trouble occurs 7 out of 8 sam ples When trouble occurs 25 out of 30 sam ples When trouble occurs 25 outof 30 sam ples Output lowering white smoke emis sion intense engine vibration possible Engine stall possi bie restart is possi ble when cam sensor is normal Back up Control based on cam when cam sen sor is normal Behavior does not change during engine running Engine is running at low speed engine stall possible After engine sta
37. supply voltage is 9 V or more 70 rpm or more DTC P0611 P1261 or P0204 is not detected Key switch input voltage is 9 V or more Key switch input voltage is 9 V or more 1630 or P1634 is not detected Key voltage more DTC 1630 or P1634 is not detected switch input is 9 V or 4 24 Common rail pressure sensor voltage is more than 4 5 V No injector 1 monitor input sig nal exists No injector 2 monitor input sig exists No injector 3 monitor input sig nal exists No injector 4 monitor input sig nal exists When engine speed is more than 2 070 rpm Boost pressure sensor voltage is less than 0 1 V Boost pressure sensor voltage is more than 4 9 V Nearly simulta neous to fault occur rence Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart 2 Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Engine hunting pos sible Back up Limited amount 1 Limitation is lifted if the speed decreases injection Black smoke emitted Back up Boost pressure default setting 150 kPa 21 8 psi Boost pressure cor rection EGR stopped Biack smoke emitted Back up Boost pressure d
38. ture sensor fault high volt age fault Open short cir cuit breakage of sensor or harness switch input voltage is 9 V or more DTC P1630 or P1633 is not detected 3 minutes or more has elapsed after starting engine 4 23 Combustion tem perature sensor voltage is more than 4 85 V Approx 4 sec At normal tempera ture Black smoke emission greater engine combustion noise possible During idling at low atmospheric temper atures Rough idling engine stall white smoke emission pos sible Back up Coolant tempera ture default setting at starting 20 C C4 F at running 80 C 176 F EGR stopped Not in particular Back up Fuel temperature default setting at starting 20 C 4 F at running 70 C 158 F Not in particular Back up Fuel temperature default setting at starting 20 C CF at running 70 C 158 F DTC descrip tion 4 Troubleshooting Item to be detected Preconditions when DTC is set DTC set condition Fault judg ment period Behavior when trou ble occurs Recov from failure Common rail pressure sen sor fault low voltage fault Short circuit in sensor or har ness Key switch input voltage is 9 V or more DTC P1630 P1635 is not detected Common rail pressure sensor voltage is less than 0 7 V Nearly simulta neous to fault occur Engine stop
39. 2 Install rotor 1 Hang the center of the rotor with jute rope and bring it near to the flywheel 2 Match the rotor coupling plate to the engine flywheel and then combine them tightening the coupling connecting bolts The coupling connecting bolts shall be high tensile bolts or more Use 2 guide bolts for this job 5606073 Size of guide bolt M i 22 PENES L A 5605047 Unit in mm __ SDG458 8B1 SDG65S 8B1 SDG100S 8B1 SDG125S 8B1 SDG150S 8B1 0 37 9 5 E 1 97 50 098 G5 10 18 Tightening torque of generator coupling rotor See 3 of 2 3 1 bolts SDG458 8B1 SDG65S 8B1 SDG100S 8B1 SDG125S 8B1 SDG1508 8B1 mm 10 1 5 40 10 1 5 30 1 1 5 20 s e a Tightening 7 z icm torque 2 8 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 Install the stator 1 Carefully push into the stator preventing the stator and rotor from rubbing each other 2 Install the flywheel
40. 240 120V i 5609006 s 5606001 5 2 5 References Molded case circuit breaker three phase SDG100S 125S 150S 8B1 3 Phase 4 Wire Series Star 3 Phase 4 Wire Parallel star Molded case circuit breaker Hand trimmer voltage regulator single phase g 2 LL c 2 Current transformer Automatic voltage regulator Ammeter change over switch Shunt coil Voltmeter Thermal relay Ammeter Ke lo x wel ro H i E ER O 2 Bic B po gt 9 Al E 9 4 d i lt amp 5 m i S hee See j PU ix tors hE gee recs I EQ ce d Tu Pg Fg f EN iw i t re DO Tj i H te nd eas i i E 3i ajz zi bi i
41. 5A DC 0 5A resistance Fluid level in oil fence when warning lamp glows L 17 3 65 4 17 3 65 4 14 5 55 14 5 55 45 4 172 Level switch is ON Fluid level in oil fence in above table shows the value calculated not actually measured 2 Dimensions Unit in mm pss E SDG45S 65S 8B1 SDG1008 1258 1508 8B1 6 85 174 12 76 324 BY 5 83 148 11 73 298 3 42 3 Electrical Parts 3 4 9 Electro magnetic pump for bleeding air from fuel line Type with built in filter SDG45S 65S 100S 125S 8B1 HOKUETSU part number 43650 02600 SDG150S 8B1 HOKUETSU part number 43650 02500 SG06076 Specifications SDG45S 1258 8B1 SDG1508 8B1 1 5A Max 1 5A Max Wal than More than y capacity 9 34eal min 1 3L min 0 37gal min 1 4L min 3 43 3 Electrical Parts 3 4 10 Coolant water temperature gauge SDG45S 65S 8B1 HOKUETSU part number 36145 06800 SDG100S 125S 8B1 HOKUETSU part number 36145 06500 SDG150S 8B1 HOKUETSU part number 36145 06700 2 1 5606040 Coolant water temperature gauge of SDG100S 125S 8B1 1 List of functions Function 1 _ _ Grounding _________ Power supply for lighting Detector for water temperature 15A fuse Power supply for water temperature gauge 2 Temperature range and resistance value of sensor SDG458 658 8B1 SDG1008 1258 8B1 SDGI1508 8B1 Sensor Sensor Sensor Temperature resistance Temperature
42. 6N m 40 8 61 2kgf 5609074 3 5 19 Boost temperature sensor The boost temperature sensor is installed onto the EGR valve upstream side of intake manifold The sensor is thermistor type The resistance in the sensor changes as the temperature changes Removal Disconnect the connector and remove it with 0 75in 19mm wrench Installation 8 0 12 0lb ft 96 1441 10 8 16 3N m 110 166kgf cm 5609075 3 57 4 Troubleshooting 4 1 Repairing Procedures When performing failure diagnosis pay special attention to the followings observing general cautions 411 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 is disassembled urgently 1 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 wor
43. DC DC oj x x x x x A a v COM X2 X3 X4 X5 X6 X7 com dyt cow2 v2 va dya vs luy IN 10 58 zi P3 12 24 P2 __ 5 8 zal d em NE ON START 0 N24 E OFF STOP A2 058 DL Eose aen cee ie ie ler ie SEE TO GENERATOR 5 4 005 55 SENSOR BOOST TEMP SENSOR CRANK ANGLE SENSOR ANGLE SENSOR COMMON RAIL PRESS SENSOR EGR MOTOR POSITION SENSOR 5 References 0 5B VCC 0 58 W 0 5L 0 5W 0 5L W 0 5B W 0 5W OUT SG _ 05G W 22 lt F01 0 5L 0 5G B F02 0 5G Y 0 5L W 5 5 0 5W E95 E91 E109 VIL E107 E108 E87 E98 E101 E100 E82 E90 E94 E93 E92 ECM E111 E112 E103 E104 E110 E102 E121 E119 E117 E116 E120 V80 67 79 E84 ENGINE SIDE 085W R e 108 U 0 85W R 0 85W B F07 1 V EGR 0 85W B DC MOTOR 0 85W L F06 d W 0 85W L 2W E01 2L E05 2L W E08 O TEN 2R E02 2L Y E07 C um 2L R E06 1 gt T 0 85R W 0 85R B PRESS SENSOR WATER TEMP SENSOR FUEL TEMP SENSOR 5609010 5 References
44. OLS ANDANI 8 2 WNW Indio BOLIAS HOLIAS ONY ALIS VIDA T3NVd IN3W NISNI 1 02 9 1 8 1 SDG65S 8B1 6290807 009 yun 54000 40 WDLLUS X Ce PMNIVET 110 3NIDN3 CLANNO ND T cp 006 ANYL IV LNGANUSITAN 096 066 0967 40 gt Ges gt 001 Wa DNILJTI SAJD T 803 SNIN3dU 905379914 9027412 144323 9014 S31V3H 4431198 ERE E HE TERES TEE ca ALIAVSS 30 W31N3J ALIAVSD JU 331N39 NOLING 8 A9N393343 WNINASL INd LAU ADAS QNVUE HOLIAS 81123135 JOVI WA 13 4 INGWISISNI ONTOS 015 1 9 1 SDG100S 8B1 LvOO80V 831194 403 53 4311941 403 3 Cv NGL TaN 3 10H60 8 IV QW m OS OV LORI WaT 1303 Py 08 0E 06 0 qe SXXIT NV 303 ONING NIV WINGRNDSTAN gt gt 596 29 8 624 Ter NONA TONE 7304 803
45. circuit protector CPR is built in in the power supply for prevention of AVR damage due to the excessive exciting current caused by wrong cable connection or disconnection to detective inlet terminal of AVR If this device functions the white push button at the top of CPR is kept pressed up In order to reset it push the white button on after getting rid of the cause of the excessive exciting current flow 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 3 Electrical Parts Adjusting V Hz characteristic If at the start stage of engine voltage adjustment and stability adjustment have been already done it is not necessary to adjust the V Hz characteristic But if at no load operation any trouble of voltage adjustment function occurs or voltage disappears adjust V Hz characteristics according the following procedures 1 Turn V Hz characteristics volume knob V F ADJ fully clockwise Notching position 310 10 2 Start engine and adjust the frequency to 57Hz and then slowly turn V Hz characteristic volume knob V gt F gt ADJ counterclockwise to set it at the position of voltage drop approx 1 of the rated voltage see the table undermentioned Notching position of V Hz characteristics volume V F ADJ 3 10 poo 240V 238V 3 The frequency compensation characteristic and V Hz corner frequency are shown in the following tab
46. speed and engine load ratio fuel injection volume and it operates EGR valve by EGR DC E104 W B m Mann mal abl motor and also it controls EGR gas volume to be onnecton terminai s mixed in engine intake air only for SDG459 65S 8B1 When power stays on fuel is sent to common rail by pressure E105 R W Suction control valve SCV Fuel injection volume to common rail is controlled by control of power supply timing of suction control valve SCV DECRE DRE 5106 3 25 3 Electrical Parts lt SDG45S 125S 8B1 gt Pin Line Connection Function No color It inputs crankshaft position CKP signal CKP signal is caused when convex portion of flywheel passes through sensor position ECM judges cylinder according to CKP signal and it W decides crank angle and counts fuel injection Bror Gr B Crapieanglesensor control and engine speed This control is performed based on CKP signal but in case crankshaft position CKP sensor is in trouble it is performed based on camshaft 2 CMP signal detected by E98 terminal Shield line e E Boost pressure sensor Boost pressure sensor SG terminal terminal R L Boost temperature sensor E109 grounding terminal Grounding rm 1B Crank angle sensor terminal Crank angle sensor terminal sensor terminal EGR DC motor W terminal EGR DC motor U terminal WR EGR DC motor U terminal Sa
47. speed coincides with voltage All accel sensor for SDG100S 125S 8B1 terminals used for this unit are blank no power exists during normal operation Operation mode frequency switching input terminal ON 60Hz constant It is possible to change 15A fuse frequency with combination of V49 V50 and V51 terminal switching This unit is set to 60Hz constant operation with this terminal directly connected to 15A fuse When engine stops with starter switch Tool TECH2 No 1 terminal and diagnosis lamp is make diagnosis V52 Y B switch ON or connect V52 terminal directly to ground Then diagnosis lamp begins to blink Diagnosis switch Blinking pattern shows present and past engine troubles External input connector No 3 terminal option Engine speed switch Pe ooo SG terminal VC terminal DC5V 3 22 3 Electrical Parts lt SDG45S 150S 8B1 gt Connection No color V62 V65 V66 It detects engine oil pressure Pressure detecting voltage signal is high when pressure is high and it is low when pressure is low It detects barometric pressure Barometric pressure sensor It counts barometric pressure from voltage OUT terminal signal and it corrects fuel injection volume high altitude compensation It detects intake air temperature of unit under operation Intake air temperature sensor In order to optimize fuel inj
