40 kVA Towable Generator

Service Manual
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Copyright © 2017 Allmand Bros., Inc. 112503USCN

Holdrege, NE, USA. All rights reserved. Rev (A)
 Preface

This service manual explains about the cautions for maintenance jobs and is to serve a
guide for the electric system, and troubleshooting for service personnel. Fundamental
matters and other things already mentioned in the “Instruction Manual” and the “Parts
Catalogue” are omitted to avoid duplication. Therefore, for the operation and handling of
this unit, we request you to refer to the instruction manual and caution plates, and
further for the structure and components of the unit, please refer to the “Parts
Catalogue” separately to be supplied with the unit.

If you should find any description which does not coincide with the instruction manual
and parts catalog, we request you to make sure to start the job after clarifying it.
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Service personnel is required to safely take quick and proper countermeasures as well
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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
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knowledge about the structure and function of the unit and should be well familiar with
such technique mentioned in them.
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Regarding the part numbers mentioned in this manual, we request you to refer to the
Parts catalogue separately supplied together with the unit, because the parts numbers
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in this manual are sometimes changed.

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Copies of this service manual are intended to be distributed to limited numbers

of our customers. The unauthorized reproduction or distribution of this service
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manual is prohibited.
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 Table of Contents
1. Specification -------------------------------------------------------------------------------------------- 1-1
1.1 Specifications ----------------------------------------------------------------------------------------------------------------- 1-1
1.2 Outline Drawing -------------------------------------------------------------------------------------------------------------- 1-3
1.3 Internal Components ------------------------------------------------------------------------------------------------------- 1-5
1.4 Instrument Panel ------------------------------------------------------------------------------------------------------------ 1-6
1.5 Protection Device ----------------------------------------------------------------------------------------------------------- 1-7
1.6 Terminal ------------------------------------------------------------------------------------------------------------------------ 1-8
1.7 Fuel Piping --------------------------------------------------------------------------------------------------------------------- 1-9

2. Overhauling --------------------------------------------------------------------------------------------- 2-1

2.1 Cautions for Overhauling ------------------------------------------------------------------------------------------------- 2-1
2.1.1 Precautions before starting work ---------------------------------------------------------------------------------- 2-1
2.1.2 Disassembly and reassembly --------------------------------------------------------------------------------------- 2-1
2.2 Tightening Torque ---------------------------------------------------------------------------------------------------------- 2-2
2.2.1 General tightening torque of bolts and nuts ------------------------------------------------------------------- 2-2
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2.2.2 Tightening torque for terminal plate ------------------------------------------------------------------------------ 2-2

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2.3 Disassembly/Reassembly of Generator Main Unit

and Connection of Generator Main Unit and Engine --------------------------------------- 2-3
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2.3.1 Disassembly of generator main unit ------------------------------------------------------------------------------ 2-3

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2.3.2 Measuring center deviation and surface deviation --------------------------------------------------------- 2-5

2.3.3 Assembly of engine flywheel and generator coupling (rotor) ------------------------------------------- 2-6
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2.3.4 Assembly of flywheel housing and generator main unit frame (stator) ----------------------------- 2-7
2.3.5 Mounting of generator main unit and engine on frame --------------------------------------------------- 2-8
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2.3.6 Changing the bearings in the generator main unit ---------------------------------------------------------- 2-11
2.3.7 Replacement of rotary rectifier ------------------------------------------------------------------------------------- 2-12
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2.4 Air Bleeding ------------------------------------------------------------------------------------------------------------------- 2-13

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2.5 Engine Maintenance Standards --------------------------------------------------------------------------------------- 2-13

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3. Electric System --------------------------------------------------------------------------------------- 3-1

3.1 Location of Electrical Appliances ------------------------------------------------------------------------------------- 3-1
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3.2 Electrical Appliances of Generator ----------------------------------------------------------------------------------- 3-2

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3.2.1 Rotary rectifier ------------------------------------------------------------------------------------------------------------ 3-2

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3.2.2 AS (Ammeter change-over switch) ------------------------------------------------------------------------------- 3-4

3.2.3 Voltage selector switch ----------------------------------------------------------------------------------------------- 3-5
3.2.4 AVR (Automatic voltage regulator : DST-100-2FA4) ------------------------------------------------------ 3-6
3.2.5 Thermal relay ------------------------------------------------------------------------------------------------------------- 3-8
3.2.6 Current transformer : CT --------------------------------------------------------------------------------------------- 3-9
3.2.7 Ammeter : A --------------------------------------------------------------------------------------------------------------- 3-9
3.3 Electronic Control System of Engine -------------------------------------------------------------------------------- 3-10
3.3.1 Electronic governor ----------------------------------------------------------------------------------------------------- 3-10
3.3.2 Electronic governor system ----------------------------------------------------------------------------------------- 3-11
3.3.3 Fault diagnosis devices ----------------------------------------------------------------------------------------------- 3-13
 Table of Contents
3.4 Electrical Appliances of Engine --------------------------------------------------------------------------------------- 3-18
3.4.1 Controller (ECU) --------------------------------------------------------------------------------------------------------- 3-18
3.4.2 Monitor lamp -------------------------------------------------------------------------------------------------------------- 3-22
3.4.3 Auto start unit (Automatic operation unit) ---------------------------------------------------------------------- 3-24
3.4.4 Sequencer PLC ---------------------------------------------------------------------------------------------------------- 3-28
3.4.5 DC-DC Converter (DC POWER SUPPLY) --------------------------------------------------------------------- 3-30
3.4.6 Power relay (1) ----------------------------------------------------------------------------------------------------------- 3-31
3.4.7 Power relay (2) ----------------------------------------------------------------------------------------------------------- 3-32
3.4.8 Alternator ------------------------------------------------------------------------------------------------------------------- 3-33
3.4.9 Main relay ------------------------------------------------------------------------------------------------------------------ 3-34
3.4.10 Starter relay --------------------------------------------------------------------------------------------------------------- 3-34
3.4.11 Glow relay ----------------------------------------------------------------------------------------------------------------- 3-34
3.4.12 Engine speed sensor -------------------------------------------------------------------------------------------------- 3-35
3.4.13 Tachometer (with hour-meter) ------------------------------------------------------------------------------------- 3-36
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3.4.14 Fuel gauge ---------------------------------------------------------------------------------------------------------------- 3-37

3.4.15 Sending unit -------------------------------------------------------------------------------------------------------------- 3-38
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3.4.16 Oil fence level switch -------------------------------------------------------------------------------------------------- 3-39

3.4.17 Electro-magnetic pump for bleeding air from fuel line ---------------------------------------------------- 3-40
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3.4.18 Coolant water temperature gauge ------------------------------------------------------------------------------- 3-41

3.4.19 Water temperature sensor (for water temperature gauge) ---------------------------------------------- 3-42
3.4.20 Water temperature sensor (for ECU) ---------------------------------------------------------------------------- 3-42
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3.4.21 Oil pressure gauge ----------------------------------------------------------------------------------------------------- 3-43

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3.4.22 Oil pressure sensor (for oil pressure gauge) ----------------------------------------------------------------- 3-44
3.4.23 Engine oil pressure switch (for emergency stop) ----------------------------------------------------------- 3-44
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3.4.24 Engine water temperature switch (for emergency stop) ------------------------------------------------- 3-44
3.4.25 Ammeter for battery charging -------------------------------------------------------------------------------------- 3-44
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4. Troubleshooting --------------------------------------------------------------------------------------- 4-1

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4.1 Repairing Procedures ----------------------------------------------------------------------------------------------------- 4-1

4.1.1 Safety caution ------------------------------------------------------------------------------------------------------------ 4-1
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4.1.2 Caution during failure diagnosis ----------------------------------------------------------------------------------- 4-1

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4.1.3 How to use the failure diagnosis ---------------------------------------------------------------------------------- 4-2

4.2 Generator Troubleshooting ---------------------------------------------------------------------------------------------- 4-3
4.2.1 No voltage is generated or voltage too low ------------------------------------------------------------------- 4-3
4.2.2 Voltage is very high or it cannot be adjusted ----------------------------------------------------------------- 4-4
4.2.3 Voltage fluctuates ------------------------------------------------------------------------------------------------------- 4-4
4.2.4 Load cannot be operated --------------------------------------------------------------------------------------------- 4-5
4.2.5 Voltage drops when load is applied ------------------------------------------------------------------------------ 4-5
4.3 Emergency Switch Functions ------------------------------------------------------------------------------------------- 4-6
4.3.1 Engine oil pressure drop is shown in monitor and it stops ---------------------------------------------- 4-6
4.3.2 Engine coolant temperature rise is displayed in monitor, and engine will stop ----------------- 4-6
4.4 Engine Troubleshooting -------------------------------------------------------------------------------------------------- 4-7
4.4.1 Anything abnormal is not shown, but it sometimes stops without its cause shown ------------ 4-7
4.4.2 At start-up, starter rotates slowly ---------------------------------------------------------------------------------- 4-7
4.4.3 It will not speed up to rated speed -------------------------------------------------------------------------------- 4-8
4.5 How to Check ----------------------------------------------------------------------------------------------------------------- 4-9
 Table of Contents
5. References ----------------------------------------------------------------------------------------------- 5-1
5.1 Generator’s Winding Wires Resistance Value ------------------------------------------------------------------- 5-1
5.2 Forced Excitation Method ------------------------------------------------------------------------------------------------ 5-1
5.3 Idling Revolution Per Minute ------------------------------------------------------------------------------------------- 5-1
5.4 Generator Wiring Diagram ---------------------------------------------------------------------------------------------- 5-2
5.5 Engine Wiring Diagram --------------------------------------------------------------------------------------------------- 5-3
5.6 List of Consumable Parts and Electrical Appliances ---------------------------------------------------------- 5-4

＊:For maintenance of engine parts, see “Engine Workshop manual and Troubleshooting manual”
published by engine manufacturer.
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 1. Specification
1.1 Specifications
Model 40kVA
Exciting system Brushless
Armature connection Star with Neutral ZigZag
Phase number Three Single
Power factor % 80 100
Generator

Frequency Hz 60
Rated output kVA 38 22
Rated output kW 30.4 22
Voltage V 240 480 240/120
Current A 91.4 45.7 91.4
Model KUBOTA V3300-BG
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Type 4-cycle, water-cooled, swirl chamber type

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Number of cylinders 4
Total displacement cu. in. (L) 203 (3.318)
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Rated output hp (kW) 46.8 (34.9)

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Engine

Revolution per minute rpm (min-1) 1,800 (1,800)

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Lubricating oil capacity gal. (L) 3.4 (13.2)

Coolant capacity
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gal. (L) 2.9 (11.0)

(including radiator)
Battery 95D31R (12V)
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Fuel tank capacity gal. (L) 106 (401)

Overall length in. (mm) 82 (2,080) (gen) / 141 (3566) (w/trailer)
Others General Specifications

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Overall width in. (mm) 39 (1,000) (gen) / 68 (1715) (w/trailer)

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Overall height in. (mm) 61 (1,560) (gen) / 73 (1852) (w/trailer)

Net dry mass (weight) lbs (kg) 2,555 (1,160) (gen) / 3575 (1622) (w/trailer)
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Operating mass (weight) lbs (kg) 3,325 (1,510) (gen) / 4345 (1971) (w/trailer)
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The capacity of oil fence gal. (L) 41 (155)

1-1
 1. Specification

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1-2
 1. Specification
1.2 Outline Drawing
40kVA (shown without trailer)
【Unit : in】

SG13052
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1-3
 1. Specification

40kVA (shown without trailer)

【Unit : mm】

SG13053
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1-4
 1. Specification
1.3 Internal Components
1 2 3 4 5 6 7 8 9 10 11 12 13

14

29

15

28

27
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26 25 24 23 22 21 20 19 18 17 16
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SG13054
40 kVA
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No. Description No. Description

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1 Control panel 16 Fuel drain valve

2 Voltage selector switch 17 Exhaust muffler
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3 Output terminal plate 18 Fuel tank

4 Ground terminal 19 Selector valve of fuel pipe
5 Air filter 20 Engine oil drain valve
GFCI receptacles breaker and Auxiliary
6 21 Sedimenter
receptacles breaker
7 Fuel filter 22 Engine oil filler port
8 Engine oil level gauge 23 Fuel air-bleeding electromagnetic pump
9 Engine oil filter 24 Auxiliary receptacles
10 Engine 25 GFCI receptacles
11 Exhaust flexible pipe 26 Generator main unit
12 Reserve tank 27 Battery ＊
13 Radiator 28 Emergency stop switch
Remote control terminal plate (for
14 Injection pump 29
automatic operation, battery charger)
15 Actuator
Instrument 27 marked“＊”is provided on the other side (opposite side of maintenance).