48. the machine side and converts the barometric pressure into voltage signal The ECM calculates barometric pressure by voltage signal and performs fuel injection amount correction high altitude correction etc by barometric pressure 3 5 16 Intake air temperature IAT sensor The intake air temperature IAT sensor is installed onto the machine side and detects the temperature of intake air for optimum fuel injection control 8 0 12 0 ft 96 1441 10 8 16 3N m 110 166kgf cm 3 5 17 position sensor It is installed in EGR valve and detects the valve lift amount of EGR Note Do not disassemble the EGR position sensor If it is faulty replace it as EGR valve assembly 3 56 5609070 ER 5609071 5609072 3 Electrical Parts 3 5 18 Boost pressure sensor The boost pressure sensor uses the pressure hose between the boost pressure sensor and intake pipe detects boost intake air pressure converts the pressure into the voltage signal and sends it 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 Removel Disconnect the connector and remove the two 0 39in 10mm mounting bolts hoses and sensor Installation p ax 3 04 40 85 53lb in 47
49. usual operation When air filter differential pressure indicator is CN1 12 G Y Auto start unit CN7 3 terminal 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 e When engine speed rises up to emergency stop P E SDG458 set speed interior contact of EMC E88 E102 CN1 13 Y E102 terminal terminal is ON and it connects ground to sends SDG1508 8B1 power Thus overspeed warning lamp glows Emergency stop set speed 2070min 69Hz No power exists during usual operation When engine oil pressure drops down to emergency stop set pressure interior contact of 1 14 G R ECM V17 terminal ECM V17 terminal is ON and it connects ground to sends power Thus engine oil pressure drop emergency stop warning lamp glows Emergency stop lamp lighting pressure 15psi 0 1MPa Alternator L terminal CN1 15 Only for SDG45S 1258 8B1 It inputs alternator signal CN1 16 W G Tachometer Engine speed It outputs engine speed 2 revolutions per 1 detection terminal pulse Grounding terminal for tachometer engine speed detection In order to show engine speed pulse signal CN1 17 Tucdomeser Grounding ee outputted from CN1 16 terminal to tachometer for engine speed detection NE pulse signal at minus side is necessary and so diode is added at ground circuit and ground level of tachome
50. 1 m CPAN ANIONS 0001 5 CI2NNOG JHL ND gt gt GSIN Ns 803 OE 3 NT Ld 066 Fe NIVEC 07 091 Use is 7 WW 80 i lo E 023 X E L 4 1 S w ud ae MANN OW MIND 30 SING S ALIAVSD 40 31 39 E 5 ALIS ANDET 8 8 WNIRETI TRITT of Y 4 ALIAS OWIE FOLIAS ONY 80133138 1 TANVd 15 JINI SIV INTO 015 2192 13120 ONT IOUS yun 1 7 L 8 S080V 60 gt GE ANYL IV INGANOSITANd 8E 6 1 SDG65S 8B1 ul HUN TIU 3NIDN3 1453 CL3NNDE JHL ND SITE mi m Ite ULV t 4 I WI 803 F 1 v Wid 3 dB 4 4 3 z es ON Td S3IV3H INV E FDI MI 3 10H MIND 30 E ALLAVSD JU 331N32 E
51. 1 revolution per 4 pulses NIE c n n i Ooo O No power exists during usual operation When power is sent to V24 terminal preheating starts When preheating interior contact in ECM is V10 B G Glow relay GR ON and it connects ground to sends power Thus glow relay GR works to preheat ECM decides glow timing pre glow glow and after glow according to engine coolant temperature and it sends power to V10 terminal each time to function glow relay GR No power exists during usual operation 11 LY Monitor lamp 1 5 terminal When preheating interior contact in ECM is Glow lamp ON and it connects ground to sends power Thus preheating lamp glows DUBELTSCINHA O y OO 3 Electrical Parts lt SDG45S 150S 8B1 gt Pin Line 5 Connection Function No color No power when starting After starting engine speed rises and exceeds 750min interior contact ECM is ON and it connects ground to sends power Thus safety relay SR functions to cut power to starter V14 B W Safety relay SR motor During auto starting V46 terminal receives start signal When this condition is kept it works to put ON OFF power to V14 terminal lone second start 5 seconds starter motor stop working operation No power exists during usual operation When engine coolant temperature rises up to emergency stop level interior contact in ECM is Monitor lamp 1 7 terminal ON and it connect
52. 8B1 HOKUETSU part number 44390 02400 SDG150S 8B1 HOKUETSU part number 44390 02300 B i ww 9 os SITES im pe ese n roe 22 5 se 5 55 57 56 05 E 5609037 3 Electrical Parts 1 General wiring diagram of engine control module ECM Some sensors are not connected to ECM depending on each model having its special specifications Some sensors have input output to ECM by signal of CAN communication For the details see engine wiring diagram of actual unit 9 4 EGR valve motor Engine IL pressure sensor Engine coolant sensor Fuel temperature sensor 15 Engine stop switch z dling selector switch Key switch ON 50A dle down switch Mode map switch 0 map switch 1 Mode map switch 2 Regulation mode switch Load advance switch Diagnostic lamp 4 5 EN A Engine oil pressure lamp 98 CMP sensor QOS indicator lamp 2 4 Gi aat Boost temperature lamp oe ee d i 4 t te a ena E em Glow relay EGR valve position sensor Injector 1 mn
53. A DNIN3U 10 WINSWNOSTANS L 9 52 NONG 08 8 29 LAINE 731 ald 8 629 58000 40 MOLIOR EMEN DNDIDEO WNIWASL 109100 HOLIMS 30193138 39VL UA Gavia HOLIAS NV Aly SNPTOOS 13 LNAWNALSNI yun O H 304 0681 aT SING 0707 NL _ dDIS INDEN X GA PY IWLNSWNDSTANS 9 10 11 15 gt SIV INNENI pore N 1x1840L1 A2L AI3LIVE JILVA SIAN 1 13 1 SDG150S 8B1 720080 C Q3NND8 JHL ND S3907 WY 803 9NIN3dD 0253 199103238 053 199143938 4 1304 1866 ANV 5114 NV 8311984 814 SAIH 4 IVINGHN STAN3 17 159 WINSANDSTANS ALIAVYD 30 831832 1913 el 9 i diy INNOD ul HUN WNIWS3L 109110 5 30123 13S 39VL IA q T 199
54. AIRMAN SERVICE MANUAL ENGINE GENERATOR 500495 8 1 500695 8B1 5001005 6 1 5061295 8 1 5061505 8 1 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 In this book the 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 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 p
55. Combination of V30 and V31 terminal switching makes engine speed UP and DOWN No power exists during usual operation When frequency adjuster switch is placed UP Frequency adjuster UP it is switched ON Engine speed rise limit 15 higher than rated speed No power exists during usual operation When frequency adjuster switch is placed DOWN it is switched Engine speed fall limit Down to low idle speed Resetting terminal of past trouble memory External input connector No 5 When terminal is ON between option connector terminal option No 5 and No 2 ground terminals past trouble memory is reset Operation mode switching input terminal No power exists during usual operation When External input connector No 1 power supply of ECM is ON and terminal terminal option between option connector No l and No 4 terminal is placed ON operation mode is switched to Regulation operation mode Frequency adjuster DOWN communication With connection of scan tool TECH2 it is r G Tool TECH2 No 7 terminal possible to diagnose engine control system and to check system MEE 37 Tool TECH2 No 14 terminal TECH2 connection terminal CAN B When power is sent to V24 terminal it works main relay MR2 Thus main relay MR2 is Main relay MR2 switched and when power is supplied to V2 and V5 terminal voltage is applied to electromagnet pump relay FR to opera
56. G 5 AON3DE3IG 0 01 TIVE 121100 aly ONTOS 261 1 153041 01 AMALLVE ALVA SADI 1 SDG125S 8B1 cv0080V 3d SILVAA QW 0931 831194 404 SIIH 109143939 90203 43039 4211941 403 310860 8 19 08 3 S1 Cv 303 DNTIDDO fidi HJLIAS AOLOITIS 39VL IDA iNGW BISNI ul pun 58000 30 WELLIE OL NIVA NVL IVINGWN SIAN3 P E 3NIDN3 L3NI ONT O09 8 238 128 INI 1304 404 NIVAC IVINGRNISTAN3 8 28 7313 403 S 55 eL Lx1840L1 A21 Ad3LIVE 30 031020 15 In qun sv 5 99 ay SIMA S318 ADD 1 12 1 SDG125S 8B1 L cvO080V 9019 amp 31v3H NV AIDAVHI AWIIVE 804 SATOH 0593199143038 003199143238 GIL 0 0 42 8 59 00 gm 0 51 1 TX 08 09 09 09 ANVI IWINGRNISTANG LINNEA HL ND ST 1313 0002 SHOT NV3 AD
57. G Y EGR motor posision sensor W terminal EGR motor posision sensor V It detects valve lift of EGR exhaust gas E93 G W terminal re circulation valve EGR motor posision sensor U E94 Sane R W Boost pressure sensor 5V terminal E95 a Power supply for left sensors DC5V ___ ______ 2 2 2 Suction control valve SCV It inputs camshaft position CMP signal CMP signal is caused when cam position of camshaft passes camshaft position CMP sensor ECM judges cylinder according to CMP signal and it decides crank angle and counts fuel W T CAM angle sensor output terminal See injection control and engine speed This control is performed based on crankshaft position CKP signal detected by E107 terminal but in case crankshaft position CKP sensor is in trouble it is performed based on camshaft position CMP signal O O Boo NIL 2 E100 B W Shieldline Grounding angle sensor terminal angle sensor terminal sensor terminal E101 rail pressure sensor SG Grounding terminal EGR motor position sensor grounding terminal Ea 02 Be RDO INDE C MEM It operates EGR DC motor and it controls valve Connection terminal is available lift of EGR valve for SDG455 658 8B1 EGR DC motor V terminal decides EGR gas volume based on engine EGR DC motor V terminal DC motor V terminal
58. LAY j FUEL PUMP 35 SEE 9 97 029 1258 6 1258 6 F t 1125 Sg ES 5 v 125870 RM ER SL 0 5Br W V30 UP VT 0 85B MR2 La x t 0 5877 Oe V31 DWN SIGN E ENGINE SPEED SIGN So POWER v 05 2 2 E SRB 50 POWER WC 16 l 4 auto Pee SORA ae BAROMETRIC PRESS SENSOR t REG MODE OPTION LOAD ADVANCE MEM CLEAR 0 5B G 0 5R W GLOW 0 5B W 0 5B W 0 5R G 2 5 03870 V37 je s MONITOR LAMP 2 TOOL 05 8 28 0 5B 0 58 6 A CNIUTP FUEL PUMP RELAY z x ve oe DIAGNOSTIC MONITOR LAMP v17 0558 PRESS swt DIAG SW au 0 58 are EE e 5 V7 BOOST TEMP x lbi v15 WATER TEMP 1 SIGNAL OF x PRESS 4 E88 ry OVER SPEED 2 SENSOR 222 OIL FENCE Je OVER CRANK 0 5W L 0 58 L Je OIL FENCE Lh nt Alan 1 AIR FILTER WITH HOUR METER 2TURNS 1PULSE_0 5W G 05178 0 5 11 60B 60B Y 2 o a a m Vi 5 5 gt 5 gt 2 39 a 8 E 2 gt ow of d Ri DM PER ues etch mach NE EM i shia fi RO E vit OZ a i BATTERY m MX STX es sic 1 95D31R Jen amp CE z3 5 Sela a bles iP 1125R i T7 T9
59. Safety relay SR Magnetic switch MR1 Automatic operation unit Automatic voltage regulator AVR Three phase circuit breaker Current transformer 11 8 8 1 5609004 11 Thermal relay 12 Terminal plate 13 Controller ECM 14 Intake air temperature sensor 15 Barometric pressure sensor 16 Fuse 15A 17 Fuse 10A 18 Fuse 60A 19 Voltage selector switch The voltage selector switch is provided on the output terminal plate of the right bonnet 3 Electrical Parts 3 2 Electrical Parts of Generator 3 2 1 Rotary rectifier SDG45S 65S 8B1 Cable connection of rotary rectifier diode module is full wave rectifier circuit Varistor is connected for whole protection in the circuit as protection of diode Diode module Cooling fan Dumper coil ge Es gt e T SS mmm Z Rotor ass y Rotary rectifier Varistor Generator field winding wire Exciter armature winding wires SG09029 Diode module Generator field winding wire Varistor SG09107 3 4 3 Electrical Parts How to check whether diode module functions correctly or not If excessive voltage is applied to diode module or if excessive current flows interior diode will be damaged If diode module damaged generator does not generate elec
60. Troubleshooting 4 4 Engine Troubleshooting 4 4 1 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 Disconnected Faulty to emergency stop 5 5 gt Repair iconnection monitor 1 Normal Check if controller Faulty Faulty controller or Replace it or repair functions well connection connection 4 4 2 At start up starter rotates slowly xu ok Al RE icu Battery specific gravity Check batt lt Fault 1 1 RE 2 low or electrolyte 1 0 Re charge and or and specific gravity supply water replace 1 short i Normal Volt more than 12V or 24V Gravity more than 1 26 Check battery cable Faulty cable Replace terminal or assembly Faulty starter motor Replace terminal or assembly Normal 3X1 When starter switch is placed at the START position the battery is not normal if B terminal voltage decreases by 10V or 20V 4 7 4 Troubleshooting 4 4 3 It will not speed up to rated speed Filter clogging Faulty filter E Clean or replace it Check air filter Normal Filter clogging Check fuel filter Normal Check how fuel Faulty Malfunction of fuel feed pump t