1-5
 1. Specification
1.4 Instrument Panel

1 2 3 4 5 6 7 8

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10 11 12 13 14 15 16 17
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SG13087
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1. Monitor lamps (for details, see 1.5) 10. Manual-automatic selector switch
2. Tachometer with hour-meter 11. Engine speed switch
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3. Fuel gauge 12. Engine oil pressure gauge

4. Frequency meter 13. Engine water temperature gauge
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5. Voltmeter 14. Ammeter for battery charge

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6. Panel light 15. Voltage adjuster

7. Ammeter 16. Current selector switch
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8. Panel light switch 17. Main circuit breaker

9. Starter switch ※ The voltage selector switch is provided
inside the unit. (See page 1-5, No.2)

1-6
 1. Specification
1.5 Protection Device

 For prevention of troubles during operation, this machine is provided with various protection devices.
When the engine stops due to function of the protection devices and circuit breaker trips, get rid of
the causes of trouble, referring to the trouble shooting clause and then restart operation.

● This machine is equipped with the following devices in the table. Repair and make necessary
treatment in accordance with the item ○.
Three-phase
Engine Lamp
Item circuit Monitor Functions
stops display
breaker trips
When engine oil pressure drops, it
Engine oil pressure functions.
○ ― ○
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drop Function pressure: less than 7.3psi

(0.05MPa)
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When water temperature of engine

Engine water rises abnormally, it functions.
○ ― ○
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temperature rise Function temperature:

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more than 230°F (110℃)

This lamp goes on when operator
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Overcrank ○ ― ○ fails to start engine, during

automatic operation mode.
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When air filter gets clogged and it

Air filter clogged ― ― ○ becomes necessary to clean or
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replace it, it functions.

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When more condensate (fuel,

＊ engine oil and coolant) than 1/3 of
Oil fence
― ― ○ capacity in the oil fence is
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accumulated, monitor lamp lights.

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It functions in case of faulty

Battery charging ― ― ○ battery.
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When starter switch is “ON”, the

Glow/Diagnosis ― ― ○ monitor lamp glows and goes off
after preheating is performed.
When the engine fails, the
diagnosis lamp glows.
Glow/Diagnosis ― ― ○ Diagnosis lamp glowing pattern
indicates states of engine failure.
Overcurrent or In case of overload or short-circuit
short-circuit ― ○ ― ― accident, it functions.
Refer to 3.3.3 “Fault diagnosis
Engine troubles ― ― ○ ― devices”.

＊When the monitor lamp lights in the oil fence, immediately drain it.
(For the capacity of the oil fence, refer to 1.1 Specifications). To protect environment, do not drain it
directly into rivers.

1-7
 1. Specification
1.6 Terminal
● The unit is equipped with three-phase output terminals, ground terminal, GFCI receptacles and
auxiliary receptacles mentioned in the following table.

Item Bolt size and length Quantity

(L1, L2, L3 terminal)
3
M14×P2.0
Three-phase output terminals
(N terminal)
1
M14×P2.0
Ground terminal M14×P2.0 1
Output terminal hole diameter (A) φ19 －
Single-phase 120V
120V 20A Socket 4
GFCI receptacles ※1
Single-phase 240/120V
240/120V 50A Socket 3
Auxiliary receptacles ※2
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※1 Auxiliary AC power will be available independently of the position of voltage selector switch.
※2 Auxiliary AC power will be available only when the voltage selector switch is turned to 240/120V.
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GFCI receptacle breakers×2

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Auxiliary receptacle
breakers×3
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Three-phase output terminal plate

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SG13060
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GFCI receptacles Auxiliary receptacles A100414

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120V 20AMPS 240/120V 50AMPS

SG12036-1E

[GFCI] [AUX.]
120V 120V

H G W W X

120V 240V

Y
A040271
A040270-1

1-8
 1. Specification
1.7 Fuel Piping

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SG13046E
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1-9
 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
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terminals before starting repair work.

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(4) Tools to be prepared

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① Measuring instruments ④ Jigs and specialized tools

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(e. g. tester, insulation resistance gauge etc.) ⑤ Solder and soldering iron
② Tools ⑥ Cleaning cloths
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③ Torque wrenches ⑦ Literatures (such as manuals etc.)

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2.1.2 Disassembly and reassembly

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① 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
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them.
② Perform disassembly work in a dust-free location whenever possible.
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③ 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.
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④ Wash disassembled parts with diesel oil (cleaning solvent) after checking for contamination or
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discoloration. However, do not wash rubber parts with diesel oil.

⑤ Be careful not to damage disassembled parts, they are precision built.
⑥ Replace consumables such as oil seals, O-rings, filters, oil, etc. with new items when reassembling
parts.
⑦ Apply a coating of clean grease to O-rings when installing them in the machine.
⑧ When reassembling parts, place each part in the order of assembly and take care that no parts are
missing or misassembled.
⑨ When reassembling an assembled part (set part), be sure to replace it as an assembly.
⑩ 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.
⑪ Check tightening torque and clearance when assembling parts.
⑫ Check the direction of rotation, speed, and oil leakage after assembly.
⑬ Before starting the machine after disassembly, run it at low idle to check for unusual noises, etc.
to prevent engine or generator damage.

2-1
 2. Overhauling
2.2 Tightening Torque
2.2.1 General tightening torque of bolts and nuts
Fasten all the bolts and nuts with the specified tightening torque when assembling.
Type Low or medium carbon steel bolt High strength steel bolt
(SS400B, etc.) (SCM435, etc.)
Strength,
classification, 4.6－6.8 (4T－6T) 8.8－12.9 (7T－12T)
and indication Indication does
example not appear in
some cases.
Torque

Hexagon headed bolt Socket bolt Hexagon headed bolt

Nominal diameter
(mm) lb･ft N•m (kgf•cm) lb･ft N•m (kgf•cm)
6 3.7 5 (51) 7.2 10 (100)
8 9 12 (124) 18 25 (245)
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10 18 25 (245) 35 49 (485)
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12 31 43 (425) 61 85 (845)
14 49 68 (675) 98 135 (1350)
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16 76 106 (1055) 152 210 (2100)

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18 105 145 (1450) 210 290 (2900)

20 148 205 (2050) 297 410 (4100)
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22 203 280 (2800) 405 560 (5600)

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24 250 345 (3450) 514 710 (7100)

For general sections such as bonnet
Applied sections. For specified sections.
and frame.
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 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
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such a case, use the specified torque only.

 Make sure to remove rust and dust before tightening.
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2.2.2 Tightening torque for terminal plate

 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 Tightening torque

Bolt size Bolt size
lb･ft N･m (kgf･cm) lb･ft N･m (kgf･cm)
M3.5 0.7 1.0 (10) M8 7.2 10 (100)
M4 1.1 1.5 (15) M10 12.7 18 (175)
M5 2.2 3 (30) M12 25 35 (350)
M6 3.7 5 (51)

2-2
 2. Overhauling
2.3 Disassembly/Reassembly of Generator Main Unit and Connection
of Generator Main Unit and Engine
2.3.1 Disassembly of generator main unit

 The generator main unit is unilaterally mounted and the clearance is small, so it must be handled with
extreme care to avoid the possibility of damage to the rotor or stator.
 Use hoisting equipment of sufficient capacity when it is necessary to lift up the engine and the
generator main unit.

(1) Lifting weight Unit : lbs (kg)

40kVA
Weight of generator
450 (205)
main unit
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Weight of engine 610 (277)

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① Generator main unit

② Engine
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③ Bolts (for coupling of the

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engine flywheel and the

generator coupling)
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④ Bolts (for connection of

the engine flywheel
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housing and the

generator main unit
A A section (coupling) details
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frame)
SG05046
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2-3
 2. Overhauling
(2) Procedures of disassembly
1. Remove cables from battery (-) terminal.
2. Remove brackets (or fittings for muffler, air filter and etc.) equipped on the bonnet.
3. Remove top cover and dismantle such parts on the bonnet so that generator main unit can be
pulled out.
4. Remove cables and pipes.
5. Remove mounting bolts of generator main unit and engine.
6. Remove engine cooling fan guard and fan shroud.
7. If necessary, remove radiator, radiator hoses, fuel tank and battery.
8. Insert an angle timber under the engine housing for inclining the engine.
9. Separate engine housing and generator stator.
10. Separate engine flywheel and generator rotor.
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SG13055
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※If insulation film is damaged by contact of stator and rotor during disassembly of generator main
unit, perform varnish drying treatment to such portion.
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(3) Demounting stator and rotor at the same time from engine
When demounting stator and rotor of generator main Generator coupling
unit at the same time from engine, place the generator
main unit with the engine coupling face upward, and
pull out the rotor.
At this time, stabilize the generator main unit frame
padded by wooden block at the bearing side face.
(The generator main unit separated from engine should Generator main
unit frame
be kept firm with the rotor in the stator fastened by wire
or rope to prevent them from moving. Then start this
job.)
Wooden block

SG13056

2-4
 2. Overhauling
2.3.2 Measuring center deviation and surface deviation
Measure them with a dial gauge pressed to the flywheel.

(1) Measuring the center deviation, turn the rotor with the dial gauge pressed to the circumference of
the coupling flange. If the biggest value measured on the same circumference exceeds 0.008in.
(0.2mm), it is necessary to repair it.
(2) Measuring the side run-out, turn the rotor with the dial gauge pressed vertically to the coupling
flange. If the biggest value measured on the same diameter exceeds 0.008in. (0.2mm), it is
necessary to repair it.
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A : Flywheel side run-out

B : Housing center deviation
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SG06059E
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2-5
 2. Overhauling
2.3.3 Assembly of engine flywheel and generator coupling (rotor)

 The mounting holes are 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

Flywheel housing
Mount the engine on the vibration isolator rubbers at
the frame side of engine. Put angle wooden block under
the engine housing and incline the engine a little. Engine

Wooden
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block
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SG06072
(2) Install rotor
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1. Hang the center of the rotor with jute rope and bring
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it near to the flywheel.

2. Match the rotor coupling plate to the engine flywheel
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and then combine them, tightening the coupling

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connecting bolts.
The coupling connecting bolts shall be high tensile
bolts 7T or more. (Use 2 guide bolts for this job.)
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SG06073
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(3) Size of guide bolt

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Unit : in. (mm)

Ｄφ 0.37 (9.5)
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Ｌ 2.95 (75)
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Ｉ 0.98 (25)
Ｍ (M10×1.5)
SG05047

(4) Tightening torque of generator coupling (rotor) (See ③ of 2.3.1 bolts)

Bolt size (mm) (M10×1.5-40)
Quantity 8
lb･ft 36.1
Tightening
[N･m] [49.0]
torque
(kgf･cm) (500)

2-6
 2. Overhauling
2.3.4 Assembly of flywheel housing and generator main unit frame (stator)

 Handle the stator with care after fastening the engine flywheel and generator coupling, to avoid
damage to either the rotor or stator.
 Tighten the connections to the specified torque.
 For connection of flywheel housing and generator main unit frame (stator), coat anti-corrosion agent
“ METAL CLEAR” on the connecting faces to prevent rust and corrosion.