61. arts 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 1 1 1 1 2 1 3 2 2 1 2 2 2 3 2 4 2 5 3 31 3 2 3 3 3 4 3 5 4 4 1 4 2 4 3 4 4 4 5 4 6 5 5 1 5 2 5 3 5 4 Table of Contents Specification e eer eoe n eorr n nnn rn MTM 1 1 Specifications 1 1 Outline Drawing 1 6 Internal Components 1 16 Overhauling eroe n e re n n rr eu nnn r rr rT MTM 2 1 Cautions for Overhauling 2 1 Tightening Torque 2 3 Disassembly Reassembly of Generator Main Unit and Connection of Generator Main Unit and Engine 2 5 Engine Maintenance Standards
62. as manuals etc 2 1 2 Overhauling 2 1 2 Disassembly and reassembly e 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 Wash disassembled parts with diesel oil cleaning solvent after checking for contamination or discoloration However do not wash rubber parts with diesel oil Be careful not to damage disassembled parts they are precision built Replace consumables such as oil seals O rings filters oil etc with new items when reassembling parts Apply a coating of clean grease to O rings when installing them in the machine 9 e Go 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 if you have to leave the repair incomplete for a long period of time Check tightening t
63. bilize the generator main unit frame Generator main unit frame T Wooden block 5606058 2 6 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 A Flywheel side run out B Housing center deviation Engine L Flywheel Dial gauge 5606059 2 7 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 Mount the engine on the vibration isolator rubbers at Flywheel housing the frame side of engine Put angle wooden block under the engine housing and incline the engine a little
64. ce at the connector on O O the generator side 7 Between J K terminal amp body 5606021 4 14 4 Troubleshooting 0 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 SDG45S 65S 8B 1 Remove varistor terminals and measure resistance between both terminals It is good if the measured resistance is more than 100kQ Tester range Cooling fan Damper coil Diode module aem Sal ZZ mmm Y EQ SSE Rotor Rotary rectifier Varistor Generator field winding wire Exciter armature winding wires 5609029 Diode module Diode Generator field winding wire Varistor 5609107 4 15 4 Troubleshooting 5061005 1255 1505 8 1 Remove varistor terminals and measure resistance between both terminals It is good if the measured resistance is more than 100k Tester range XkQ Insulating plate Silicon rectifier Silicon rectifier Lead wire EX ead wire EX Conductive plate Conductive plate Lead wire alternator Insulating plate 5605092 4 16 4 Troubleshooting 4 6 Engine Trouble Diagnosis Function With regard to this electronic gove
65. contact of ECM V11 terminal is ON and then power flows When OFF preheating is completed Co Monitor lamp CN1 12 No power exists during usual operation CNT3 terminal When air filter differential pressure indicator is Air filter clogging warning ON for 10 seconds interior contact of Y3 terminal lamp is ON and air filter clogging warning lamp glows 3 32 3 Electrical Parts y Line Connection Function color 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 terminal detects engine start speed more than 750 At the time if within 5 seconds engine start speed is not inputted auto start cranking ends without success and if auto start operation is repeated and 3 times without success interior contact of PLC unit Y4 terminal is and start stall signal is outputted to monitor panel CN1 11 terminal No power exists during usual operation Monitor lamp CN1 3 terminal 4 reos SK Oil fence water level rise When oil fence level switch is interior contact Monitor lamp CN1 11 terminal Start stall warning lamp CN7 5 CN7 6 CN7 7 7 of 5 terminal is ON and oil fence water level rise warning lamp warning lamp glows It outputs engine speed 2 revolutions per 1 pulse Engine spe
66. converter DC1 And XO relay works and voltage is applied to PLC unit XO terminal Then 2 seconds later interior contact of Y1 terminal is ON and preheating starts Then when X6 terminal detects preheating finished interior contact of Y2 terminal is ON and starter Remote start stop switch motor begins cranking and start engine CN6 6 Y W Via external output terminal W Stop plate 1 terminal Remote start stop switch is OFF to make XO relay switch OFF but power is supplied to PLC unit itself for 5 seconds with power input from CN6 1 terminal Then after engine performs cooling operation for 5 seconds interior contact between 0 terminals is OFF and engine is brought to stop EIn case pushing emergency stop button When pushing emergency stop button on operation panel power supply of auto start unit CN6 1 terminal 15 shut down to stop immediately It detects generator unit L1 L3 generating power CN6 7 Generator unit T7 terminal When engine automatically starts no power exists on X7 relay And in case no voltage is applied to X7 terminal interior contact of PLC unit Y1 Y2 CN6 8 Generator unit T9 terminal terminal is OFF and to stop engine start and to cancel auto re start function CN6 9 Grounding Line Connection Function color It detects preheating finish when starting 11 terminal While preheating interior
67. cted ROMfault fault EEPROM fault EEPROM fault Power supply wiring short to sensor or breakage in element circuit for power supply regulation inside ECM Open short circuit damage of relay or harness Open short circuit damage of lamp or harness Open short circuit deterioration of sensor or harness Short circuit in sensor or harness Common rail pressure abnormal increase Common rail pressure abnormal increase Open short circuit in injection common 1 side electrical wiring EDU output part fault Open short circuit in injection common 2 side electrical wiring EDU output part fault Short circuit in sensor or harness Open short circuit breakage of sensor or harness Pressure limiter 1s opened Fuel leakage large amount Common rail pressure sensor fault D 7 Short circuit in sensor or harness low voltage fault Common rail pressure does not increase to the required area Open short circuit breakage of sensor or harness high voltage fault p g 2 System open circuit tB Open short circuit of SCV harness Open short circuit in electrical wiring No 1 cylinder injection Open short circuit in electrical wiring No 2 cylinder injection Open short circuit in electrical wiring No 3 cylinder injection Open short circuit in electrical wiring No 4 cylinder injection Engine oil pressure sensor fault low Open short circuit breakage of sensor or harness voltage fault Engine oil p
68. d Such device in which cooling device is equipped is called as cooled EGR system High temperature EGR gas exhausted is cooled through cooler and the cooled gas is mixed and cooled Thus combustion gas temperature is cooled and NOX reduction is fulfilled more effectively than usual EGR gas Further cooled intake air density increases and accordingly intake air increases Thus combustion becomes perfect and it causes fuel consumption increase and PM black smoke reduction EGR function ECM is to operate EGR motor according to such engine conditions as engine RPM and engine load and to control EGR valve lift Valve lift is detected by EGR position sensor Outlet port Inlet port of coolant of coolant i EGR cooler ES gt gt EGR position sensor BN Exhaust rature sensor Boost pressure sensor EGR valve gt lt UUU Intake air Intake air temperature Engine speed sensor EGR system schematic diagram ECT sensor Engine load 5609035 3 15 3 Electrical Parts 3 3 3 Idle speed control When placing engine speed switch at LOW position at start up engine starts at low speed and warming up operation begins During this operation it
69. e Valve lift in mm 0 39 10 2 Overhauling ig RN SDG1008 1258 8B1 Engine model ISUZU BL4HK1XYGD 02 Tightening torque of head bolts IN he 13 3 18 0 183 5 natal Firingorder _______ Injection timing BTDO Electronic control _______ Nozzle injection pressure psi MPa ___ _______ Temperature for oF 180 82 start of release Thermostat Full open of 203 95 temperature Valve lift 0 39 10 1016 0 4 Valve clearance RII oA NN SDGI508 8B1 Engine model __ ____ ISUZU BH 6HK1XYGD 02 Tightening torque of head bolts UNT 9 6 13 0 132 5 0 016 0 4 Valve clearance 0 016 0 4 156024 Injection timing BTDC __ Electronic control pi MPa 000 000 psi MPa 441 3 09 Rotation speed 200rpm 00min Temperature for eF 180 82 start of release temperature Valve lift 0 39 10 2 17 2 Overhauling 2 5 Suction Control Valve SCV Replacement Procedure Supply pump Note The illustration indicates the supply pump unit only in order to explain easily Disconnect the suction control valve SCV connector Suction control valve SCV 5609043 Wash the outside of the suction control valve SCV using a cleaning spray Note Wash the suction control valve SCV to remove dust or foreign matter in the pump housing or on the installation
70. e OFF 5609104 4 Troubleshooting 9 When the diagnostic trouble code DTC has recovered to normal in the ignition cycle that the diagnostic trouble code DTC is detected the back up mode will be recovered normally but the diagnosis lamp does not go off 1 Diagnostic trouble code DTC is detected 2 Returned to normal 4 30 Key ON switch and Engine OFF run ane Sees Diag lamp OFF SG09105 5 References 5 1 Generator s Winding Wires Resistance Value At the temperature of 68 F 20 C SDG45S SDG65S SDG100S SDG125S SDG150S 8B1 8B1 8B1 8B1 8B1 Voltage selection switch position 480 277V Generator armature 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 battery 5606022 3 Magnetize for 1 to 2 seconds then remove the wires and check if voltage is 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 in thickness Generated voltage from forced excitation at 480V V Voltage generated V at the temperature of 104 F 40 C
71. e control Fuel injection pressure is controlled by fuel pressure control in common rail ECM counts fuel pressure in common rail based on engine RPM and fuel injection volume and it controls suction control valve SCV and sends proper fuel volume by pressure to common rail 3 Injection time control ECM counts proper fuel injection timing from engine RPM and fuel injection volume 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 Fuel injection correction ECM counts fundamental injection volume according to signals of boost pressure sensor crankshaft position CKP sensor camshaft position CMP sensor At the time suction control valve SCV switching timing and injector live timing is controlled according to such conditions as common rail pressure and engine coolant temperature Then they are corrected to be most suitable injection timing and injection volume 3 14 3 Electrical Parts 3 3 2 EGR Exhaust gas recirculation control EGR is a exhaust gas recirculation system Part of the exhausted gas is mixed again together with intake air to control oxygen density in combustion chamber in order to soften combustion and to lower combustion temperature Thus nitrogen oxides NOX can be reduce
72. e 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 62 5Hz 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 Notching position of voltage adjustment VOLT ADJ 6 5 10 62 5Hz 252V 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 adjusting volume STAB ADSJ 4 10 Adjusting time constant Instantaneous characteristic is set at the best point So it is not necessary to adjust it Adjustment is prohibited notching position of time constant adjustment volume 1 10 Protection against excessive exciting current A
73. eck whether load starting Reduce load capacity to suit generator kVA exceeds rated output of capacity Or use a higher kVA generator generator that suits load capacity Any problem in load or cable such as short circuit or loose connections Engine output Js insufficient Repair See Engine manual 4 5 4 Troubleshooting 4 3 Emergency Switch Functions 4 3 4 Engine oil pressure drop is shown in monitor and it stops i i Short Check engine oil Replenish or replace quantity Check oil filter Filter clogging Normal Check engine oil pressure Normal i Defective oil pressure Replace it iSwitch Check cable connection Looseness of cable 1 3 Faulty to engine oil pressure connection or i Repair switch separated 4 3 2 Engine coolant temperature rise is displayed in monitor and engine will stop Check water quantity Shortage and quality in radiator Normal Check ambient temperature Lower than 104 F 40 Check water temperature switch Normal Check cable connection Faulty to water temp switch Shortage of coolant amp ee Replenish or replace quality Higher than 104 40 C Lower ambient temperature down to less than 104 F 40 C NE Malfunction of switch Replace it Looseness of cable 1 1 1 connection or Repair separated 4 6 4
74. ection control with ECM it detects intake air temperature at unit in use In front of engine air intake device NIL V74 BR Boost temperature sender It detects intake air temperature in intake manifold V75 NIL V76 NIL VTI NIL V78 NIL Oil pressure sensor SG terminal V79 BY Water temperature sensor grounding terminal Fuel temperature sensor grounding terminal V80 W B Oil pressure sensor VCC terminal eee RUDI On V81 Grounding 3 23 3 Electrical Parts 3 1 List of E terminal function 40 pins SDG45S 65S 100S 125S 8B 1 Pin Line Connection Function No color It detects common rail pressure fuel pressure It detects fuel pressure in common rail and it earl OUT converts it voltage signal and inputs it It is used E82 W Br inal for fuel injection control Pressure detecting voltage signal is 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 E83 Y G Fuel temperature sensor temperature and 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 te
75. ed 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 Starter switch ACC terminal Starting When remote start stop switch is XO relay works to supply power to PLC unit XO terminal and 2 seconds later interior contact of 1 terminal is ON Thus MX relay works and engine power relay supply is outputted from CN7 7 terminal Outputted power from CN7 7 is to activate MR1 relay and supply power to ECM for starting preheating Tachometer Via monitor lamp CN1 8 terminal 8 88 CNT9 NIL 3 Electrical Parts y Line Connection Function color Starter switch C terminal Starter relay SY It outputs start signal when automatically starting When PLC unit X6 terminal CN7 1 terminal detects end of preheating Y2 terminal interior contact is ON to activate STX relay and it outputs start signal to starter relay from CN7 8 terminal Start signal is inputted to X3 terminal CN6 2 terminal When engine speed exceeds 750min Y2 terminal interior contact is OFF and cuts output Thus automatic start cranking operation is brought to stop After start signal is outputted engine speed to be inputted to X3 terminal will not rise not geared Y2 terminal interior contact is kept ON power is supplied and OFF to engine controller ECM V14 termi
76. efault setting 150 kPa 21 8 psi Boost pressure cor rection gEGR stopped 4 Troubleshooting DTC descrip Item to be tion detected Crank sensor fault no signal Open circuit in sensor wiring Crank fault fault Broken teeth unnecessary signal mixed such as short circuit with other wiring sensor signal Cam sensor fault no signal Open circuit in sensor wiring Broken teeth unnecessary signal mixed such as short circuit with other wiring sensor signal Glow relay fault Open short cir cuit damage of relay or har ness Glow lamp fault Open short cir cuit damage of lamp or har ness Preconditions when DTC is set DTC set condition Fault judg ment period Behavior when trou ble occurs Key switch input voltage is 9 V or more CMP sensor pulse is normal DTC P0335 P0336 P0340 P0341 P1345 or P1634 is not detected Engine is running Key voltage more CMP sensor pulse is normal DTC P0335 P0336 P0340 P0341 P1345 or P1634 is not detected Engine is running switch input is 9 V or Key switch input voltage is 9 V or more Crank pulse is nor mal DTC P0335 P0336 P0340 P0341 P1345 or P1635 is not detected Engine is running Key switch input voltage is 9 V or more Crank pulse is nor mal DTC P0335 P0336 P0340 P0341 P1345 or P1635 is
77. efore installing it 14 5 21 71 19 6 29 4N m 200 300kef cm 5609060 3 58 3 Electrical Parts 3 5 11 Overheating switch The overheating switch is installed on the water outlet pipe and it is turned ON when the engine coolant temperature exceeds 221 105 Removal Loosen the nut using a 0 31in 8mm wrench to remove the harness and remove the sensor using a 0 83in 21mm wrench Installation roan Sensor 20 25lb ft 27 34 m 275 347kef cm Nut 0 6 0 7Ib ft 7 1 8 91 0 8 1 0N m 8 2 10 2kgf cm 5609062 3 5 12 Crankshaft position sensor The crankshaft position CKP sensor is installed onto flywheel housing and produces the CKP signal when the convex portion of flywheel passes the sensor The ECM distinguishes the cylinders by the CMP signal input 2 from camshaft position CMP sensor determines the LJ crank angle and uses it to contorl fuel injection and calculate the engine speed These contorls are performed SG09063 usually based on CKP signal However it is done based on CMP signal if the crankshaft position CKP sensor is faulty Removal E di Disconnect the connector and remove the 0 391 10mm mounting bolt and sensor Installation J 11 1816 14 7 24 5N m 150 250kgf em 5 17 D 0 39in 10mm l EE 5609064 3 54 3 Electrical Parts
78. ent 6 Remove the assembly level plates and place the cushion rubbers in their respective places on the frame Insert or place adjusting shims on the vibration isolator 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 Placing vibration isolator rubbers for SDG65S make sure to put plain washers on the rubbers If not the vibration isolator rubbers are left loose So vibration could damage vibration isolator rubbers and machine 8 Make sure to coat the bolts with anti corrosion agent Metal Clear which are tightened for vibration isolators 8 points consisting of upper side 4 pieces and under side 4 pieces Engine 7 generator C L Bracket A TX Cushion rubber 7 Frame i Engine mounting posisition 52 SG05049E X Before installing vibration isolators 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 SDG458 8B1 SDG65S 8B1 SDG1008 8B1 SDG125S 8B1 SDG150S 8B1 3 78 96 4 10 104 461017 4 04 102 5 3 23 82 3 78 96 3 78 96 4 63 117 5 3 58 91 Assembly 1 level plate
79. ermistor is little when temperature is high and it is large when temperature is low It detects engine coolant temperature t lt hich ch ding t E84 R B Water temperature sensor t Mis resistance and then it counts engine coolant temperature dope ee EB NIL __ Common rail pressure sensor VCC terminal Power supply for left sensors DC5V EGR motor 77 sensor power 77 terminal Suction control valve SCV It detects common rail pressure fuel pressure It detects fuel pressure in common rail and it converts it voltage signal and inputs it It is used Common rail pressure sensor OUT PT E90 Br innui for fuel injection 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 pressure E91 L Boost pressure sensor OUT It counts boost intake air pressure from terminal detected voltage signal for fuel injection control Voltage is high when pressure is high and it is low when pressure is low 3 27 3 Electrical Parts lt SDG150S 8B1 gt No color E92 G Y EGR motor posision sensor W terminal EGR motor posision sensor V It detects valve lift of EGR exhaust gas E93 G W terminal re circulation valve E94 G B EGR motor posision sensor U terminal E95 R W pressure sensor 5V terminal Power supply for boost pressure sensor DC5V
80. housing and the stator tightening the connecting bolts The bolts should be high tensile 7T or more 3 Remove the angle wooden block from under the flywheel housing and place the generator main unit and engine horizontally 5606060 Tightening torque of generator main unit frame staton connecting bolts See 4 of 2 3 1 Bolts Tightening torque 2 9 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 Engine 3 Bracket D Bolt Shim Cushion rubber Nut 5605048 2 Overhauling 1 Centering method 1 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 Lift the engine mounted onto the generator main unit leaving the shims in the four places after adjustm
81. ies are deleted 4 21 4 Troubleshooting 4 6 3 List of diagnostic trouble codes DTC The following diagnostic trouble codes DTC are listed based on those of ISUZU Engine model B1 4HK1X mounted on SDG1008 125S 8B1 The flash codes marked show the blinking flash patterns of the diagnostic lamps DTC descrip tion No pump pres sure feed fuel leakage Item to be detected Preconditions when DTC is set Common rail pressure does not increase to the required area Key voltage more 900 rpm or more switch input is 9 V or Common pressure fault 1st stage Common rail pressure fault 2nd stage Common rail pressure fault Excessive pressure feed in pump SCV drive sys tem open cuit short or ground short Barometric pressure sen sor fault low voltage fault Common rail pressure abnormal increase Common pressure abnormal increase Common pressure abnormal increase Open short cir cuit of SCV hamess Open short cir cuit deteriora tion of sensor or harness Key switch input voltage is 9 V or more DTC P0088 P0192 P0193 or P1635 is not detected Actual rail pressure is 2 MPa 290 psi or more and 70 rpm or more DTC set condition Actual rail pres sure is 15 Mpa 2 176 1655 Rail pressure is more than 185 MPa 26 832 psi Approx 3 sec Approx 5
82. is possible to control idling speed using Frequency adjustment switch and also to adjust the proper speed according to engine coolant temperature Frequency adjustment switch UP While you are pushing UP side engine speed rises and it can raise idling speed DOWN While you are pushing DOWN side engine speed drops and it can lower engine idling speed but it can not be lowered lower than the lowest speed 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 is OFF 3 3 4 Preheating control QOS Quick On Start system The ECM determines the period required for glow pre glow 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 Electrical Parts 3 4 Electrical Parts of Engine 3 4 1 Engine control module ECM SDG45S 65S 8B1 HOKUETSU part number 44390 02600 SDG100S 125S
83. j Injector 4 mn j Injector 3 mj Injector 2 mn SCV rw pressure UID 8 E CS LI Intake air Ex temperature sensor 6 1 134 Boost pressure HD I el s 4 Boost Memory clear switch SG09038E 3 18 3 Electrical Parts 2 List of V terminal function 81 pins SDG45S 65S 100S 125S 150S 8B1 color V1 B Grounding B Grounding 2 4 V4 B Grounding o No power exists during usual operation When engine trouble interior contact in ECM is ON and it connects ground to sends power Monten lamin CON 156 Thus diagnosis lamp of monitor lamp glows V6 L B Diagnosis lamp At the time it makes engine stop once and when the starter switch is placed to ON again and push diagnosis switch to send electricity to V52 terminal the lamp begins to flicker and this shows engine trouble at present and past No power exists during usual operation When boost temperature rises higher than specified one interior contact in ECM is Monitor lamp CN1 2 terminal and it connects ground to sends power V7 Br R Boost temperature lamp Thus boost temperature rise warning lamp glows Warning lamp lighting temperature 185 F 85 C It outputs engine speed V8 Auto start unit CN6 2 terminal Revolution ratio pulse type
84. le Frequency compensation characteristics and V Hz corner frequenc Corner frequency Output voltage 96 Frequency Hz 3 Electrical Parts 3 2 5 Thermal relay tting dial Setting dia Auto reset button Terminals for Test button instrument circuit Terminals for main circuit SDG 002 Thermal relay set value init 506455 8 1 SDG65S 8B1 Rated voltage 20 40 240 480 152 E IE 54 rated operation CT ratio Wound rolls Rolls of unit 561006 8 1 SDG125S 8B1 SDG150S 8B1 Rated voltage 240 40 240 480 940 41 rated operation CT ratio Wound rolls Rolls of cables through CT Tripping of over current is set to be reset automatically 3 Electrical Parts 3 3 Electronic Control System of Engine The engine control system is 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 9 Idle speed control The engine control system also has the following system control functions other than engine control D QOS Quick On Start system Engine speed signal output Self diagnosis function 7 CAN Controller Area Network communication 3 3 1 Electronic control fuel injection system Common rail type ECM engine co