(1) Install the stator

1. Remove casing from stator.
2. Carefully push into the stator, preventing the stator and rotor from rubbing each other.
3. Install the flywheel housing and the stator, tightening the connecting bolts.
The bolts should be high tensile 7T or more.
4. Remove the angle wooden block from under the flywheel housing, and place the generator main
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unit and engine horizontally.

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5. Install the casing to the stator.

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SG13057
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(2) Tightening torque of generator main unit frame (stator) connecting bolts. (See ④ of 2.3.1 Bolts)
Bolt size (mm) (M10×1.5-55)
Quantity 12
lb･ft 18.4
Tightening
[N･m] [25.0]
torque
(kgf･cm) (260)

2-7
 2. Overhauling
2.3.5 Mounting of generator main unit and engine on frame

 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.

① Generator main unit

② Engine
③ Bracket
④ Bolt
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⑤ Shim
⑥ Cushion rubber
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⑦ Nut
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SG05048
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2-8
 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
adjustment.
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.)
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7. Place the engine with the generator main unit on the cushion rubbers and fasten it with nuts.
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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.)
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SG13058

※ 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)

Generator side 1.4 (34)
Engine side 1.4 (34)

SG13088E

2-9
 2. Overhauling
(2) Check the gap between the cooling fan and fan shroud

 Maintain an adequate gap in both the vertical and horizontal directions.

 If the fan is mounted incorrectly so that it leans toward one side wall of the shroud, leading to a
smaller gap in one direction, the fan may produce abnormal noise due to rubbing against the shroud
during starting or stopping and may also overheat.

Gap size Unit : in. (mm)

Fan outer diameter (a) 16.9 (430)
Shroud inner diameter (b) 18.1 (460)
Top gap (c) 0.47 (12)
N

Bottom gap (d) 0.71 (18)

ot

Side gap (e) 0.59 (15)

f or

SG05050
R
ep

(3) Retighten the bolts at the lifting portions as shown in the figure ※ ※
ro

● When assembling the bonnet after having mounted 1

the generator unit and engine, retighten the bolts for
du

lifting the bonnet for sure. Torque of bolt “1” is

110lb･ft(150N･m).
ct

● Coat the tips of the bolts marked ※ with sealant

“ThreeBond 1212”as shown in the figure to prevent
io

rain water from entering inside the bonnet.

n

SG12089

Coat the circumference of

the bolt tip with sealant
“ThreeBond 1212”
SG12088

2-10
 2. Overhauling
2.3.6 Changing the bearings in the generator main unit

 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 to 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
become necessary to replace the bearings, follow the under mentioned procedures.

Replacement of bearings
1. Remove bearing shield (casing).
N

2. Pull out the bearing from the shaft, using bearing removing tools (gear puller).
ot

3. Clean the surface of the shaft and check for any damages.
4. Prepare a new bearing, and check it by turning it by hand before installing it.
f

5. Heat the bearing in the bearing heater, etc. at average 100 to 118℃ (Never heat it over 120℃ or
or

partially.) and then install the bearing using a bearing installer (Heated bearing can be installed
to the shaft.)
R

6. Set guide bolts to the generator main unit frame.

ep

7. Push in the bearing shield (casing), hitting it with a plastic hammer evenly.
ro
du
ct
io
n

SG05051-1E SG05052E

2-11
 2. Overhauling
2.3.7 Replacement of rotary rectifier

 When installing diode module, it is necessary to be careful not to damage it due to over-tightening.
 Shorten time to keep soldering iron touch on diode module.
 Degrease such surfaces where thread looseness is prevented by thread locking fluid.
 It is impossible to replace varistor only because it is built-in insulating plate.

① Diode module
② Varistor
N
ot
f or

2
(1) Tightening torque SG10018
R

Thread size M6 (Nut)

Rotary rectifier

ep

lb･in 36.5
Tightening
[N･m] [4.1]
torque
(kgf･cm) ( 42 )
ro

Thread ThreeBond
locking fluid 1402B
du

S30VT80
Model
(M3 Screw)
Diode module

ct

lb･in 7.8
Tightening
[N･m] [0.9]
torque
io

(kgf･cm) (9)
Thread ThreeBond
n

locking fluid 1402B

Replacement procedures of rotary rectifier

1. Remove rotor according to 2.3.1 “Disassemby of generator main unit”.
2. Pull out bearings from the shaft, using bearing puller.
3. Record positions of cable connection of the rotary rectifier.
4. Remove rotary rectifier, disconnecting cables fitted to the rotary rectifier.
5. Remove diode module.
6. Install new diode module.
7. Tighten diode module to the specified torque, using a torque wrench.
8. Install the rotary rectifier in the reverse order to removal according to the specified torque.
9. Diode module should be connected by soldering iron.

2-12
 2. Overhauling
2.4 Air Bleeding
Should the machine stop due to the shortage of fuel, perform the air bleeding operation according to the
following procedures.
<Procedure>
1. Place the operation selector switch to the “MANUAL” position.
2. Place the starter switch to “RUN” position to put electromagnetic pump into operating conditions.
3. Air bleeding will be completed within 20 to 30 seconds.
4. Place the operation mode selection switch to “LOW” position and start engine.
5. Keep warming up operation for 3 minutes after engine has started.
6. Then place the operation mode selection switch to “HIGH” position and raise engine speed up to
the rated speed (RPM). Thereafter, repeat mode selection operation “LOW”⇔“HIGH” several
times.

2.5 Engine Maintenance Standards

N

40kVA
ot

Engine model KUBOTA V3300-E3B-BGHE-1

lb･ft 76
Tightening torque of head bolts
[N･m(kgf･cm)] [103(1050)]
f or

Air intake in. (mm) 0.009－0.0106 (0.23－0.27) [normal temperature]

Valve clearance
Discharge in. (mm) 0.009－0.0106 (0.23－0.27) [normal temperature]
Firing order 1-3-4-2
R

Injection timing (BTDC) ° 9±0.75

ep

Nozzle injection pressure psi (MPa) 1,987 (13.7)

625－654 (4.31－4.51)
Compression psi (MPa)
ro

[Rotation speed 250－265rpm(250－265min-1)]

Temperature for
°F (°C) 166－173 (74.5－78.5)
du

start of release
Thermostat Full open
°F (°C) 194 (90)
temperature
ct

Valve lift in. (mm) 0.31 ( 8)

io
n

2-13
 3. Electric System
3.1 Location of Electrical Appliances

1 2 3 4 5 6 14

13 12 11 10 9 8 7
N
ot
f or
R
ep
ro
du
ct
io

15
n

SG13059

1. Fuse (10A) 9. Terminal plate

2. Fuse (10A) 10. Starter relay
3. Fuse (5A) 11. Glow relay
4. Automatic operation unit 12. Main relay
5. Thermal relay 13. Controller (ECU)
6. Current transformers 14. Voltage selector switch
7. Three-phase circuit breaker 15. Fuse (60A)
8. Automatic voltage regulator (AVR)

3-1
 3. Electric System
3.2 Electrical Appliances of Generator
3.2.1 Rotary rectifier
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

Ac1

Ac2

Ac3
SG12122

1
N
ot
f or

Rotor ass’y

Generator field winding wire Exciter armature winding wires

R

SG09029 2
ep

SG12129
Rotary rectifier
ro

① Diode module
② Varistor
du
ct

Diode module
io
n

Diode
Generator field winding wire

Exciter armature winding wires

Varistor
SG09107

3-2
 3. Electric System
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 electricity. In order to check
whether diode module is in good order or not, it is necessary to check resistance according to the
following procedures.

< Procedures > Diode module

1. Remove casing of generator. Diode
2. Removing casing, you can see diode module.

Generator field winding wire

Then disconnect all cables connected to the
diode module.
3. Availing of resistance measurement range
of the tester, measure forward direction
resistance and reverse direction resistance
Exciter armature
of each diode. When forward direction
N

winding wires
resistance is found less than 10Ω and
ot

reverse direction resistance more than 100k

Varistor Diode module
Ω, the diode is in good order.
f

When diode is found electric current flowing

or

in both forward and reverse directions, the

diode is judged to be in disorder. Ac1
R

Disconnect Ac2
When any diode is judged to be in disorder cables
ep

Ac3
during the inspection, it is necessary to replace
it by a good one.
ro

Diode module
du
ct
io
n
Black lead wire

Black lead wire

Black lead wire

Black lead wire

Red lead wire

Red lead wire

Red lead wire

Red lead wire

Forward direction Forward direction Reverse direction Reverse direction

resistance resistance resistance resistance
SG08004
Testing method of resistance of diode module

Direction Tester lead pole Tester Tester lead pole

Direction Tester
Red lead Black lead Red lead Black lead
of diode wire wire value of diode value
wire wire
(＋) Ac1 Ac1 (＋)
(＋) Ac2 Ac2 (＋)
Forward (＋) Ac3 less than Reverse Ac3 (＋) more than
direction Ac1 (－) 10Ω direction (－) Ac1 100kΩ
Ac2 (－) (－) Ac2
Ac3 (－) (－) Ac3

3-3
 3. Electric System
3.2.2 AS (Ammeter change-over switch)
Part number:46913 01000

N
ot

SG13061
f or
R
ep
ro
du
ct

SG06068
io
n

3-4
 3. Electric System
3.2.3 Voltage selector switch
Part number:46917 01200

SG13062

System of contacts arrangement

N
ot
f or
R
ep
ro
du
ct
io
n

SG13063

3-5
 3. Electric System
3.2.4 AVR (Automatic voltage regulator : DST-100-2FA4)
Part number:46950 02600

(5)

(1)

(4)

(2)
N
ot

(3)
f or

Name Function 9 Pin (female) 6 Pin (female)

Adjustment of V/Hz
R

(1) V. F. ADJ
characteristics
ep

(2) VOLT. ADJ Adjustment of voltage

(3) STAB. ADJ Adjustment of stability
ro

Over-excitation protection
(4) CPR
circuit protector
1:Brown 4:Yellow 7:Purple 1:Brown 4:Yellow
du

Time
(5) Adjustment of time constant 2:Red 5:Green 8:Gray 2:Red 5:Green
constant, ADJ
3:Orange 6: ／ 9: ／ 3:Orange 6: ／
ct

[AVR CONNECTOR]
io

No. Line color Connection Remarks

1 Brown Hand trimmer
n

Variable resistor 2kΩ 5W

2 Red Hand trimmer
6 pins 3 Orange NIL
(female) 4 Yellow No.5 of connector 6P To get corner frequency 57Hz, No.5 connector 6P
5 Green No.4 of connector 6P and No.4 connector 6P short circuited
6 NIL
1 Brown Generator cable No.3
2 Red Generator cable No.4 AVR power supply (Generator cable No.3 & No.4)
Detect generator output voltage between
3 Orange Generator cable E3
generator cable No.3 and E3
9 pins 4 Yellow Generator cable J Field winding of exciter
(female) 5 Green Generator cable K Field winding of exciter
6 NIL
7 Purple Generator cable U Auxiliary winding
8 Gray Generator cable V Auxiliary winding
9 NIL

3-6
 3. Electric System
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, there is
any trouble such as voltage hunting, adjust it according to the following procedures.

[Adjustment of AVR]
1. Start engine, and adjust the frequency to 60Hz at no load operation.
2. Turn the voltage adjuster (hand trimmer) on the instrument panel fully to the right to the
maximum position.
3. Under this condition, turn the voltage adjuster of AVR in the control panel, using a driver, so that
the upper value of voltage may meet the value mentioned in the following table.

Voltage
240V 480V
Frequency
60Hz 252V 504V
N

4. The driver slot of voltage adjusting volume of AVR should be coated with silicon caulking paste
ot

and fully sealed.

f

[Adjustment of stability]
or

It is possible to adjust the response speed of generator output voltage at no load operation by the
adjusting volume knob of stability.
R

1. Turning the volume knob of stability adjustment clockwise reduces the response speed, and
ep

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).
ro

Notch position of stability adjustment volume (STAB.ADJ) : 4/10 ※

du

[Adjustment of time constant]

ct

Instantaneous characteristic is set at the best point. So it is not necessary to adjust it. (Adjustment is
prohibited.)
io

Notch position of time constant adjustment volume : 1/10 ※

n

[Over-excitation protection]
A 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.