85. le Note Never proceed any investigation or measurement which may cause further greater damage 5 Procedures of diagnosis When you become 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 1 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 1 4 Troubleshooting 4 1 3 How to use the failure diagnosis Standard Possible Impossible Abnormal Normal 1 In 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 3 In the troubleshooting column the countermeasures or treatment are mentioned in the double lined parenthesis 4 under each column means the index of explanation 4 2 4 Troubleshooting 4 2 Generator Troubleshoo
86. lls engine will not start Back up Engine running based crank when it is normal After engine stops Unable to identify cylinder unable to restart Behavior does not change during engine running Engine is running at low speed engine stall possible After engine stalls engine will not start Back up Engine running based crank when it is normal After engine stops Unable to identify cylinder unable to restart Recov from failure Deterioration of start ability at cold weather Back up No back up action Operationality is not affected Back up No back up action DTC descrip tion EGR position fault Brushless specification EGR valve control fautt Engine oii pressure sor fault low voltage fault Engine oil pressure sor fault high voltage fault 4 Troubleshooting to be detected Open short cir cuit breakage of sensor or harness Troubie open circuit or valve engage stuck in drive motor side Preconditions when DTC is set Main relay input voltage is 9 V or put more DTC P1630 P1635 is not detected DTC set condition EGR position out signal abnormal ____ Fault judg ment period Behavior when trou ble occurs Exhaust affected Back up Instruction to fully close EGR valve gas is P1630 P1635 or P0488 is not detected Main
87. me as E102 E104 terminal us 12 Connection terminal is available only for SDG45S 65S 8B1 When power stays on fuel is sent to common rail by pressure E113 R W Suction control valve SCV Fuel injection volume to common rail is controlled by control of power supply timing of suction control valve SCV N __ ______ ___ oo E116 Injector23 Power supply for injector 2 amp 3 2 X Line color shows the line color for SDG100S 125S 8B1 3 26 3 Electrical Parts 3 2 List of E terminal function 40 pins SDG150S 8B1 Pin Line Connection Function No color It detects common rail pressure fuel pressure It detects fuel pressure in common rail and it converts it voltage signal and inputs it It 1s used Common rail pressure sensor OUT deor E82 W terminal for fuel injection control Pressure detecting voltage signal is 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 E83 Y G Fuel temperature sensor temperature and 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 th
88. mperature is high and it is large when temperature is low It detects engine coolant temperature E84 HIB Water temperatune sensor It detects voltage which changes according to resistance and then it counts engine coolant temperature 24424 EB6 angle sensor terminal E87 R L Common rail pressure sensor VCC Power supply for left sensors DC5V terminal L EGR motor position sensor power supply terminal No power exists during usual operation When engine speed rises up to emergency stop set speed interior contact in ECM is ON and E88 Y Monitor lamp CN1 13 terminal it connects ground to sends power Thus overspeed warning lamp glows Emergency stop set speed 2070min 69Hz It detects common rail pressure fuel pressure It detects fuel pressure in common rail and it Communal pressure conser OUT converts it voltage signal and inputs it It is used 90 W Br bata for fuel injection control Pressure detecting voltage signal is high when pressure is high and it is low when pressure is low 3 24 3 Electrical Parts lt SDG45S 125S 8B1 gt Pin Line Connection Function No color It detects engine intake boost intake air pressure E91 L Boost pressure sensor OUT It counts boost intake air pressure from terminal detected voltage signal for fuel injection control Voltage is high when pressure is high and it is low when pressure is low E92
89. n power supply volt element circuit age is between 7 and for power sup 16 V ply regulation inside ECM P1633 55 Voltage fault in Power supply P1630 is not 5 V power sup wiring short to detected ply 3 Sensor switch input breakage in power supply volt element circuit age is between 7 and for power sup 16 V ply regulation inside ECM 4 28 Fault Diag Recov a judg Behavior when trou DTC set condition ment hie occurs d from period amp failure No injector 2 and Approx Engine stopped ON 74 3 monitor input 35 Back up signal exists Engine stopped and can not restart Correct cam When Behavior does not 54 pulse does not trouble change during exist in crank gap 59 engine running position outof10 After engine stalls sam engine will not start ples Back up No back up action Main relay system Approx Engine does not ON 2 voltage is 1 V or 2sec start less with main Back up relay coil output No back up action ON Relay does not Approx Vehicle power sup 1 cut off despite of 5sec ply cannot be shut main relay coil off output OFF indi Back up cation No back up action A D conversion Immedi Engine stopped ON 2 failure ately Back up Engine stopped and can not restart Key switch power Approx Idling ON 2 supply voltage is 0 5 sec Back up 5 5 V
90. n 5V power supply 3 Barometric pressure sensor fault low voltage fault Barometric pressure sensor fault high voltage fault 77 Check engine lamp fault Common rail pressure fault 1st stage Common rail pressure fault 2nd stage Common rail pressure fault Excessive pressure feed in pump Injection nozzle common 1 drive amem 5 2 2 5 S EIS lt S uu o uiuo eic 5 IG hs LA n lt n ct 151 158 Injection nozzle common 2 drive m Fuel temperature sensor fault low voltage fault Fuel temperature sensor fault high voltage fault Pressure limiter open 211 n lt n ct 225 297 No pump pressure feed fuel leakage No pump pressure feed fuel leakage Open circuit injection nozzle 1 drive Open circuit injection nozzle 2 drive n lt ct Om lt lt lt e 8 m m H H ET m 5 2 2 3 3 3 3 amp 5 Q Q 5 5 m 5 5 245 247 271 272 273 74 2 294 ground short Boost temperature sensor fault lo voltage fault Boost temperature sensor fault high voltage fault Results of trouble diagnosis Item to be dete
91. n of E106 Crank angle sensor terminal flywheel passes through sensor position ECM judges cylinder according to CKP signal and it decides crank angle and counts fuel injection control and engine speed This control is performed based on CKP signal but in case crankshaft position sensor is E107 W Crankangle sensor terminal in trouble it is performed based on camshaft position CMP signal detected between E98 E99 terminals 3 28 3 Electrical Parts lt SDG150S 8B1 gt No color E108 Shield line Boost pressure sensor SG terminal E109 R L Boost temperature sensor Grounding grounding terminal It operates EGR DC motor and it controls valve E110 W L EGR DC motor W terminal 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 EM2 2 E113 Same as E105 terminal E114 When power stays on it injects fuel to injector 2 E115 When power stays on it injects fuel to injector 4 E116 _ Injector 4 5 6 Power supply for injector 4 5 amp 6 When power stays on it injects fuel to injector 3 When power stays on it injects fuel to injector 6 When power stays on it injects fuel to injector 1 When power stays on it injects fuel to injector 5 E121 E111 W R EGR DC motor U terminal 3 29 3 Electrical Pa
92. n rail Proh The common rail receives fuel from supply pump holds Flow damper limiter the common rail fuel pressure and distributes fuel to each cylinder The common rail has common rail pressure sensor flow damper and pressure limiter Note For work procedure refer to Engine section in the Common rail service manual ec SG09056 3 5 6 Flow damper The flow damper is installed onto outlet port to each limiter injector of common rail limits pressure pulsation in common rail and prevents over injected fuel from injector When the flow damper operates fuel supply to injector is stopped Removal Common rail Common rail Do not replace the flow damper pressure sensor If it is damaged replace it as common rail assembly 5609056 3 51 3 Electrical Parts 3 5 7 Pressure limiter Pressure The pressure limiter operates to release the pressure in Flow damper _ limiter 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 Common rail Common rail pressure sensor 5609056 3 5 8 Pressure LM Flow damper limiter The common rail pressure sensor is installed onto common rail detects fuel pressure in common rail converts the pressure into the voltage signal and sends it to ECM Voltage becomes higher as pressure becomes higher and lower a
93. nal Again repeat one second start and 5 seconds stop automatic start operation Unless engine speed inputted to X3 terminal will exceed 50min even after it is repeated three times Y4 terminal interior contact is start stall signal is outputted from CN7 4 terminal to make overcrank warning lamp glow lt Function of ECM V14 terminal interior contact when it is not geared gt 1 second ON od L JL JL 5 seconds Three times 3 34 O b 0 n OS eco otf LED BOOST ra 0 00 3 Electrical Parts 3 4 3 Emergency lamp SDG45S 1255 8 1 SDG150S 8B1 1 External schematic diagram Connector No and Pin No of controlle ECM Engine controller Trouble lump Boost L temperature Overspeed Oil pressure Water temperature 7 Glow 777 Oil 4 On at air filter clogged 777 Battery 12V or 22 77 Controller CN1 6 CN1 4 CN1 2 CN1 13 CN1 14 CN1 7 CN1 5 CN1 11 CN1 3 CN1 12 CN1 15 CN1 8 CN1 16 CN1 10 CN1 1 3 35 CN1 17 HOKUETSU part number 46870 47901 HOKUETSU part number 46870 47401 98765 4321 Trouble signal 221 controller Alterna
94. ntrol 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 in this system Common rail Pressure ___ pressure sensor Common rail limiter Electromagnet pump Fuel filter Flow damper Pre fuel filter F Injector p Fuel tank 2008 p O C Various sensors boost pressure and engine coolant temperature etc Camshaft Crankshaft position position CMP sensor CKP sensor 8609034 1 Fuel system Fuel is supplied to supply pump from fuel tank and then sent to common rail after it is pressurized by pressure pump At the time fuel volume supplied to common rail is controlled by suction control valve SCV 3 Electrical Parts 2 Injection pressur
95. ome necessary to replace the bearings follow the under mentioned procedures Replacement of bearings 1 Remove bearing shield end cover Pull out the bearing from the shaft using bearing removing tools gear puller Clean the surface of the shaft and check for any damages Prepare a new bearing and check it by turning it by hand before installing it Heat the bearing in the oil bath at average 100 to 118 C Never heat it over 120 C or partially and then install the bearing using a bearing installer Heated bearing can be installed to the shaft 6 Set guide bolts to the generator main unit frame C N 7 Push in the bearing shield end cover hitting it with a plastic hammer evenly Bearing Installer End cover Guide bolt 5606061 5606062 2 Overhauling 2 3 7 Replacement of rotary rectifier IMPORTANT When installing diode module silicon rectifier it is necessary to be careful not to damage it due to over tightening Shorten time to keep soldering iron touch on diode module silicon rectifier Degrease such surfaces where thread looseness is prevented by thread locking fluid 9 is impossible to replace varistor only because it is built in insulating plate SDG45S 65S 8B 1 D Diode module Varistor Insulating plate 4 Lead wire alternator 5609106 Above shows rotary rectifier fitted to SDG45S 8B1 SDG100S 125S 150S 8B1 D Silicon rec