[Adjustment of V/Hz characteristics]

As the V/Hz characteristics are set at the best position, any adjustment is not required.
Notch position of V/Hz characteristics adjustment volume (V.F.ADJ) : 3/10 ※

※ 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.

3-7
 3. Electric System
3.2.5 Thermal relay
Part number:46928 01500

Upper part: B contact:

normally close
Lower part: A contact:
N

normally open
ot

SG12022E
f or

(1) Thermal relay set value

unit 40kVA
Rated voltage V 240 480
R

Rated current A 91.4 45.1

ep

Detected current at
A 45.7
rated operation
CT ratio 5/150
ro

Wound rolls (Rolls of

2 rolls
cables through CT)
du

Set value A 2.8

Tripping of over current is set to be reset automatically.
ct
io
n

3-8
 3. Electric System
3.2.6 Current transformer :CT
Part number:46923 04500

150AT
Specification
150/5A window×2
Model CW-5L
Nothing abnormal is found on
its appearance
Measurement of insulation
Maintenance
resistance
checks
More than 2,000MΩ shall SG12026E
exist between secondary coil
and mounting bracket
N

3.2.7 Ammeter :A
ot

Part number:46154 14500

f or

0－75A 75/5A
Specification
0－150A class 2.5
Model ACF-6
R
ep

SG12027E
ro
du
ct
io
n

3-9
 3. Electric System
3.3 Electronic Control System of Engine
3.3.1 Electronic governor
This machine is equipped with electronic governor (electronic governed controller, actuator) as
standard equipment and the revolution speed is controlled by electronic governor and mechanical
governor.
Should the electronic governor get damaged, only the mechanical governor can control the revolution
speed. In this case, follow the under-mentioned countermeasures.

1. When the actuator is broken, or the cable connected to the actuator is disconnected, fuel feed is
shut out. The engine is enabled to be operated by the function of mechanical governor activated
by removing the actuator.
2. The adjustment of the revolution speed can be possibly done by the control of the stopper bolt of
the governor lever.
3. When stopping engine, pull the fuel cut lever to stop engine.
N
ot
f or
R
ep
ro
du
ct
io

SG13064
n

V3800DI-T-E3CB

3-10
 3. Electric System
3.3.2 Electronic governor system
(1) Software block diagram

SG13065
N

1. Target of engine speed 6. Proportional solenoid

2. ECU(Controller) 7. Engine
ot

3. Speed control 8. Engine speed sensor

4. Current control 9. Current of proportional solenoid
f or

5. PWM(Pulse Width Modulation) 10. Engine speed

■NOTE
R

・Feedback signal : Equivalent fuel injection quantity substituted from the current of engine speed and
ep

proportional solenoid.
ro

(2) Construction
du
ct
io
n

SG13066

1. Injection pump 5. Engine speed

2. Control rack 6. Accelerate lever (fixed at maximum speed)
3. Proportional solenoid 7. Governor spring
4. ECU(Controller) 8. Governor weight

3-11
 3. Electric System
(3) Controlling mechanism

SG13067
ot

1. Quantity reduction 5. Mechanical governor fuel control

2. Quantity increase 6. Isochronous control
f

3. Fuel quantity 7. Mechanical governor operating curve

or

4. Engine speed

A : Within the range of the mechanical governor, free speed control occurs.
R

B : If the engine rotational speed increases, priority is given to the mechanical governor control function.
ep
ro
du
ct
io
n

3-12
 3. Electric System
3.3.3 Fault diagnosis devices
The models are equipped with the following protection devices. And each device has such function
marked ○ in case of each trouble itemized in the following table, together with lighting of warning
lamp.
When the trouble diagnosing function actuates, it makes warning lamps go on and flicker. The
pattern of flickering indicates the conditions of the trouble.
N

Glow / Diagnosis lamp

ot
f or
R

A100407
ep

Three-
Flickering
phase
Engine Lamp Trouble pattern of
ro

Item circuit Functions

stops indicator indicator trouble
breaker
indicator
du

trips
Overcurrent or In case of overload or short-circuit
○
short-circuit accident, it functions.
ct

When air filer gets clogged and it

Air filter clogged ○ becomes necessary to clean or
io

replace.
This lamp goes on when operator
n

Overcrank ○ ○ fails to start engine, during

automatic operation mode.
When more condensate (fuel,
Containment engine oil and coolant) than 1/3 of
○
level capacity in the oil fence is
accumulated, monitor lamp lights.
When engine rotates excessively.
Excessive RPM ○ ○ ○ L1 and S1 RPM speed: higher 115% than
rated speed
When engine oil pressure drops.
Engine oil
○ ○ ○ L1 and S2 Function pressure: less than 7.3psi
pressure drop
(0.05MPa)
Battery charging When disconnection of fan belts
○ ○ ○ L1 and S3
faulty stops charging battery.
When water temperature of engine
rises abnormally.
Water temp. rise ○ ○ ○ L1 and S4
Function temperature: more than
230°F (110℃)

3-13
 3. Electric System

Three-
Flickering
phase
Engine Lamp Trouble pattern of
Item circuit Functions
stops indicator indicator trouble
breaker
indicator
trips
Protection of When starter is ON continues to
○ ○ L1 and S7
starter work longer than 12 seconds.
When RPM sensor is in disorder or
Malfunction of
○ ○ L2 and S1 cable connection is cut or
RPM sensor
short-circuited.
Trouble of When cable of actuator is
○ ○ L2 and S2
solenoid disconnected or short-circuited.
Disconnection of
When cable of water temperature
water temp. ○ ○ L2 and S4
sensor is disconnected.
sensor
Short-circuiting
When cable of water temperature
of water temp. ○ ○ L2 and S5
N

sensor gets short-circuited.

sensor
Disconnection of
ot

When cable of alternator L

alternator L ○ ○ L2 and S6
terminal is disconnected.
terminal
f

Trouble of power When power cable for ECU gets

or

○ ○ L2 and S7
supply for sensor short-circuited.
When voltage of alternator rides
Excessive voltage ○ ○ L3 and S1
abnormally. Function voltage: 18V
R

Running out of When engine stops due to running

○ ○ L3 and S2
ep

fuel out of fuel or fuel system clogging.

Fuse failure ○ ○ L4 and S1 When 5A fuse fails.
ro

L and S mean long time and short time alternatively. Also the numbers of each L and S mean
repeated time of flickering lamp.
du
ct
io
n

3-14
 3. Electric System
How to treat such case when the glow/diagnosis lamp flickers
When trouble diagnosis mechanism functions and the glow/diagnosis lamp flickers, take the
following countermeasures.
Flickering
Item pattern of Countermeasures
trouble indicator
When the engine speed exceeds 115% of the rated speed, the
Excessive EPM L1 and S1 indicator flickers this signal. It is not necessary to adjust the
electronic governor.
Engine will be stopped for the protection of engine, in case that
engine speed exceeds specified speed and also the oil pressure
switch is ON (oil pressure drop).
Check oil level by oil level gauge. If it is short, replenish it. In case
Engine oil
L1 and S2 that this phenomenon occurs even if the oil level is filled up to the
pressure drop
upper level, check whether the wire is correctly connected. In case
that when the wire of oil pressure is rubbed, or if it touches engine
body or something and gets short-circuited, this same phenomenon
N

occurs.
In case that L terminal of alternator will not rise up to 12V at
ot

engine over speed, it can be judged that this is caused due to fan
belt trouble. Stop engine and check the fan belts and around the
alternator.
f or

Check it according to the following steps.

1. Check whether the fan belts are disconnected or not and belt
R

tension is proper.
Battery charging
L1 and S3 2. When the key switch is turned to ACC, glow lamp is ON or not?
faulty
ep

If it flickers, suitable treatment is required. If the wire of

alternator is found disconnected at this stage, the glow lamp
flickers. Check and repair it.
ro

If this phenomenon occurs even after alternator and its periphery

du

have been checked, check the wiring of alternator again. In case

that the cable of L terminal is rubbed and touches the grounding to
cause short-circuit, the same phenomenon occurs.
ct

In case that the water temperature switch is ON at engine

over-speed, it stops engine for protection against overheating.
io

After waiting for one minute till engine cools down, check coolant
n

Water temp. rise L1 and S4 level. If this error is found while engine is cool, check wiring. In
case that the cable of water temperature switch is rubbed and
touches the grounding to cause short-circuit, the same
phenomenon occurs.
It can be judged that engine is turning, according to the states of
key switch and L terminal of alternator, but in case that even in
such conditions no output from revolution sensor and RPM is
shown 0, stop engine because engine speed is not correctly
controlled. In this case, 10 seconds after starting engine, it rises up
to the max. speed of mechanical governor at no load.
The following steps should be taken.
Malfunction of
L2 and S1
RPM sensor 1. Removing the connector of RPM sensor, measure the voltage of
both sides fittings. When 12V is indicated, it is OK.
2. Then measure the voltage of the fittings on the left side and the
fitting middle. If it indicates 5V, it is OK.
3. When no problems are found after finishing the above steps,
replace RPM sensor and restart engine.
4. In case that RPM sensor is still abnormal even after replacing
the RPM sensor, ECU controller should be replaced.

3-15
 3. Electric System

Flickering
Item pattern of Countermeasures
trouble indicator
Turning the key switch to ACC, ECU controller judges that engine
starts and it sends full current to the actuator. Then, if the ECU
controller detects trouble, it cuts the current to the actuator so that
engine may not start.
Check it according to the following steps.
Trouble of
1. Remove the cable 18 and 34 of the actuator, and measure the
solenoid L2 and S2
resistance (R1).
(actuator)
2. Then, remove the cable from the actuator, and measure the
actuator itself (R2).
3. In case that R2 exceeds 2.8Ω±10%, actuator is in disorder.
Replace it.
If R2 is OK and R1 and R2 are out of proper values, check the
wiring for short-circuit or disconnection.
N

Engine imaginable temperatures are:

Operating ambient temperature: -30 to +50℃
ot

Ambient temperature during storage: -40 to +65℃

Therefore, lower temperature than the imaginable temperatures is
Disconnection of
f

called as temperatures of water temperature sensor detecting

or

water temp. L2 and S4

abnormality and disconnection. If the signal cable of water
sensor
temperature sensor is disconnected, the temperature becomes
-50℃. Detecting method is follows; Remove the connector from the
R

sensor, and check whether the one of two fittings is 5V and the
ep

other is GND.
Engine imaginable temperatures are:
Operating ambient temperature: -30 to +50℃
ro

Ambient temperature during storage: -40 to +65℃

Max. temperature of cooling water is imagined to be 120℃.
du

Short-circuiting of
water temp. L2 and S5 (Around this temperature, water temperature switch functions.)
sensor Therefore, lower temperature than this said temperature is called,
ct

the temperature which water temperature sensor detects as

abnormal temperature. If the signal cable of the sensor gets
io

short-circuited, the obtained temperature becomes 150℃. Check

the cable from ECU controller to the sensor.
n

The voltage of L terminal of alternator is OV when engine stops.

Disconnection of As it is pulled up to be 5V inside the ECU controller and in case of
alternator L L2 and S6 disconnection, engine is in the same state as in the state of engine
terminal turning while engine is stopping. Check the cable from ECU
controller to alternator.
The voltage of battery is always watched, and if the power supply
voltage exceeds 18V, current flow to actuator is stopped for
Excessive voltage L3 and S1 protection of actuator and so engine is also stopped. Check the
battery voltage using a tester and replace it by the battery of rated
voltage.