96. opped and can not restart Engine stopped Back up Engine stopped and can not restart Due to back up equivalent to 2 000 m 6 562 ft Black smoke emit ted at high altitude Back up Barometric pres sure default setting 80 kPa 11 6 psi EGR stopped DTC descrip tion Barometric pressure sen sor fault high voltage fault 4 Troubleshooting Item to be detected Short circuit in sensor har ness Preconditions when DTC is set Key switch input voltage is 9 V or more DTC P1630 or P1632 is not detected DTC set condition Fault judg ment period Behavior when trou ble occurs Diag nosis lamp Recov ery from failure Barometric sure sensor volt age is more than 3 8 V pres Approx 5 sec Intake air tem perature sor fault low voltage fault Intake air tem perature sor fault high voltage fault Engine coolant temperature sensor fault low voltage fault Engine coolant temperature sensor fault high voltage fault Fuel tempera ture sensor fault low volt age fault Short circuit in sensor or har ness Open short cir cuit deteriora tion of sensor or harness Short circuit in sensor or har ness Open short cir cuit breakage of sensor or harness Short circuit in sensor or har ness Key switch input voltage is 9 V or more DIC P1630 or P1632 is no
97. or more or Same to accelerator 4 5 V or less sensor fault Key switch power Approx Due to back up ON 2 supply voltage is 0 5 sec equivalent to 2 000 5 5 V or more or 6 562 ft 4 5 V or less Black smoke emit ted at high altitude Back up Same to baromet pressure and intake air tempera ture sensor fault Key switch power Approx Engine stopped ON 2 supply voltage is 0 5 sec Back up 5 5 V or more or 4 5 V or less Engine stopped and can not restart DTC Flash code DTC descrip tion 4 Troubleshooting Item to be detected Preconditions when DTC is set DTC set condition Fault judg ment Behavior when trou Recov ery P1634 55 Voltage fault in 5 V power sup ply4 Power supply wiring short to Sensor or breakage in element circuit for power sup ply regulation inside ECM P1630 is not detected Key switch input power supply volt age is between 7 and 16 V Voltage fault in 5 V power sup ply 5 DTC P1630 is not detected Key switch input power supply volt age is between 7 and 16 V Power supply wiring short to Sensor or breakage in element circuit for power sup ply regulation inside ECM About recovery from failure There are three modes for recovery from failure Key switch power supply voltage is 5 5 V or more or 4 5 V orless Key switch power supply voltage is 5 5 V or more or 4 5 V or less
98. orque and clearance when assembling parts Check the direction of rotation speed and oil leakage after assembly Before starting the machine after disassembly run it at low idle to check for unusual noises etc to prevent engine or generator damage 2 2 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 Low or medium carbon steel bolt High strength steel bolt SS400B etc SCMA35 etc Strength gi d 4 6 6 8 AT 6T 8 8 12 9 77 127 Indication does and indication example not appear in some cases N minal diameter Hexagon headed bolt Socket bolt Hexagon headed bolt Es Nm s J s se 3080 s mes __ 3568 em s ow J a sw s sss s sem s 159 as 5 1m 26x i5 3 m x 514 0 T 105 145 1450 290 2900 148 205 2050 410 4100 203 280 2800 560 5600 a s s sa mow Applied sections For BenerabsecHoDsiucmasponner For specified sections and frame IMPORTANT Each clamping torque listed in the above mentioned table applies to bolts being used for generators The list shows normal clamping torque In some sections special specified torque is required In such a case use the specified torque only Make sure to remove r
99. ped Back up Engine stopped and can not restart Common rail pressure sen sor fault high voltage fault Open circuit in injection noz zie 1 drive system Open circuit in injection noz zie 2 drive system Open circuit in injection noz zle 3 drive system Open circuit in injection noz zle 4 drive system Overrun Boost pres sure sensor fault low volt age fault Boost pres sure sensor fault high volt age fault Open short cir cuit breakage of sensor harness Open short cir cuit in electrical wiring No 1 cylinder tor Open short cir cuit in electrical wiring No 2 cylinder tor Open short cir cuit in electrical wiring No 3 cylinder tor Open short cir cuit in electrical wiring No 4 cylinder injec tor Engine speed abnormally high Open short cir cuit breakage of sensor or harness Short circuit in sensor or har ness Key voltage more DTC P1630 P1635 is not detected Switch input is 9 V or Main relay power supply voltage is 9 V or more 70 rpm or more DTC P0611 P1261 or P0201 is detected Main relay power supply voltage is 9 V or more 70 rpm or more DTC P0612 P1262 or P0202 is not detected Main relay power supply voltage is 9 V or more 70 rpm or more DTC P0612 P1262 or P0203 is not detected Main relay power
100. r Main relay power common 2 in injector supply voltage is 9 V drive system common 2 side or more fauit electrical wir 70 rpm or more ing EDU out None of the follow put part fault ing DTC sets are detected DIC P0612 P1262 and P0202 DTC P0612 P1262 and P0203 P1345 16 Cam sensor Camshaft gear Key switch input out of phase crankshaft gear voltage is 9 V or installing angle more is out of phase DTC P0335 P0336 or damage in P0340 P0341 gear P1345 or P1635 is not detected sensor pulse is normal Crank pulse is nor mal P1625 416 Main relay sys Open ground Key switch input tem fauit Not short circuit in voltage is 9 V or enter harness relay more OFF anchoring DTC P1630 is not detected 3 seconds or more has elapsed after key Switch ON Main relay drive indication ON Harness B DTC P1625 short relay ON P0606 is not anchoring detected P1630 36 A D conver A D sion fault sion fault z P1631 55 Voltage fault in Power supply P1630 is not 5 V power sup wiring short to detected ply 1 sensor or Key switch input breakage power supply volt element circuit age is between 7 and for power sup 16 V ply regulation inside ECM P1632 55 Voltage fault in Power supply P1630 is not 5 V power sup wiring short to detected ply 2 Sensor ori Key switch input breakage i
101. ransported or if any pump fuel pipes Repair pipes and bleed air mixed faulty alr Normal Faulty controller or Replace it or repair icable connection connection Engine body fault compression pressure X1 valve clearance turbocharger supply Repair the trouble and ipump injector common rail and other get rid of the cause mechanical trouble etc Saja oie ae alata X1 For the detailed countermeasures refer to Troubleshooting manual Service manual published by Isuzu Motors 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 5 The resistance decreases when the knob is turned in the direction of A The resistance increases when the knob is turned in the direction of B Also make sure resistance varies smoothly 5606067 8 Measurement of Generator Winding Wires Resistance The standard resistance value of each wire includes the generator s winding wires resistance value Please refer to the sentence 5 1 Generator s Winding Wires Resistance Value SDG45S 65S 8B 1 1 Generator armature winding wires 4 Exciter field winding wire Diode module
102. reign 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 you remove high pressure pipes fuel system make sure to replace them by new ones If you re use them it could damage sealing face and cause fuel leakage Make sure to replace spare parts such as gasket and O ring by new ones 4 20 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 DTC will not be deleted in this case It is necessary to compulsorily delete this memory according to the following procedures 2 Deletion by memory clear switch Switch ON key switch Switch ON diagnosis switch Switch ON memory clear switch connection of ECM V32 terminal and ground connection Wait for 3 seconds with these switches ON Switch OFF memory clear switch connection of ECM V32 terminal and ground connection Switch OFF diagnosis switch Switch OFF key switch Wait for 10 seconds with the switches OFF Switch ON key switch Switch ON diagnosis switch 1 0 OB OD Check and confirm that memor
103. relay voltage is between 9 and 16 V Difference between target EGR opening angie and actual one is 2096 or less Difference between target valve lift actual position is more than 20 Recov ery from failure Exhaust affected Back up Instruction to fully close EGR valve gas is Open short cir cuit breakage of sensor or harness Short circuit in sensor or ness Key switch voltage more DTC P1633 is not detected input Key switch input voltage is 9 V or more P1633 is not detected is 9 V or Engine oil pres sure sensor volt age is less than 0 1 V Engine oil pres sure sensor volt age is more than 4 85 V Approx Engine stopped 4 sec Approx 4 sec ROM fault ROM fault EEPROM fault EEPROM fault is faulty Reflash failure Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart EEPROM faulty CPU fault CPU monitor ing IC fault Charge circuit fault bank 1 Charge circuit fault bank 2 Sub CPU fault ECU charge circuit 1 fault internal burn open cuit etc ECU charge circuit 2 fault internal bum out open cir Cuit etc Sub CPU detects main CPU fault in 100 msec after key switch ON SUB CPU resets CPU
104. rences BOOST PRESS SENSOR OUT ENGINE SIDE Q 75R W 0 75R L BOOST TEMP E SENSOR zm ale SHIELD LINE ole CRANK ANGLE 0 5Gr B SENSOR 0 758 SHIELD LINE zm picem s 0 5Y CAM ANGLE 005 0 51 SENSOR 2 4 0 50 B C 0 75B W VCC pr COMMON RAIL a 0 5Br 2 SG pm 0 5L W 0 5Br hore zi fee ae SHIELD LINE 1 0 751 F0 0 75G B EGR MOTOR POSITION V 6 03 0 75G W SENSOR F02 0 75G Y Fo0s 0 75L W 5 7 E95 E91 E109 107 108 87 98 101 100 E82 E90 E94 E93 E92 ECM ENGINE SIDE 0 75W R F08 U 0 75W B EGR E103 DC MOTOR T 0 75W L Bu 2W E01 Eis 2L E05 At 2L W E08 aif 2R E02 E120 ZAR 07 e CYL 3 T 2L R E06 1 2105 0 79 R W as 015R W Sey 0 75R B 0 758 B 0 75W B m 0 75L Y PS OIL PRESS E84 dp WATER TEMP E SENSOR LLL E 0 75Y G G01 Eco c sensor PER UR ES SG09012 5 References An Example SDG150S 8B1 3 R W STAR emm Wire of Red White Line SWITCH ASSY ON B Black White Lg Light green Br L O Orange V Violet Gren P Pink T Tan R Gray
105. resistance Temperature resistance range range C range value value value 3 Lamp specifications SDG45S 125S 8B1 12V 3 4W SDG150S 8B1 3 44 3 Electrical Parts 3 4 11 Thermo sensor for water temperature gauge SDG45S 65S 8B1 HOKUETSU part number 44334 17600 SDG100S 125S 8B1 ISUZU part number SDG150S 8B1 HOKUETSU part number 44364 00100 SG06077 Characteristic of temperature resistance SDG45S 658 8B1 SDG1008 1258 8B1 o 7 7 160 qp _ e 440 cp o 3 Characteristic of temperature resistance 176 80 221 105 239 115 3 45 3 Electrical Parts 3 4 12 Oil pressure gauge 506455 1255 8 1 HOKUETSU number 36143 03600 SDG150S 8B1 HOKUETSU part number 36143 03800 1 Grounding HW Connector for lightin O 5 SG06041E 1 Indicated pressure and Standard current value Indicated pressure psi 0 60 0 41 113 8 0 78 Resistance value 0 2 List of functions Function Power supply for oil pressure gauge Detector for oil pressure Grounding 3 Lamp specifications Lamp specifications 500458 1258 SBI 5001505881 3 46 3 Electrical Parts 3 4 13 Oil pressure sensor for oil pressure gauge HOKUETSU part number 44365 00300 5606042 Standard pressure and Standard resistance value
106. ressure sensor fault high Short circuit in sensor or harness voltage fault Open short circuit breakage of sensor or harness Short circuit in sensor or harness 4 19 4 Troubleshooting Results of trouble diagnosis Item to be detected pattern relay austen fault NoE ente Open ground short circuit in harness relay OFF 416 anchoring Main relay system fault Not enter Harness short relay ON anchoring Overheat condition Engine speed abnormally high 7 Necessary measures for the results of diagnosis trouble See list of blinking patterns flash codes and results of diagnosis trouble mentioned on previous pages For the detailed countermeasures refer to Troubleshooting manual Service manual published by Isuzu Motors If scan tool is fitted it is possible to check or read troubles by scan tool operation Take special care in handling fuel system and so refer to the following cautions Fuel pipes gt Injector pipe Never use such pipes as used high pressure pipes of fuel system and injector pipes Make sure to replace used ones by new ones Never change pressure limiter common rail pressure sensor only If they are in trouble change it as an assembly and all fuel pipes Pressure Common rail limiter pressure sensor 5609080 Cautions about maintenance of fuel system the parts of fuel system and holes clearances as fuel passage are precision machined so that entrance of fo
107. rnor engine Common rail electronic control fuel injection engine this engine itself is equipped with trouble diagnosis function When it is in trouble it is possible to check and confirm how the trouble is by monitor lamp blinking pattern flash code 4 6 1 Engine trouble diagnosis 1 Check and confirmation of trouble Ginnie cab When engine fails diagnosis lamp 1 on monitor Os wm panel lights For the details of the trouble press CE diagnosis switch 2 and then it displays trouble COL CO conditions with blinking pattern flash code 5 2 lt Procedure gt D Turn starter switch to RUN position and continue pressing diagnosis switch 2 2 While you are pressing diagnosis switch 2 diagnosis lamp 1 flickers blinks and its flickering 090120 blinking pattern flash code indicates the details of trouble Example of blinking pattern Flash code 1 2 2 3 Case of code 2 3J V st Xf Xt MEAE ON 1 2 3 4 1 1 2 3 of code 413 it it It i gt Og Xt Xf ON 5609079 Short interval blinking 4 times and long interval blinking 1 time and short interval blinking 3 times mean blinking pattern flash code 413 Long interval blinking approx 1 2 seconds Short interval blinking approx 0 3 seconds
108. rter relay SY Glow relay GR Magnetic switch MR1 Automatic operation unit Thermal relay Automatic voltage regulator AVR Current transformer Three phase circuit breaker 3 1 m E L 4 o 519 PL mfi eom I oe o l9 9 le J ON J sit ul 9 o 16 15 14 13 12 11 10 5609002 11 Fuel pump relay FR 12 Safety relay SR 13 Main relay MR2 14 Terminal plate 15 Fuse 60A 16 Controller ECM 17 Fuse 15A 18 Fuse 20A 19 Fuse 10A 20 Voltage selector switch The voltage selector switch is provided on the output terminal plate of the right bonnet 3 Electrical Parts 18 17 16 15 14 13 SDG100S 125S 8B1 1 2345 6 7 8 589999 cs sin p lololol
109. rts 4 Power supply OFF for ECM Power in ECM is not yet OFF 10 seconds after key Key iem e switch is OFF In case that it is necessary to switch OFF power supply by clear memory See 4 6 2 it is necessary that you should wait longer than 10 seconds after Key switch OFF switching OFF key switch of power supply 10 sec 5609039 5 Removal of ECM 1 Switch OFF key switch 2 Remove minus cable of battery 3 In order to make removal job easier remove parts such as relays around ECM 4 Remove ECM connector from ECM 81 pins and 40 pins connectors 5 Loosen fixing bolts nuts and remove ECM 6 Installation of ECM Install ECM in reverse order to disassembly On replacement of ECM make sure to learn EGR valve position taking the following procedures 1 Switch ON key switch ON 2 Switch OFF key switch 3 Wait for 10 seconds in the conditions Without learning ECG valve position EGR diagnostic trouble code DTC will be detected 3 30 3 Electrical Parts 3 4 2 Auto start unit Automatic operation unit 506455 1255 8 1 SDG150S 8B1 List of functions 3 1 Connection Function color CN6 2 V8terminal CN6 3 CN6 5 CN Air filter differential pressure indicator Manual Auto selector switch Oil fence level switch CN6 HOKUETSU part number 46760 46210 HOKUETSU part number 46760 43810
110. s 1 5 1 1 2 Outline Drawing SDG45S 8B1 L G 9080Y 8 E2w NIVAC 7303 IN SIV ON 024 NIVET NVI TVINGRNUSIANG Gr 271 9 19 NINI SHIT HR WD L3NNDE ND gt n 28 5 1313 a F Heg 195907 XNVI Und pr Nivel It gt 07 WINGANUSTAN SNOUT WVJ 9NIN3dU rere i 5 1 gt P Eque 3 ES E RT m r3 z Sd ONG 11 8 X ab m 831830 ALIAVAD 30 W3IN32 NOLLNG E TS 8 WNIRS3I nding lo Y ROLIAS QNVUE HJIIAS ERN 123135 VIDA 13894 15 ya ONIL 2 0c 1 6 1 SDG45S 8B1 075080 006 NL TV LNGANUSITANG 096 066 cr oy 026 058 NIVET INV WINGANDSTANG 09 0
111. s ground to sends power V15 G W Water temperature lamp Thus engine coolant temperature rise emergency stop lamp glows Emergency stop lamp lighting temperature 221 F 105 C nuu o og c c vie 0 No power exists during usual operation When engine oil pressure drops down to emergency stop level interior contact in ECM is Monitor lamp CN1 14 terminal ON and it connects ground to sends power V17 G R Oil pressure lamp Thus engine oil pressure drop emergency stop lamp glows Emergency stop lamp lighting pressure 15psi 0 1MPa TECH2 connection terminal CAN communication B W Tool TECH2 No 6 terminal With connection of scan tool TECH2 it is possible to diagnose engine control system and to check system NIS qn E eS When power is sent to V24 terminal it works main relay MR2 Thus main relay MR2 is switched and when power 18 supplied to V2 and V5 terminal voltage is applied to electromagnet relay FR to operate the pump EL starter switch to input R W 15A fuse signal Preheating starts V5 NIL 0 vee _______ E 8 SN 22 2 3 20 3 Electrical Parts lt SDG45S 150S 8B1 gt Pin Line 5 Connection Function No color No power exists during usual operation When placing frequency adjuster switch UP or V29 GY R Frequency adjuster DOWN it is switched ON
112. s 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 5609056 Removal Do not replace the common rail pressure sensor If it is damaged replace it as common rail assembly 5609057 3 52 3 Electrical Parts 3 5 9 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 Bi injector to control fuel injection amount and injection timing C SG09058 3 5 10 Engine coolant temperature ECT sensor The engine coolant temperature ECT sensor is installed onto engine block and the thermistor changes the resistance according to the temperature Resistance is low at high engine coolant temperature and high at low engine coolant temperature The ECM energizes the voltage 5V to the ECT sensor through pull up resistance and calculates engine coolant temperature based on 5609059 change of voltage to use for various controls such as fuel injection 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 Removeal Disconnect the connector and remove it with 0 75in 19mm wrench Installation Apply Loctite 572 b
113. se you will lose reliance or trust from clients operators and users Therefore it is absolutely necessary to investigate the trouble more carefully 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 is necessary to ask users or operators about the following questions 1 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 6 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 1 The 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 troub
114. sec Behavior when trou ble occurs Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine stopped and can not restart Recov ery from failure Key switch input voltage is 9 V or more DTC P0088 P0192 P0193 or P1635 is not detected Actual rail pressure is 2 MPa 290 psi or more and 70 rpm or more Key switch input voltage is 9 V or more DTC P0089 P0192 P0193 or P1635 is not detected Coolant tempera is 60 140 more and 375 rpm or more Main relay power supply voltage is 9 V or more DTC P1630 is not detected 5 drive duty is between 15 and 85 switch input voltage is 9 V or more DTC P1630 P1632 is not detected 4 22 Common rail pressure fault 1st stage is com pleted and rail pressure is more than 190 MPa 27 557 psi Actual rail pres sure is 40 MPa 5 802 psi or more higher than target rail pres sure And duty to SCV is 40 or more or SCV target pressure feed is 90 mm sec 0 0055 cu in sec or less When SCV drive current exceeds 2 450 mA or drops below 100 mA or when the difference between target and actual current exceeds 1 000 mA or more Barometric pres sure sensor volt age is lower than 0 5 V Approx 5 sec Engine stopped Back up Engine stopped and can not restart Engine stopped Back up Engine st
115. surface when replacing it not allow cleaning solvent of the spray to enter inside of the suction control valve SCV connector 3 Remove the two bolts which tighten the suction control valve SCV 5609045 2 Overhauling D Pull out the suction control valve SCV Note If it is hard to pull it out due to the resistance on the O ring pull it out while rotating it from side to side To prevent foreign matter from entering do not put gloves on from the next work 5609046 Remove the O ring of the suction control valve SCV Note Be careful not to let foreign matter enter the pump housing at removal 5609047 Check the replacement part Note Make sure that you have got all parts indicated in the illustration 5609048 7 Place the new O ring in the O ring groove Note not touch the O ring with dirty hands Perform this work after making sure there is no foreign matter in the O ring groove 5609049 2 Overhauling After placing the O ring apply oil to it Note Use clean oil such as new engine oil not let foreign matter on the O ring 0 Insert the suction control valve SCV into the pump housing Note Insert the suction control valve SCV by hand until it contacts the housing If it is hard to insert the suction control valve SCV insert it while rotating it from side to side slightly 5609050
116. t detected Intake air temper ature sensor age is less than 0 1 V Key switch input voltage is 9 V or more 1630 or P1632 is not detected 3 minutes or more has elapsed after starting engine Key switch input voltage is 9 V or more DTC P1630 P1633 is not detected Key switch input voltage is 9 V or more DTC P1630 P1633 is not detected 3 minutes or more has elapsed after starting engine Key switch input voltage is 9 V or more DTC P1630 P1633 is not detected Intake air temper ature sensor volt age is more than 4 95 V Engine coolant temperature sen sor voltage is less than 0 1 V Engine coolant temperature sen sor voltage more than 4 85 V Combustion tem perature sensor voltage is less than 0 1 V 4 sec Due to back up equivalent to 2 000 m 6 562 ft Black smoke emit ted at high altitude Back up Barometric pres sure default setting 80 kPa 11 6 psi EGR stopped Not in particular Back up Intake air tempera ture default setting at starting 109 14 F at running 25 77 F EGR stopped Not in particular Back up Intake air tempera ture default setting at starting 10 C 14 F at running 25 C 77 F EGR stopped Engine stopped Back up Engine stopped and can not restart 2 Approx 4 sec Fuel tempera
117. t produces a result of 1M or more while a result of less than that value indicates failure 1 Measurement of insulation resistance of generator armature winding wires Procedure Megger tester required EUH R EU 1 Remove the load side cable from the output terminal Bonnet board 4 2 Remove the cable between the terminal N and terminal Ground which are connected on the back of the output terminal plate N 3 Remove the AVR connector inside the generator control panel 4 Switch ON the three phase breaker and then measure each insulation resistance between the A040180 1 terminals L1 L2 L3 terminal and bonnet 5 Insulation resistance when measured with a 500V AVR Connector megger tester must be above 1 MQ 6 After finishing the measurement of insulation resistance re connect the cable between the terminal N and terminal Ground A WARNING After making sure that the insulation resistance of the generator is higher than 1 MQ be sure to re connect the cable between the terminal N and terminal Ground just as it was originally connected If it is left disconnected the grounding becomes imperfect so that it could cause electric shock