3-16
 3. Electric System
Troubles difficult to be found
1. At the same time when engine starts, engine rises up to max. RPM
(1) Check the cable of RPM sensor. If the sensor and the cable have any defect, RPM signal will not
enter ECU controller but rises up to the max. RPM. In this case, glow/diagnosis lamp flickers
(Long 2, and Short 1).
(2) It is possible that actuator is fixed at the increased side. Remove the actuator, operate the key
switch, and check whether the rod top end functions with ON-OFF of ACC. If it will not function,
replace the actuator. (If the ACC is kept ON for a long time, actuator becomes too hot and it may
cause burns. Check it with short time ON-OFF.)
2. Defective contact
Trouble detection by trouble diagnosis function: It diagnoses trouble only when the state of trouble
continues for a certain time without malfunction due to noise etc. But it sometimes occurs that it is
impossible to diagnose the trouble when the state of trouble changes due to the vibration caused by
engine stopping and checking it using a tester, ECU controller indicates the trouble by the state of
N

flickering of glow/diagnosis lamp. When measuring the respective points using a tester, it is
ot

recommendable to change the fixing state of cables and carefully.

f or
R
ep
ro
du
ct
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n

3-17
 3. Electric System
3.4 Electrical Appliances of Engine
3.4.1 Controller (ECU)
40kVA Part number:44390 03300

N
ot
f or
R

Connector terminal arrangement

ep

SG10003
(1) ECU Controller function
Line
ro

Pin No. Connection Function

color
CN1-1 B Grounding
du

CN1-2 － NIL
CN1-3 － NIL
ct

CN1-4 － NIL
io

Main relay
(Via 10A fuse)
n

Glow relay coil

CN1-5 R/W Power supply
Fuel pump
Power supply for each
instrument
Terminal for hour-meter function.
Tachometer When electricity is sent to CN1-15 terminal (Power supply),
CN1-6 B/R
(Hour-meter) internal connection between CN1-6 and CN1-19 terminal
(grounding) turns ON, and hour-meter functions.
Exciting terminal for starter relay.
When start signal is input to CN1-12 terminal, internal
CN1-7 B/W Starter relay coil connection between CN1-7 and CN1-19 terminal
(grounding) will be ON. Accordingly, starter relay functions
and the starter motor C terminal is input by start signal.
Terminal for glow relay function.
During preheating, internal connection between CN1-8 and
CN1-8 B/G Glow relay coil
CN1-19 (grounding) turns ON, and glow relay functions for
preheating.
Monitor lamp ･For turning on the lamp while preheating.
CN1-9 L/Y
Glow/Diagnosis lamp ･For turning on the lamp when engine trouble occurs.

3-18
 3. Electric System

Line
Pin No. Connection Function
color
CN1-10 － NIL
CN1-11 － NIL
Start signal input terminal.
Starter switch C When start signal is input to CN1-12 terminal, internal
CN1-12 R/L
terminal connection between CN1-7 and CN1-19 terminal
(grounding) turns ON, and starter relay functions.
Detecting terminal for engine coolant temperature.
According to the detected coolant temperature, the
Water temperature
CN1-13 G/L preheating time [connect time of internal connection
sensor terminal (ECU)
between CN1-8 and CN1-19 terminal (grounding)] at start
is controlled.
CN1-14 － NIL
Power supply.
When power supply is input to CN1-15 terminal, internal
N

connection between CN1-8 and CN1-19 terminal

ot

CN1-15 R/W 10A fuse (grounding) turns ON, it makes glow relay function for
preheating. And at the same time, engine speed adjusting
signal is output from the terminal CN1-34 terminal to open
f

engine fuel rack.

or

Power supply for sending abnormality signal to monitor

CN1-16 R/G 5A fuse
panel No.5 terminal from ECU CN1-9 terminal.
Detecting engine RPM.
R

Engine RPM is detected by the generated voltage between

ep

CN1-17 G/O RPM sensor terminal two terminals.

The generated voltage at operation at rated RPM at no load
operation: 5(V)
ro

Inputting engine RPM adjusting signal.

CN1-18 L/B Actuator terminal The actuation of the actuator by changing the voltage
du

between two terminals.

CN1-19 B Grounding
ct

Detecting engine RPM.

Engine RPM is detected by the generated voltage between
io

CN1-20 G/B RPM sensor terminal two terminals.

The generated voltage at operation at rated RPM at no load
n

operation: 5(V)
CN1-21 － NIL
CN1-22 － NIL
CN1-23 － NIL
CN1-24 － NIL
CN1-25 － NIL
Detecting defective charging of alternator.
Detecting defective charging, it cuts the CN1-34 terminal
CN1-26 W Alternator L terminal
output (engine RPM adjusting signal) to make engine
emergency stop.
Engine oil pressure Detecting engine oil pressure drop.
switch for emergency Detecting engine oil pressure drop, it cuts the CN1-34
※ stop terminal output (engine RPM adjusting signal) to make
G/R
CN1-27 engine emergency stop.
Monitor lamp terminal For turning on the oil pressure lamp of monitor lamps when
engine oil pressure drops.

3-19
 3. Electric System

Line
Pin No. Connection Function
color
Engine water Detecting rise of engine coolant temperature.
temperature switch for Detecting rise of engine coolant temperature, it cuts the
emergency stop CN1-34 terminal output (engine RPM adjusting signal) to
CN1-28 G/W
make engine emergency stop.
Monitor lamp terminal For turning on the water temperature lamp of monitor
lamps when engine water temperature rises.
CN1-29 － NIL
CN1-30 － NIL
Operation mode Input of warming up operation signal (idling).
CN1-31 R/B (Idling-Rating) selector When operation mode is at “warming up operation” side, it
switch terminal is switched ON.
CN1-32 － NIL
CN1-33 － NIL
Outputting engine RPM adjusting signal.
N

CN1-34 L/R Actuator terminal The actuation of the actuator is controlled by changing the
ot

voltage between two terminals.

※ The detection of abnormality : The abnormality detecting circuit is opened about 10 seconds after
f

power signal of alternator by the function of start time lag timer.

or
R
ep
ro
du
ct
io
n

3-20
 3. Electric System
(2) Characteristics of water temperature / glowing time and air heater time (Key OFF→ON)
Lamp glows/Glowing time t1 (seconds)
Water temp. (℃)
40kVA
Less than -20 10
-10 8.25
0 6.5
10 4.75
More than 20 3

40kVA
N
ot
f or
R

SG13049E
ep

(3) Chart of function

ro

※1(st) st
ST
Starter
du

ON
Switch OFF
ct

t1
ON
io

Lamp OFF
n

t1
ON
Glow OFF
(Air heater)
※2 ※2

The chart marked ※1 shows the function chart at which the starter switch is placed at “st” position.
※2 When the engine speed reaches the set speed, it is judged that the starting function has been
finished and the glow conduction is cut.

3-21
 3. Electric System
3.4.2 Monitor lamp
Part number:46870 55800

SG13068
(1) External schematic diagram
ot
f or
R
ep
ro
du
ct
io
n

SG13069

3-22
 3. Electric System
(2) List of functions
Line
Pin No. Connection Function
color
CN1-1 B Grounding
Detecting defective charging signal, it makes
CN1-2 W ECU CN1-26 terminal
warning lamp and abnormality indicator lamp go on.
Detecting decrease of free capacity of oil fence.
CN1-3 B/L Auto start unit Y05 terminal When oil fence level switch is ON, warning lamp
goes on.
CN1-4 － NIL
･Inputting of operational abnormality signal by ECU
controller, it makes abnormality indicator lamp go
CN1-5 L/Y ECU CN1-9 terminal
on.
･For turning on the glow lamp when preheating.
CN1-6 － NIL
No power exists during usual operation.
When engine coolant temperature rises up to
N

emergency stop set temperature, interior contact of

ECU is “ON”, and it connects ground to sends power.
ot

CN1-7 G/W ECU CN1-28 terminal Thus engine water temperature rise emergency stop
lamp glows.
f

●Emergency stop lamp lighting temperature:

or

230ﾟF (110℃)
CN1-8 － NIL
R

CN1-9 － NIL
CN1-10 R/W 10A fuse Power supply
ep

No power exists during usual operation.

When engine speed rises up to emergency stop set
ro

speed, interior contact of ECU is “ON” and it

CN1-11 L/W Auto start unit Y04 terminal
connects ground to sends power. Thus overspeed
du

warning lamp glows.

●Emergency stop set speed: 2070min-1 (69Hz)
No power exists during usual operation.
ct

When air filter differential pressure indicator is

CN1-12 G/Y Auto start unit Y03 terminal “ON” for 10 seconds, interior contact of auto start
io

unit Y03 terminal is “ON” and air filter clogging

warning lamp glows.
n

CN1-13 － NIL
No power exists during usual operation.
When engine oil pressure drops down to emergency
stop set pressure, interior contact of ECU is “ON”
and it connects ground to sends power. Thus engine
CN1-14 G/R ECU CN1-27 terminal
oil pressure drop emergency stop warning lamp
glows.
●Emergency stop lamp lighting pressure:
7.3psi (0.05MPa)
CN1-15 － NIL
CN1-16 － NIL
CN1-17 － NIL

3-23
 3. Electric System
3.4.3 Auto start unit (Automatic operation unit)
Part number:46760 46210

N
ot

SG13070
f or

(1) List of functions

Line
Pin No. Connection Function
color
R

When pressing emergency stop switch also during

ep

manual operation, main relay becomes OFF and

CN(1)-1 Emergency stop switch No.2
B/R power supply of controller (ECU) and power supply
[P1] terminal
of automatic start unit (AOU) become OFF. Then it
ro

will be brought to emergency stop.

CN(1)-2 － NIL
du

No power exists during usual operation.

Air filter differential pressure rises “ON”.
When air filter differential pressure indictor stays
ct

“ON” for 10 seconds, interior contact of Y3 terminal

CN(1)-3 Air filter differential pressure
io

Y/G of PLC (Programmable logic controller) will be

[X04] indicator
changed to “ON” and it makes monitor warning lamp
n

turn on.
●Function differential pressure: more than 0.9psi
(6.2kPa)
Power supply for remote start-stop switch.
When remote start-stop switch (between external
CN(1)-4 Manual-Auto selector switch output terminal plate A1 and A2) is placed on with
Y/R
[P0] No.3 terminal power supplied to P1 terminal of automatic
operation unit (AOU), XO relay works to start
auto-start operation.
No power exists during usual operation.
Fluid level in oil fence rises “ON”.
When oil fence level switch is “ON” for 10 seconds,
CN(1)-5
W/L Oil fence level switch interior contact of PLC Y5 terminal is switched “ON”
[X05]
and monitor warning lamp glows.
●Warning lamp lighting capacity: more than 1/3
of blank capacity

3-24
 3. Electric System

Line
Pin No. Connection Function
color
Remote start-stop switch connector terminal.
With AOU P1 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 converter (DC1). PLC:
Programmable Logic Controller
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,
Remote start-stop switch interior contact of Y2 terminal is “ON” and starter
CN(1)-6
Y/W (Via external output terminal motor begins cranking and start engine.
[A1]
plate A1 terminal) ■Stop
Remote start-stop switch is “OFF” to make XO relay
switch “OFF”, but power is supplied to PLC unit for
N

5 seconds with power input from AOU P1 terminal.

ot

Then after engine performs cooling operation for 10

seconds, interior contact between COM0-Y0
terminals is “OFF”, and engine is brought to stop.
f

■In case pushing emergency stop button

or

When pushing emergency stop button on operation

panel, power supply of AOU P1 terminal is shut
R

down to stop immediately.

CN(1)-7 It detects generator unit (L1-L3) generating signal.
Y Generator unit T7 terminal
ep

[T7] When auto start operation, no power exists on X7

relay. And in case no voltage is applied to X7
CN(1)-8 terminal, interior contact of PLC unit Y1, Y2
ro

L Generator unit T9 terminal

[T9] terminal is “OFF” and to stop engine start and to
cancel auto re-start function.
du

CN(1)-9
B Grounding
[N]
ct

Figure in [ ] shows wire label No.

io

Line
Pin No. Connection Function
n

color
Detecting that preheating at start is completed, it
CN(2)-1 turns starter by placing interior contact of Y2
L/Y ECU CN1-9 terminal
[V11] terminal of PLC unit “ON” and operating starter
relay SR from STX relay.
CN7-2 － NIL
No power exists during usual operation.
When air filter differential pressure indicator is
CN(2)-3 Monitor lamp: air filter
G/Y “ON” for 10 seconds, interior contact of PLC unit Y3
[Y03] clogging warning lamp
terminal is “ON” and air filter clogging warning
lamp glows.