118. te the pump NIL Operation mode switching input terminal No power exists during usual operation When terminal between option connecter No 6 and External input connector No 6 No 4 terminal is placed ON operation mode is terminal option switched to Driving ahead load mode In order to minimize operation speed loss due to load increase engine speed is raised only one time 3 21 3 Electrical Parts lt SDG45S 150S 8B1 gt No color V46 C ierminal Inputting start signal Auto start unit CN7 8 terminal 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 vas Operation mode frequency switching input terminal ON 60Hz constant It is possible to change V49 R W 15 fuse frequency with combination of V49 V50 and V51 terminal switching This unit is set to 60Hz constant operation with this terminal directly connected to 15A fuse Operation mode frequency switching input terminal When power is inputted When ON and V50 terminal is switched with Engine speed switch operation mode is switched as follows OFF high side 60Hz constant ON low side idling speed External input connector No 2 But when power is on accel sensor terminal terminal option V20 V41 V42 V63 and V64 terminal the Connection terminal is available
119. ter cooled direct injection turbo charged intercooled id EIE E EH capacity of oil fence gal L 41 155 Generator eneral Specifications 1 2 1 Specification _ _ _ ee E ee Voltage 240 480 240 120 Current 241 120 242 Model ISUZU 4 1 water cooled direct injection turbo charged intercooled Cid 9 ion Gas E d capacity of oil fence gal L 38 145 Generator neral Specifications 1 3 1 Specification Freer a 5 a CO Voltage 240 480 240 120 Current 300 150 300 Model ISUZU 4 1 water cooled direct injection turbo charged intercooled Cid 9 100 Gas E EH capacity of oil fence gal L 38 145 Generator neral Specifications 1 4 1 Specification O SERES SG O ed s Current 361 180 363 Model ISUZU 6 4 cycle water cooled direct injection turbo charged intercooled Cid 126 6 190 5 EH capacity of oil fence gal L 112 423 Generator eneral Specification
120. ter is raised 1 2V higher 3 37 3 Electrical Parts 3 4 4 Alternator SDG45S 65S 100S 125S 8B1 IC REGULATOR E 5609016 Voltage Current 12V 110A Regulator adjusted voltage 14 4 0 3 SDG150S 8B1 5609017 Voltage Current 24V 50A Regulator adjusted voltage 28 541 3 Electrical Parts 3 4 5 Tachometer with hour meter 506455 1255 8 1 HOKUETSU number 36146 05901 SDG150S 8B1 HOKUETSU part number 36146 06200 2 20 TACHOMETER SG06074 Tachometer of SDG45S 125S 8B1 1 Specifications DG458 12588Bi SDG150S 8B1 2 List of functions _ __ Grounding S S O Input of hour meter function signal Panel light switch Power supply for lighting Female coupler Groundng Ground for lighting shows line color and connection of SDG150S 8B1 3 39 3 Electrical Parts 3 4 6 Fuel gauge 506455 1255 8 1 HOKUETSU number 36158 00500 SDG150S 8B1 HOKUETSU part number 36158 00601 SS 5609025 1 Position of meter pointer X marked The figures of the remaining fuel in the table are for model SDG45S 65S 2 List of functions 1 RW __ Power supply fuel gauge __2 G Sendingunit Detector for remaining fuel 3 YW __ Panellight switch Power supply for lighting
121. there any unbalance between by balancing it among single phase load phases phases or increase NO generator capacity Please refer to the sentence 4 4 3 It will not speed up to rated speed Are revolutions stabilized at 1 800 min 1 YES Any faulty connection found in control panel NO Check whether stability of AVR 1s correctly adjusted or not YES Disconnect each connection between generator and control Fault in generator panel And when magnetized winding wire forcibly the generated voltage Repair among phases 15 balanced Fault in AVR YES Looseness found Readjust 4 4 4 Troubleshooting 4 2 4 Load cannot be operated Generated voltage and frequency are normal If it cannot be adjusted YES at all please refer to troubleshooting 4 2 1 No voltage is generated or voltage too low Circuit breaker MCB is ON Turn MCB on Immediately the YES circuit breaks automatically Check load When is is specified voltage found among output Fault in MCB contact terminals R S T and O or selector switch Any looseness in output terminals R S T U V W and Retighten and correct O connection Check cable used for load Please refer to the sentence 4 2 1 No voltage is generated or voltage too low 4 2 5 Voltage drops when load is applied When the load is applied how is generator rpm Drop Normal Ch
122. tifier Varistor 9 Conductive plate Insulating plate Lead wire alternator Lead wire exciter AS 016 Above shows rotary rectifier fitted to SDG100S 125S 8B1 2 14 2 Overhauling Tightening torque 5 SDG1008 8B1 Tightening torque Thread Three Bond locking fluid 1402B Brass Meme oe Rotary rectifier Tightening torque LR s Thread Three Bond locking fluid 1402B ar S30VT80 M3 zea SKR26 J Tightening torque Thread Three Bond locking fluid 1402B the above table SDG45S 65S 8B1 are equipped with diode module and 1505 8 1 with silicon rectifier Accordingly tightening torque and thread locking fluid are based on 506455 655 8 1 with diode module and 5061005 1505 8 1 with silicon rectifier m a gt 2 O X Diode module Silicon rectifier Replacement procedures of rotary rectifier D Remove rotor according to 2 3 1 Disassemby of generator main unit 2 Pull out bearings from the shaft using bearing puller 2 Record positions of cable connection of the rotary rectifier 4 Remove rotary rectifier disconnecting cables fitted to the rotary rectifier 0 Remove diode module silicon rectifier 6 Install new diode module silicon rectifier Silicon rectifier of SDG100S 125S 150S 8B1 has forward direction polarization to K side and reverse direction polarization to J side
123. ting 4 2 1 No voltage is generated or voltage too low Check the frequency meter Raise the speed to the de and confirm that engine specified value Refer 0 Engine speed during no load watching the frequency manual operation corresponds to the meter following values No load speed About 62 5 Hz 1 875 min Check the AC output Check the terminal voltage of output terminals voltage of the voltage Replace the meters R S and T meter None or low The Ex startor connectors uim zm PUT properly correctly Defective resistor hand trimmer If magnetized forcibly how Voltage normal Residual magnetism does the voltage change does not exist any more 0 or lower Conductivity in AVR resistor hand trimmer Winding wire broken in generator or insulation Fault in rotary poor rectifier Repair winding wire in generator 4 8 4 Troubleshooting 4 2 2 Voltage is very high or it cannot be adjusted Adjust the speed to the specified speed with the speed adjusting bolt Defective resistor HT Speed should be about 1 875 NO Higher min for 62 5 Hz during no load operation Check resistance in AVR resistor hand trimmer Broken wire Is AC voltage at AVR input terminal 3 E3 proper Is DC voltage at AVR connector NO Very high J K proper Fault in AVR 4 2 3 Voltage fluctuates Use single phase load Is
124. tor Tachometer 5609021 5609022 3 Electrical Parts 2 List of functions Line Connection color a B 2 1 2 ECM V7 terminal CN1 3 Auto start unit CN7 5 terminal ECM V52 terminal ECM V11 terminal ECM V6 terminal G W ECM V15 terminal CN1 8 L Auto start unit CN7 6 terminal Function Grounding 0 00 00 e No power exists during usual operation When boost temperature intake air pressure rises higher than set temperature interior contact in ECM is ON 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 8 When engine stops with starter switch and diagnosis lamp is make diagnosis switch ON or connect ECM V52 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 preheating interior contact of ECM V11 terminal is ON and it connects ground to sends power Thus preheating lamp glows No power exists during usual operation When engine is in disorder interior contact of ECM V6 terminal is and it connects ground to sends power
125. tricity In order to check whether diode module is in good order or not it is necessary to check resistance according to the following procedures lt Procedures gt Diode module Remove end cover of generator LC Diode Removing end cover you can see diode J module Then disconnect all cables connected to the diode module Availing of resistance measurement range of the tester measure forward direction resistance and reverse direction resistance Exciter armature of each diode When forward direction winding wires Generator field winding wire resistance is found less than 100 and reverse direction resistance more than 100k Varistor the diode is in good order Diode module When diode is found electric current flowing in both forward and reverse directions the diode is judged to be in disorder Disconnect When any diode is judged to be in disorder cables during the inspection it is necessary to replace va Diode module it by a good one Black lead wire Black lead wire Red lead wire Forward direction Forward direction Reverse direction Reverse direction resistance resistance resistance resistance 5608004 Testing method of resistance of diode module Direction Tester lead pole Tester Direction uer lead pole Tester Red lead Black lead value of diode Black lead value wire wire wire wire 0 Ad Forward less than Reverse more than
126. ult Starter cut relay fault Lamp fault Fuel leakage large amount Pressure lim iter is opened Open short cir cuit breakage of sensor or harness Short circuit in sensor or har ness Overheat con dition Key switch power supply voltage is between 8 and 16 V switch input voltage is 9 V or more Key switch input voltage is 9 V or more 1 200 rpm or more DTC P0192 P0193 P1093 P0091 P1291 P1292 P1635 is not detected No starter relay monitor sig nal exists against starter cut relay drive instruction Approx 5 sec The starter cannot be operated if it fails in open condition No drop in output The starter cannot be driven if it fails in closed condition Not started Back up No back up action No check engine lamp monitor sig nal exists Actual rail pres sure is 50 MPa 7 252 psi or more lower than target sure And duty to SCV is 33 or less or pressure feed is 28 000 mm sec 1 7 cuin sec or more switch voltage is 9 V or more DTC P1095 P0192 P0193 P1630 or P1635 is not detected 50 rpm or more Key switch input voltage is 9 V or more P1634 is not detected Key switch input voltage is 9 V or more Coolant tempera ture is 50 122 F or more 5 minutes or more has elapsed after starting switch input voltage is 9 V
127. ust and dust before tightening 2 2 4 10 12 14 16 6 18 20 22 24 2 3 2 Overhauling 2 2 2 Tightening torque for terminal plate IMPORTANT When connecting the output terminals of the generator it is important to tighten the screws according to the designated torque Since the terminal is so small it could be burned or damaged without the proper torque Tightening torque 0 7 1 0 0 4 5 6 8 10 1 2 4 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 Lifting weight Unit lbs kg loc SDG458 500658 5061005 5061255 5061505 8B1 8B1 8B1 8B1 8B1 452 205 595 270 794 360 980 445 1 224 555 unit 740 335 705 820 1 036 470 1 373 623 Generator main unit Engine 2 Bolts for coupling of the engine flywheel and the generator coupling Bolts for connection of the engine flywheel D housing and the NS 2 I generator main unit
128. ve SCV fuel temperature FT sensor and feed pump Suction control valve SCV 5609040 3 5 3 Suction control valve SCV M Suction control The suction control valve SCV is installed onto supply valve SCV 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 5609041 The connector parts of suction control valve SCV are different in color between 12V and 24V 12V Light gray 24V Light brown 5609042 3 50 3 Electrical Parts 3 5 4 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 is high and is high when the temperature is low The ECM energizes the voltage 5V 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 5 temperature is high the voltage becomes low if the Nags c resistance is high temperature is low the voltage becomes high S o Removal AE Do not replace the fuel temperature FT sensor If it is faulty replace it as supply pump assembly A SG09055 3 5 5 Commo

Engine Generator: 45S-8B1

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