3-25
 3. Electric System

Line
Pin No. 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. When starter works and X07 contact
is “ON” by generation signal, PLC unit judges that
Monitor lamp: overcrank
CN(2)-4 starting is completed, but when X7 contact is not
L/W warning lamp
[Y04] “ON” even after cranking is tried 10 seconds, it stops
(Start stall warning)
8 seconds and cranking operation will be repeated 10
seconds. When engine will not start even after this
operation is tried three times, make the interior
contact of PLC unit Y4 terminal “ON” and output
start stall signal to monitor panel and then
over-crank warning lamp goes on.
No power exists during usual operation.
N

CN(2)-5 Monitor lamp: oil fence water When oil fence level switch is “ON”, interior contact
B/L
ot

[Y05] level rise warning lamp of PLC unit Y5 terminal is “ON” and oil fence water
level rise warning lamp glows.
CN(2)-6 － NIL
f or

Power supply for engine starting when automatically

Starter switch ACC terminal starting.
When remote start-stop switch is “ON”, AOU XO
CN(2)-7
R

R/Y relay works to supply power to PLC (XO) terminal,

[C4]
MR relay(Via starter switch and 2 seconds later interior contact of Y1 terminal is
ep

ACC terminal) “ON”. Thus MX relay works, and starting

preheating.
ro

It outputs start signal when automatically starting.

When PLC unit X6 terminal (V11 terminal) detects
end of preheating Y2 terminal interior contact is
du

Starter switch C terminal “ON” to activate STX relay and it outputs start
signal to starter relay SR from AOU C6 terminal. ス
ct

Starter works and cranking operation continues 10

seconds. When generation signal is inputted to
io

CN(2)-8 PLC(X7) terminal during the time, it makes interior

R/L
[C6] contact “OFF” to cut power supply and then
n

cranking operation stops.

When generation signal is not inputted to PLC(X7)
Starter relay coil (SR) even after cranking operation is tried 10 seconds, it
stops 8 seconds and cranking operation is repeated is
tried and this operation is repeated three times.
When generation signal is not inputted to PLC(X7)
terminal, start stall warning is outputted.
CN(2)-9 － NIL
Figure in [ ] shows wire label No.

3-26
 3. Electric System
(2) Operating procedure
1. Start the generator unit under the procedure of manual operation and adjust the frequency and
voltage rating.
2. Turn the starter switch to “STOP” position and stop the engine.
3. Turn the circuit breaker of output terminal “ON” after the generator unit stopped when you use
the circuit breaker and single phase receptacle on the control panel.
4. Turn the operating selector switch to “AUTO” position on the control panel, switch “ENGINE
SPEED” switch to “HIGH” position.
5. The unit will be under stand by and start once the start signal is sensed.
※This explains how the unit equipped with automatic power transfer is automatically started.

(3) Function
● When start signal activates in stand-by conditions, it starts the generator engine after preheating.
When stop signal activates, it continues 10 seconds cooling down operation to stop engine and the
machine is placed again in stand-by conditions.
N
ot
f or
R
ep
ro
du

SG13071
● In order to start generator unit surely, cranking operation is repeated after it stops for 8 seconds,
in case that engine will not start even after cranking operation for 10 seconds. In case the engine
ct

will not start even after cranking operation is repeated three times, trouble signal goes on
io

showing difficulty in starting.

● In case that the lamp “OVERCRANK” goes on, switch off power supply once, pressing the button
n

“EMERGENCY STOP ”. Then after releasing the button “EMERGENCY STOP”, get rid of the
cause of trouble why engine would not start.

SG13072

Perform periodical inspection and maintenance of the generator

 For maintenance of the generator, try operation 5 to 10 minutes once a week.

3-27
 3. Electric System
3.4.4 Sequencer PLC PLC is an abbreviation of Programmable Logic Controller
Part number:46879 45800

N
ot

SG13073
(1) List of functions
Line
f

Pin No. Connection Function

No.
or

DC-DC converter (＋V) DC24V

(＋) P2 24V power supply for sequencer
output terminal
R

DC-DC converter (－V) DC24V

(－) N2 Grounding
output terminal
ep

COM COM X0 relay No.6 terminal Grounding

COM N PLC (BY0－) terminal Grounding
ro

X0 X00 X0 relay No.5 terminal X0 relay (automatic remote starting function)

X2 X02 PLC (X3) terminal Unused
du

X2 X02 NIL Unused

X3 X02 PLC (X2) terminal Unused
ct

Air filter differential pressure When differential pressure indicator functions, it

X4 X04
indicator [Via connector (1)] makes interior contact of PLC(Y3) terminal close.
io

Oil fence level switch When oil fence level switch functions, it makes
X5 X05
n

[Via connector (1)] interior contact of PLC(Y5) terminal close.

It transfers preheating completion signal to PLC(X6)
Diode SD1 is connected to
X6 X06 terminal from glow lamp circuit. (Check the timing
anode side
of cranking)
It decides whether it is to be continued or stopped by
X7 X07 X7 relay No.3 terminal
detecting generation signal.
Power supply for STX relay coil (starter relay
COM0 P1 STX relay No.1 terminal
function)
COM0 P1 STX relay No.4 terminal Power supply for starter relay SR
DC-DC converter (＋V) DC12V
Y0 P3 Power supply for DC-DC converter 12V
input terminal
When remote auto start signal is inputted, it closes
Y0 P3 X0 relay No.4 terminal
X0 relay and starts auto start.
COM1 N PLC (COM2) Grounding
DC-DC converter (－V) DC12V
COM1 N Grounding
input terminal
Y1 Y01 MX relay No. 5 terminal Power supply for MX relay coil (preheat function)
COM2 N PLC (BY0－) terminal Grounding

3-28
 3. Electric System

Line
Pin No. Connection Function
No.
Power supply for STX relay coil (starter relay
Y2 Y02 STX relay No.5 terminal
function)
Monitor lamp: air filter
Y3 Y03 warning lamp When air filter gets clogged, warning lamp glows.
[Via connector (2)]
Monitor lamp: overcrank
Y4 Y04 warning lamp In case of start stall, it makes warning lamp glow.
[Via connector (2)]
Monitor lamp: oil fence When condensates in oil fence accumulate more than
Y5 Y05 warning lamp 1/3 of condensate capacity, it makes warning lamp
[Via connector (2)] go on.
BY0
BY0＋ AOU connector 2 Unused
＋
BY0－ N PLC (COM2) terminal Grounding
N

BY0－ N PLC (COM) terminal Grounding

Cathode
ot

It transmits preheating completion signal to

side of
V11 Monitor lamp: glow lamp PLC(X6) terminal through SD1 diode from glow
SD1
diode lamp circuit. (Check the timing of cranking)
f or
R
ep
ro
du
ct
io
n

3-29
 3. Electric System
3.4.5 DC-DC Converter (DC POWER SUPPLY)
Part number:46872 01300

N
ot

SG13074
(1) List of functions
f

Line
Pin No. Connection Function
or

－
No.
OUT ＋V P2 PLC (＋) terminal It supplies DC24 power to PLC
PUT
R

－V N2 PLC (－) terminal Grounding

It supplies DC12V power to DC-DC
ep

＋V P3 PLC (Y0) terminal

converter
kIN Grounding [Via auto start unit
PUT －V N Grounding
connector (1)]
ro

－V N PLC (COM1) terminal Grounding

du
ct
io
n

3-30
 3. Electric System
3.4.6 Power relay (1)
Part number:46177 08500 (X7 relay, AC220V)
Part number:46177 08300 (MX, STX relay, DC12V)

SG13075
(1) List of function (X7 relay): Generating signal relay
N

Line
Pin No. Connection Function
No.
ot

It sends generation signal to PLC(X7) terminal

3 X07 PLC (X7) terminal
from X7 relay
f

When remote auto-start signal is inputted to X0

or

4 COM X0 relay No.6 terminal relay, it closes X0 relay contact and starts
auto-start operation.
1 T9 Control panel T9 terminal Power supply for X7 relay coil
R

5 T7 Control panel T7 terminal Power supply for X7 relay coil

ep

(2) List of function (MX relay): Preheating relay

ro

Line
Pin No. Connection Function
No.
du

3 C4 Anode side of SD2 diode It supplies DC12V power to DC-DC converter

3 C4 Starter switch ACC terminal It supplies DC12V power to DC-DC converter
ct

4 P1 X0 relay No.3 terminal Terminal for remote auto-start function

4 P1 STX relay No.4 terminal Terminal for starter function
io

Emergency stop button No.2 When emergency stop button is pressed, it

1 P1
terminal disconnects AOU unit power supply and stops it.
n

Power supply for STX relay coil (starter relay

1 P1 STX relay No.1 terminal
function)
5 Y01 PLC (Y1) terminal Power supply for MX relay coil (preheat function)

(3) List of function (STX relay): Starter relay

Line
Pin No. Connection Function
No.
When it detects preheating completion at PLC X6
3 C6 Starter relay No.3 terminal
terminal, it makes starter relay function.
4 P1 MX relay No.4 terminal Power supply of STX relay and MX relay
4 P1 PLC (COM0) terminal PLC common power supply (DC12V)
1 P1 MX relay No.1 terminal Power supply for MX relay coil (preheat function)
1 P1 PLC (COM0) terminal PLC common power supply (DC12V)
Power supply for STX relay coil (starter relay
5 Y02 PLC (Y2) terminal
function)

3-31
 3. Electric System
3.4.7 Power relay (2)
Part number:46177 08400 (X0 relay, DC12V)

SG13076
(1) List of function (X0 relay): remote auto start relay
Line
Pin No. Connection Function
N

No.
Cathode
ot

side of P3 X0 relay No.4 terminal Power supply for 12V input to DC-DC converter
SD2 diode
Anode side
f or

of SD2 C4 MX relay No.3 terminal Power supply for 12V input to DC-DC converter
diode
When generation signal is being transmitted to
R

X7 relay, it closes X7 relay contact and switches

6 COM X7 relay No.4 terminal
“OFF” starter relay power supply to stop
ep

starter.
6 COM PLC (COM) terminal Grounding
ro

When remote auto start switch is “ON”, 2

3 P1 MX relay No.4 terminal
seconds later it makes MX relay function.
du

It transmits remote auto start signal to

5 X00 PLC (X0) terminal
PLC(X0) terminal from X0 relay.
When remote auto start switch is “ON”, it
ct

4 P3 PLC (Y0) terminal

supplies 12V power to PLC.
It prevents ACC circuit of DC-DC converter
io

4 P3 Cathode side of SD2 diode

input power from throwing power.
n

Power supply of X0 relay coil is inputted from

1 P0 Switch ass’y No.3 terminal
switch ass’y No.3 terminal.
When contact between remote control terminal
Remote control terminal plate
8 A1 A1 and A2 is “ON”, A1 terminal is grounded
(A1) terminal
and X0 relay functions.

3-32
 3. Electric System
3.4.8 Alternator

SG13031E
N
ot
f or
R
ep
ro
du

SG13032E
ct

Voltage － Current 12Ｖ－30Ａ

io

Regulator adjusted voltage 14.4Ｖ±0.3Ｖ

n

3-33
 3. Electric System
3.4.9 Main relay
Part number:44346 13200

Rated voltage DC12V

Motor load
Rated load
40A at steady state
Coil resistance 51.5Ω

PC12044

3.4.10 Starter relay

Part number:44346 15300
N
ot

Rated voltage DC12V

f

20A
or

Rated load Motor load

Halogen load
Coil resistance 80Ω
R

SG13033
ep
ro
du

3.4.11 Glow relay

Part number:44346 15200
ct
io

Rated voltage DC12V

n

Coil resistance 0.19±0.04A

SG13034

3-34
 3. Electric System
3.4.12 Engine speed sensor
(1) For tachometer
Part number:44381 04000

Evaluation criterion
When the clearance between
flywheel ring gear and tip of speed
During sensor is 0.0512in (1.3mm), speed
operation at the sensor functions in good order if
rated conditions the voltage (ACV) between speed
sensor terminals is more than
1.0V. SG13077
Measurement of voltage between speed sensor terminals
should be performed within ACV range of digital type tester.
N

Tightening torque
ot

：28.9－36.2lb･ft [39.2－49.0N･m (400－500kgf･cm)]

f or
R

(2) For ECU

Engine maker part number:T1060-32271
ep

Evaluation criterion
ro

1. Measure the voltage (DCV)

between terminals of harness
du

side after extracting speed

sensor connector.
2. When the figures measured are
ct

same as mentioned in the table,

ECU is good. But sensor is bad,
io

When key switch so it should be replaced.

n

is positioned at 3. When the figures measured are

ACC position lower than the figures in the
table, ECU is bad and so it
should be replaced.
Voltage between terminals (DCV) SG13078
1←→ 3 12V
1←→ 2 5V

Tightening torque
：5.8－6.8lb･ft [7.9－9.3N･m (80－95kgf･cm)]

3-35
 3. Electric System
3.4.13 Tachometer (with hour-meter)
Part number:36146 08800

N
ot
f or
R
ep

SG13079E
ro

(1) Specifications
du

Operation voltage 10－15V

Operation temperature -4ﾟF－140ﾟF (-20℃－60℃)
ct

Revolution ratio (pulse type) 1 revolution per 1 pulse

io
n

(2) List of functions

Pin No. Line color Connection Function
L G/B Tachosensor Detection of pulse (1 revolution per 1 pulse)
Y R/W 10A fuse Power supply for tachometer
R R/W 10A fuse Power supply for hour-meter
B B/R ECU Hour-meter functions (Grounding)
Male
Y/W Panel light switch Power supply for lamps
coupler
Female
B Grounding Grounding for lighting
coupler

(3) Lamp specifications

12V 1.7W

3-36
 3. Electric System
3.4.14 Fuel gauge
Part number:36158 00500

N
ot
f or
R
ep

SG09051
(1) Position of meter pointer
Pointer position Resistance value (Ω) Remaining fuel [gal.(L)]
ro

E 95
1/2 32.5
du

F 7
ct
io

(2) List of functions

Pin No. Line color Connection Function
n

1 B Grounding
2 Y/W Panel light switch Power supply for lamps
3 G Sending unit Detector for remaining fuel
4 R/W 10A fuse Power source

(3) Lamp specifications

12V 3.4W

3-37
 3. Electric System
3.4.15 Sending unit
Part number:36159 03000

N
ot
f or
R
ep
ro
du
ct
io
n

SG10009E1

(1) Position of meter pointer for resistance value

Pointer position Resistance value (Ω) Remaining fuel [gal. (L)]
E 110
1/2 32.5
F 3

3-38
 3. Electric System
3.4.16 Oil fence level switch
Part number:46813 08100

N
ot
f or
R
ep
ro
du
ct

SG13037E
io
n

(1) Specifications
Maximum working current AC 0.5A, DC 0.5A
Maximum primary contact Less than 100mΩ
resistance (excluding lead line)
Fluid level in oil fence when
warning lamp glows [gal. (L)]
(Level switch is ON)
Fluid level in oil fence in above table shows the value calculated, not actually measured.

3-39
 3. Electric System
3.4.17 Electro-magnetic pump for bleeding air from fuel line
Without filter type
Part number:43650 02400

N
ot
f

SG13038E
or
R

(1) Specifications
Rated voltage 12V
ep

Operating current Less than 1.5A

Delivery capacity More than 0.1gal./min (0.4L/min)
ro
du
ct
io
n

3-40
 3. Electric System
3.4.18 Coolant water temperature gauge
Part number:36145 06500

N
ot
f or
R
ep

SG06040
(1) List of functions
Pin No. Line color Connection Function
ro

1 B Grounding
2 Y/W Panel light switch Power supply for lighting
du

3 G/W Water temperature sensor Detector for water temperature

4 R/W 10A fuse Power supply
ct
io
n

(2) Temperature and resistance value of sensor

Temperature [ﾟF (℃)] Resistance value (Ω)
120 (49) ｢156｣
175 (79.5) 52.3
210 (99) 28.4
250 (121) ｢17｣
｢ ｣ marked: reference value

(3) Lamp specifications

12V 3.4W

3-41
 3. Electric System
3.4.19 Water temperature sensor (for water temperature gauge)
Part number:44364 06200

SG13039
(1) Characteristic of temperature resistance
Temperature [ﾟF (℃)] Resistance value (Ω) Tolerance
122 (50) ｢153.9｣
176 (80) 51.9 ±4.4
212 (100) 27.4 ±1
N

248 (120) ｢16.1｣

｢ ｣ marked: reference value
ot
f or

3.4.20 Water temperature sensor (for ECU)

R

Part number:44364 06400

ep

(1) Characteristic of temperature

Water temp. [ﾟF (℃)] Resistance (kΩ)
ro

-45.4(-43) ｢76.83｣
du

-4 (-20) 18.8
104 (40) 1.136
212 (100) 0.1553
ct

SG13080
248 (120) ｢0.0905｣
io

｢ ｣ marked: reference value

n

(2) Evaluation criterion

Voltage between harness side terminal 1 and 2
should be measured with water temperature
sensor extracted.
When key switch is
・In case that measured voltage is 5V, ECU is
positioned at ACC
good. Sensor is not good, and so it should be
position
replaced.
・In case that voltage measured is less than 5V,
ECU is bad and it should be replaced.

3-42
 3. Electric System
3.4.21 Oil pressure gauge
Part number:36143 03600

N
ot
f or

SG13081
(1) Indicated pressure and resistance value
R

Indicated pressure [psi (MPa)] 0 60 (0.41) 113.8 (0.78)

Resistance value (Ω) 83 43 12.3
ep
ro

(2) List of functions

du

Pin No. Line color Connection Function

1 R/W 10A fuse Power supply
ct

2 G/R Oil pressure sensor Detector for oil pressure

3 B Grounding
io

4 Y/W Panel light switch Power supply for lamps

n

5 B Grounding

(3) Lamp specifications

12V 3.4W

3-43
 3. Electric System
3.4.22 Oil pressure sensor (for oil pressure gauge)
Part number:44365 00300

SG06042-2
(1) Standard pressure and standard resistance value
Standard pressure [psi (MPa)] 0 60 (0.41) 113.8 (0.78)
Standard resistance value (Ω) 83 43 12.3
N
ot

3.4.23 Engine oil pressure switch (for emergency stop)

f or

Part number:44328 20500

R

OFF in case of less than

Setting pressure
7.3psi (0.05MPa)
ep

SG12048
ro
du

3.4.24 Engine water temperature switch (for emergency stop)

Part number:44334 17700
ct

ON in case of more than

io

Setting temperature
230±37ﾟF (110±3℃)
n

SG12049

3.4.25 Ammeter for battery charge

Part number:46154 15300

SG13082E
Power supply voltage DC12V

3-44
 4. Troubleshooting
4.1 Repairing Procedures
When performing failure diagnosis, pay special attention to the followings, observing general
cautions.

4.1.1 Safety caution

(1) Removing such cap and/or plug for receiver tank, fuel tanks and pipes where pressure is loaded,
stop the machine and relieve all the interior pressure. Install measuring instruments connected
firmly.
(2) When doing the job with co-worker(s) together, make sure to give signal to the other person(s) and
do not allow other persons to come near to the job site.
(3) Take care not to touch hot portions and not to be involved in turning portions.

4.1.2 Caution during failure diagnosis

(1) Do not make haste to disassemble the unit
If the unit 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
N

increase more. What is worse, you will lose reliance or trust from clients，operators and users.
Therefore, it is absolutely necessary to investigate the trouble more carefully in advance and to
ot

follow the required procedures for failure diagnosis.

(2) Ask the clients about the trouble in details
f or

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?
R

2. Anything abnormal occurred before this trouble?

3. Did this trouble happen unexpectedly? Or the unit had been operated in bad conditions before?
ep

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?
ro

(3) Inspection items before starting diagnosis

du

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?
ct

2. Check each cable connection for any disconnection.

3. Check the other portions for any damage.
io

(4) Confirmation of trouble

n

Discuss with user(s) and/or operator(s) sufficiently about the trouble. As a result, judge whether
their judgment is based on the numerical comparison or sentimental basis. Make him (them)
understand well the reparation or correction you have finished.
Then check and confirm by yourself the cause of the trouble.
Note) Never proceed any investigation or measurement which may cause further greater damage.
(5) Procedures of diagnosis
When you become 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

A B C
High

Possible

Impossible

Abnormal

Normal
N
ot

1. In the troubleshooting column something abnormal is mentioned in lined parenthesis.

f or

2. In the troubleshooting column the cause of the said trouble is mentioned in dotted parenthesis.
R
ep

3. In the troubleshooting column the countermeasures or treatment are mentioned in the double
ro

lined parenthesis.
du

4. A under each column means the index of explanation.

ct
io
n

4-2
 4. Troubleshooting
4.2 Generator Troubleshooting
4.2.1 No voltage is generated or voltage too low

Check the frequency meter and Lower No speed

speed Raise the speed to the increases
confirm that engine speed during Refer to "Engine
specified value, watching
no-load operation corresponds to manual".
the following values. the frequency meter.

OK
No-load speed
-1
60Hz About 60Hz/1,800min

Check the AC output voltage of OK Check the terminal voltage OK

Replace the meters.
output terminals L1, L2 and L3. of the voltage meter.

None or low
N

NO (Disconnected)
ot

The Ex.startor connectors (J,K) Connect again correctly.

are connected properly.

OK
f or

Conductivity in AVR resistor hand NO Defective resistor hand

trimmer? trimmer.
R

OK A
ep

If magnetized forcibly, how does Voltage normal Residual magnetism does

the voltage change. not exist any more.
ro

0 or lower
du

Winding wire broken in generator NO

Fault in rotary rectifier.
or insulation poor?
ct

YES B, C D
io
n

Repair winding wire in

generator.

4-3
 4. Troubleshooting
4.2.2 Voltage is very high or it cannot be adjusted

Speed should be about NO (Higher) Adjust the speed to the

1,800min-1 for 60Hz during specified speed with the
no-load operation. speed adjusting bolt.

YES

Check resistance in AVR resistor NO

hand trimmer? Defective resistor HT.

YES

Is AC voltage at AVR input Broken wire

terminal (3-E3) proper? Repair.

YES

NO (Very high)
N

Is DC voltage at AVR connector

Fault in AVR.
(J-K) proper?
ot
f or

4.2.3 Voltage fluctuates

R

Use single-phase load by

Is there any unbalance between YES balancing it among
ep

single-phase load phases? phases, or increase

generator capacity.
NO
ro

Are revolutions stabilized at NO

Repair / adjust engine.
du

-1
1,800min ?

YES
ct

Any faulty connection found in YES (Looseness found)

io

Repair.
control panel?
n

NO

Check whether stability of AVR is NO

Readjust.
correctly adjusted or not.

YES

Disconnect each connection

between generator and control NO Fault in generator
panel. And when magnetized winding wire.
forcibly, the generated voltage Repair.
among phases is balanced?
B
YES

Fault in AVR.

4-4
 4. Troubleshooting
4.2.4 Load cannot be operated

Generated voltage and frequency NO

are normal? Adjust.

If it cannot be adjusted at
YES all, please refer to
troubleshooting "4.2.1 No
voltage is generated or
voltage too low".

NO
Circuit breaker (MCB) is "ON"? Turn MCB on.

Immediately the
YES
circuit breaks
automatically.

YES
Specified voltage found at load? Check load.
N

NO
ot

When MCB is on, is specified NO Fault in MCB contact or

voltage found among output
f

selector switch.
or

terminals L1, L2, L3, and N?

YES
R

Any looseness in output terminals YES

Retighten and correct.
ep

L1, L2, L3 and N connection?

NO
ro

Check cable used for

load.
du
ct
io

4.2.5 Voltage drops when load is applied

n

Please refer to the

When the load is applied, how is Normal sentence "4.2.1 No voltage
generator rpm? is generated or voltage
too low".
Drop

Load capacity
Check whether load starting kVA too high Reduce load capacity to suit generator
exceeds rated output of capacity. Or, use a higher kVA generator
generator? that suits load capacity.

OK

Any problem in load or cable such YES

as short-circuit or loose Repair.
connections?

NO
Engine output
insufficient. Repair.
See Engine manual.

4-5
 4. Troubleshooting
4.3 Emergency Switch Functions
4.3.1 Engine oil pressure drop is shown in monitor and it stops

Shortag
Check engine oil quantity. Shortage of oil. Replenish or replace.

Proper

Faulty
Check oil filter. Filter clogging. Replace it.

Normal

Faulty Defective oil pressure

Check engine oil pressure. Replace it.
switch.

Normal
N

Check cable connection to Faulty Looseness of cable

Repair.
connection or separated.
ot

engine oil pressure switch.

f or
R

4.3.2 Engine coolant temperature rise is displayed in monitor, and engine will stop
ep

Check water quantity and Shortage Shortage of coolant and

ro

quality in radiator. bad quality. Replenish or replace.

du

Normal
Higher than
Check ambient 104 ﾟF (40℃) High ambient Lower ambient
ct

temperature. temperature. temperature down to less

than 104 ﾟF (40℃).
Lower than
io

104 ﾟF (40℃)
n

Check water temperature Faulty

Malfunction of switch. Replace it.
switch.

Normal

Check cable connection to Faulty Looseness of cable

connection or separated. Repair.
water temperature switch.

4-6
 4. 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 to Disconnected

Faulty cable connection. Repair.
emergency stop monitor.

Normal

Check if actuator Faulty Malfunction of actuator

Replace it.
(solenoid) functions well. (solenoid).

Normal

Check if controller (ECU) Faulty Faulty controller (ECU) Replace it or repair

functions well. or cable connection. connection.
N
ot
f or

4.4.2 At start-up, starter rotates slowly

R

※
Faulty Battery specific gravity
Check battery voltage and Re-charge and or supply
too low or electrolyte
ep

specific gravity. water/replace.

short.
Normal
ro

Volt: more than 12V

Gravity: more than 1.26
du

Faulty Replace terminal or

Check battery cable. Faulty cable.
assembly.
ct

Normal
io

Repair or replace
Faulty starter motor.
n

assembly.

※When starter switch is placed at the “START” position, the battery is not normal if B terminal voltage
decreases by 10V.

4-7
 4. Troubleshooting
4.4.3 It will not speed up to rated speed

Filter clogging
Check air filter. Faulty filter. Clean or replace it.

Normal

Filter clogging
Check fuel filter. Fuel filter faulty. Replace it.

Normal

Check how fuel Faulty Malfunction of fuel feed Replace feed pump.
transported or if any air pump or fuel pipes faulty. Repair pipes and bleed
mixed. air.
Normal
N

Faulty
Check nozzle injection. Faulty nozzle. Replace it.
ot

Normal
f

Pressure drop Repair the trouble and

or

Check engine
Faulty compression.
compression. get rid of the cause.

Normal
R

Maladjustment of Repair the trouble and

ep

injection pump. get rid of its cause.

ro
du
ct
io
n

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 Ω－2kΩ
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.
N
ot

SG12035-1
f

［B］Measurement of generator winding wire resistance

or

The standard resistance value of each wire includes the generator’s winding wire resistance value.
(Please refer to the sentence “5.1 Generator’s Winding Wires Resistance Value”.)
R
ep
ro
du
ct
io
n

Voltage selection switch position 480/277V

SG13083

(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.)

T1 terminal－T4 terminal , T7 terminal－T10 terminal

T2 terminal－T5 terminal , T8 terminal－T11 terminal
T3 terminal－T6 terminal , T9 terminal－T12 terminal

4-9
 4. Troubleshooting
(2) Measurement of generator field winding wire resistance
Disconnect the wires ① and ② leading to the rotary
rectifier, then measure the resistance between the
wires.
Two wires
Diode module
N

Shaft
ot
f or

Varistor ① Varistor ②

③Three wires
R

Diode module
ep

(3) Measurement of exciter armature winding wires

resistance
Disconnect the wires ③ (three wires at center of diode
ro

module) leading to the rotary rectifier, and measure

the resistance between the wires.
du
ct
io
n

(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.

J K
Between J & K terminal
SG06020

4-10
 4. Troubleshooting
［C］Measurement of insulation resistance of generator winding wires
Measurement is performed with a 500V megger. The situation is considered to be satisfactory if the
measurement 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

①Disconnect 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
N

②Method of periodic inspection

ot

[Procedure]
1. Remove the load side cable from the output terminal
f

board.
or

Bonnet
2. Remove the cable between the terminal "N" and
terminal "Ground" which are connected on the back
R

of the output terminal plate.

ep

[Back of the output terminal board]

Ground N L3 L2 L1
ro

Remove cable
du

A040180-1
ct
io

AVR Connector
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
terminals L1, L2, L3 terminal and bonnet.
5. Insulation resistance when measured with a 500V
megger tester must be above 1 MΩ.
6. After finishing the measurement of insulation
resistance, re-connect the cable between the terminal A080518
"N" and terminal "Ground".

 After making sure that the insulation resistance of the generator is higher than 1 MΩ, 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.

4-11
 4. Troubleshooting
(2) Measurement of insulation resistance of generator field
winding wire
Disconnect the wires ① and ② leading to the rotary
rectifier, then measure the insulation resistance
between the disconnected wires ①, ② and the shaft.
Two wires
Diode module
N

Shaft
ot
f or

Varistor ① Varistor ②
R

Diode module ③Three wires

ep

(3) Measurement of insulation resistance of exciter armature

winding wires
ro

Disconnect the wires ③ (three pieces) and short-

circuit them, then measure the insulation resistance
du

between these wires and the shaft.

ct
io
n

J K
(4) Measurement of insulation resistance of exciter field
winding wire
Disconnect the field connector (J,K) in the control
panel, and measure the resistance at the connector on
the generator side.

Between J or K terminal & body

SG06021
4-12
 4. Troubleshooting
［D］Checking rotary rectifier and varistor
1. How to check rotary rectifier (diode module)
How to judge whether rotary rectifier (diode module) is in good order or in disorder. For the details,
see “3.2.1 Rotary rectifier”.

2. How to check varistor

Remove varistor terminals and measure resistance between both terminals. It is good if the
measured resistance is more than 100kΩ. (Tester range×kΩ)

Cooling fan
Damper coil

1
N
ot
f or
R

2
SG12129
Rotor ass’y
ep

Rotary rectifier

Generator field winding wire Exciter armature winding wires

ro
du

SG09029

① Diode module
ct

② Varistor
io

Diode module
n

Diode
Generator field winding wire

Exciter armature winding wires

Varistor
SG09107

4-13
 5. References
5.1 Generator’s Winding Wires Resistance Value

［At the temperature of 68°F (20°C)］

0.388
Voltage selection switch (T1–T2)
Ω
position 480/277V (T2–T3)
(T3–T1)
Generator 0.097
armature (T1–T4)
winding wires (T7–T10)
－ Ω (T2–T5)
(T8–T11)
(T3–T6)
(T9–T12)
Generator field winding wire Ω 2.384
Exciter armature winding wires Ω 0.519
N

Exciter field winding wire Ω 17.40

Auxiliary winding wires Ω 1.562
ot
f or

5.2 Forced Excitation Method

1. Run the generator at the rated r.p.m.
R

2. Disconnect the field connector in the control panel,

and apply the battery voltage to the exciter winding
ep

wire.
J and (＋) terminal of battery
ro

K and (－) terminal of battery

SG13084
du

J K
3. Magnetize for 1 to 2 seconds, then remove the wires
and check if voltage is generated.
ct

Note: Thickness of lead wires between battery terminal and connector should be the same
io

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.
n

Generated voltage from forced excitation (at 480V) (V)

Voltage generated (V) [at the temperature of 104°F (40℃)]
Battery 12V Battery 24V
450 580
* The generating voltage is only for reference because it will change due to the ambient temperature.

5.3 Idling Revolution Per Minute

It is set to the figure in the table by engine governor.
Revolution per minute
1,100±25
rpm (min-1)

5-1
 5. References
5.4 Generator Wiring Diagram
Molded case circuit breaker
MCB
(three-phase)
Molded case circuit breaker
MCB1－5
(single-phase)
SHC Shunt coil
A Ammeter
V Voltmeter
F Frequency meter
IL Illumination lamp

N
CT Current transformer
51 Thermal relay

ot
AVR Automatic voltage regulator
HT Hand trimmer (voltage regulator)
AS Ammeter change-over switch

for
R
ep
ro
du
ct
io
n
A100400

SG09005

5-2
 5. References
5.5 Engine Wiring Diagram
An Example
B Black G Green
3 R/W Y Yellow R Red
Wire of Red/White Line L Blue W White
Wire size (mm2)

N
ot
for
R
ep
ro
du
ct
io
n
SG13085

5-3
 5. References
5.6 List of Consumable Parts and Electrical Appliances
Item 40kVA

●Element / Filter / Belt

37438 08800
Engine oil filter cartridge
(Eng. maker part No.:1C020-32433)
Air filter ASS’Y 32100 40700
Air filter element 32143 11700
43534 04900
Fuel filter cartridge
(Eng. maker part No.:16631-43562)
43550 03100
Sedimenter
(Eng. maker part No.:RD819-51263)
Sedimenter element
(Eng. maker part No.:RD819-51281)
(strainer)
Breather filter －
Belt (Eng. maker part No.:1G517-97011)
N

Engine fuel hose (suction) (Eng. maker part No.:09661-70360)

ot

Engine fuel hose (return) (Eng. maker part No.:09661-40170)

●Electrical appliances
f

44390 03300
Controller (ECU)
or

(Eng. maker part No.:1K951-60601)

Monitor lamp 46870 55800
Auto start unit (AOU) 46760 46210
R

Sequencer (PLC) 46879 45800

ep

DC-DC Converter 46872 01300

Power relay (X7) 46177 08500
ro

Power relay (MX,STX) 46177 08300

Power relay (X0) 46177 08400
du

Main relay 44346 13200

Starter relay 44346 15300
ct

Glow relay 44346 15200

io

Tachometer (with hour-meter) 36146 08800

Fuel gauge 36158 00500
n

Sending unit 36159 03000

Oil fence level switch 46813 08100
Fuel air-bleeding
43650 02400
electromagnetic pump
Air filter indicator 32148 03000
Water temperature gauge 36145 06500
Water temperature sensor 44364 06200
(for water temperature gauge) (Eng. maker part No.:31351-32381)
Water temperature sensor 44364 06400
(for ECU) (Eng. maker part No.:T1063-65661)
Oil pressure gauge 36143 03600
Oil pressure sensor
44365 00300
(for oil pressure gauge)
44328 20500
Oil pressure switch
(Eng. maker part No.:15841-39012)
44334 17700
Water temperature switch
(Eng. maker part No.:51601-37671)

5-4
 5. References

Item 40kVA

44381 04000
Tachosensor (for tachometer)
(Eng. maker part No.:56713-42931)
Tachosensor (for ECU) (Eng. maker part No.:T1060-32271)
Ammeter for battery charge 46154 15300
Emergency stop switch 44336 03001
44322 07200
Starter switch
(Eng. maker part No.:17422-63591)
Fuse (5A) 46934 05000
Fuse (10A) 46934 03200×2
Fuse (60A) 44470 02300
N
ot
f or
R
ep
ro
du
ct
io
n

5-5
 n
io
ct
du
ro
ep
rR
fo
ot
N
 n
io
ct
du
ro
ep
rR
fo
ot
N
 n
io
ct
du
ro
ep
rR
fo
ot
N