SH15-17D SM表紙-0957 600 2000

FRAME & GENERATOR

＜TYPE:R.S.D＞

SHOP MANUAL

0957 600 2000

CONTENTS SH15D

- � -

1. SPECIFICATIONS 1-1. SPECIFICATIONS ................................................................................. 2

1-2. PERFORMANCES ................................................................................. 3

1-3. DIMENSIONAL DRAWINGS ............................................................... 4

1-4. WIRING DIAGRAM .............................................................................. 5-7

2. SERVICE INFORMATION 2-1. SAFETY PRECAUTIONS ..................................................................... 8

2-2. ELECTRICAL PRECAUTIONS .......................................................... 8

2-3. MAINTENANCE STANDARDS

2-3-1. GENERATOR ............................................................................ 9

2-3-2. ENGINE ....................................................................................... 10-13

2-3-3. TORQUE VALUES...................................................................... 14

2-4. ENGINE REVOLUTION ADJUSTMENT ........................................... 15

3. TROUBLESHOOTING 3-1. GENERATOR

3-1-1. EVIDENT PHYSICAL DEFECTS ........................................... 16

3-1-2. VOLTAGE FAULTS .................................................................... 17

3-1-3. ENGINE CIRCUIT TROUBLESHOOTING ........................... 18-20

3-2. ENGINE .................................................................................................. 21-23

4. DISASSEMBLY AND SERVICING 4-1. EXTERNAL COMPONENT ................................................................. 24-25

4-2. GENERATOR ......................................................................................... 26

4-3. SERVICING ............................................................................................ 27-30

�. SPECIFICATIONS SH15D

- � - - � -

1-1. SPECIFICATIONS

SH15D-R SH15D-D SHT15D-R SHT17D-SG

ener

ato

r

Frequency 50 Hz 60 Hz 50 Hz 60 HzR

ated

Output 12 kVA 13 kVA 15 kVA (12 kW) 16.3 kVA (13 kW)Voltage 220 V 120/240 V 380/220 V 380/220 VAmps 54.5 A 54.2 A× 2/54.2 A 22.8 A 24.8 APower factor 1.0 0.8

Type 2-pole, field rotating typeNo. of phase Single ThreeNo. of poles 2Voltage reg. system AVRInsulation class Rotor : F, Stator : B

En

gin

e

Model D1005-E2B-DGSEType Vertical, water cooled, 4-cycle, diesel engineNo. of cylinders 3Bore × Stroke 76 × 73.6 mm (2.99 × 2.90 in)Displacement 1,001 cm3 (61.08 cu. in.)STAND-BY ISO 3046 14.5 kW (19.5 HP) / 3,000 rpm

16.8 kW (22.5 HP) / 3,600 rpmNET CONT. ISO 3046 16.8 kW (22.5 HP) / 3,000 rpm

19.4 kW (26.0 HP) / 3,600 rpmCombustion chamber Spherical type (E-TVCS)Fuel injection pump Bosch MD type mini pumpGovernor All speed mechanical governorInjection nozzle Mini nozzle (DNOPD)Injection timing 0.31 rad. (18) before T.D.C. / 3,000 rpm

0.37 rad. (21) before T.D.C. / 3,600 rpmInjection pressure 13.73 MPa (140 kgf/cm2, 1,991 psi)Compression ratio 24 : 1Lubricating system Forced lubrication by trochoid pumpLubricating filter Full flow paper filter (cartridge type)Lubricating oil Quality better than CD classLubricating oil capacity 5.1 L (1.35 U.S. gal)Fuel Diesel fuel No.2-D (ASTM D975)Fuel tank capacity 53 LCooling system Pressurized radiator, forced circulation with water pumpStarting system Electric starting with starter (12 V, 1.0 kW)Starting support device By glow plug in combustion chamberCharging Alternator 12 V , 360 WDirection of rotation Counterclockwise (viewed from flywheel side)Battery 12V, 65AH equivalent

Acc

esso

ry

Volt meter YesAmpere meter YES NO YESHour meter YesWarning lights Indicator lights (4-conditions)Output TerminalATS terminal Yes

Weight (dry) 387 kg

- � -

SH15D

- � -

1-2. PERFORMANCES

ModelSH15D-R, SHT15D-R

50 HzSH15D-D, SHT17D-S

60Hz

Voltageregulation

Transient % less than 10Steady % less than 5Recovery time sec less than 3

Voltage stability % less than 5

Frequencyregulation

Transient % less than 10Steady % less than 5Recovery time sec less than 7

Frequency stability % less than 5Insulation resistance Mohm more than 10Wave-form distortion % less than 7Circuit protector capacity A 60 (24)* 60 (26)*Insulation class --- Rotor : F, Stator : BFuel consumption (full load) L/h less than 4.9 (4.8)* less than 5.9 (5.6)*Continuous operable hours (full load) h less than 10.8 (11.1)* less than 9.0 (9.5)*Fuel tank capacity L 53Sound level (7m) dB(A) 69.5 72.8

*:3-phase model

SH15D

- � - - � -

1-3. DIMENSIONAL DRAWINGS

698 mm

1,474 mm

869

mm

- � -

SH15D

- � -

1-4. WIRING DIAGRAMSH15D-R

SH15D

- � - - � -

1-4. WIRING DIAGRAMSH15D-D

- � -

SH15D

- � -

1-4. WIRING DIAGRAMSHT15D-RSHT17D-S

2. SERVICE INFORMATION SH15D

- � - - � -

2-1. SAFETY PRECAUTIONS

• Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely.

• Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the possibility of several hazards:

Carbon monoxide poisoning from engine exhaust.Be sure there is adequate ventilation whenever you run the engine.

Burns from hot parts.Let the engine cool before you touch it.

Injury from moving parts.Do not run the engine unless the instruction tells you to do so. Even then, keep your hands, fingers, and clothing away.

• To reduce the possibility of a fire or explosion, be sure when working around fuel. Use only a nonflammable solvent, not fuel, to clean parts. Keep all cigarettes, sparks, and flames away from all fuel-related parts.

2-2. ELECTRIC PRECAUTIONS

1) Check the connector terminals for bend, excessive extrusion, missing terminal, or other abnormalities before connecting the connector.

2) To connect, insert the connector as full as it goes.

3) Check the connector cover for breakage and check whether the connector female terminal is not open excessively. Then, connect the connector securely.

4) Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving parts and the hot parts.

5) Route and connect the wire harnesses properly. Be sure that the harnesses are not slack, twisted or pulled taut.

6) Take care not to pinch the wire harnesses during installation of a part.

7) Read the tester manufacturer's operation instructions carefully before operation with a tester.

- � -

SH15D

- � -

2-3. MAINTENANCE STANDARDS

2-3-1. GENERATOR (A) Resistance (SH15D-R, SHT15D-R) (at 20℃)

(A) Resistance (SH15D-D, SHT17D-S) (at 20℃)

(B) Others

Item Mesuring part

50 HzSingle phase Three phase

SH15D-R SHT15D-RWiring color,

wiring symbolResistancevalue (Ω )

Wiring color,wiring symbol

Resistancevalue (Ω )

Rotor 33.7 33.7

Stator

Main coil

Red - Blue 0.14Red - Black

(U - O)0.29

White - Black

(V - O)0.29

Blue - Black

(W - O)0.29

Exciter coil 2P connector

Light Green/White

|Light Green/

White

2.14

Light Green/White

|Light Green/

White

2.80

Pick-up coil

Single phase:3P connector Three phase:4P connector

Brown - Brown 0.04 Red - Black 0.04

White - Black 0.04

Blue - Black 0.04

Item Mesuring part

60 HzSingle phase Three phase

SH15D-D SHT17D-SWiring color,

wiring symbolResistancevalue (Ω )

Wiring color,wiring symbol

Resistancevalue (Ω )

Rotor 33.7 33.7

Stator

Main coil

Red - White

(U - O)0.07

Red - Black(U - O)

0.29

White - Blue

(V - O)0.07

White - Black(V - O)

0.29

Red - Blue

(U - V)0.14

Blue - Black(W - O)

0.29

Exciter coil 2P connector

Light Green/White

|Light Green/

White

1.54

Light Green/White

|Light Green/

White

2.40

Pick-up coil

Single phase:3P connector Three phase:4P connector

Brown - Brown 0.04 Red - Black 0.04

White - Black 0.04

Blue - Black 0.04

Circuit protector capacitySingle phase model ; 60 A

Three phase model50 Hz type ; 24 A60 Hz type ; 26 A

Bearing Part No. 6206 032 00X0Weight 77 kg

SH15D

- 10 - - 11 -

2-3-2. ENGINE

(A) Engine BodyItem Factory specification Allowable limit

Cylinder head surface flatness - 0.05 mm

Top clearance 0.55 - 0.70 mm -

Compression pressure 3.72 - 4.12 MPa -

38 - 42 kgf/cm2

Difference among cylinders - 10% or less

Valve clearance (cold) 0.145 - 0.185 mm -

Valve seat Width (In/Ex) 2.12 mm -

Angle (In) 1.047 rad. (60˚) -

Angle (Ex) 0.785 rad. (45˚) -

Valve face Angle (In) 1.047 rad. (60˚) -

Angle (Ex) 0.785 rad. (45˚) -

Valve recessing In/Ex -0.05 - 0.25 mm 0.40 mm

Valve stem to valve guide Clearance 0.035 - 0.065 mm 0.10 mm

Valve stem O.D. 6.960 - 6.975 mm -

Valve guide I.D. 7.010 - 7.025 mm -

Valve spring Free length 37.0 - 37.5 mm 36.5 mm

Setting load 117.4 N / 31.0 mm 100.0 N / 31.0 mm

11.97 kgf / 31.0 mm 10.2 kgf / 31.0 mm

Tilt - 1.0 mm

Rocker arm shaft to rocker arm Clearance 0.016 - 0.045 mm 0.10 mm

Rocker arm shaft O.D. 11.973 - 11.984 mm -

Rocker arm I.D. 12.000 - 12.018 mm -

Push rod Alignment - 0.25 mm

Tappet to tappet guide Clearance 0.020 - 0.062 mm 0.07 mm

Tappet O.D. 19.959 - 19.980 mm -

Tappet guide I.D. 20.000 - 20.021 mm -

Camshaft Side clearance 0.07 - 0.22 mm 0.30 mm

Alignment - 0.01 mm

Cam height In 28.80 mm 28.75 mm

Ex 29.00 mm 28.95 mm

Camshaft journal to cylinder block bore Oil clearance 0.050 - 0.091 mm 0.15 mm

Camshaft journal O.D. 35.934 - 35.950 mm -

Cylinder block bore I.D. 36.000 - 36.025 mm -

- 10 -

SH15D

- 11 -

(A) Engine Body (continued)Item Factory specification Allowable limit

Timing gear

Crank gear to idle gear 1 Backlash 0.032 - 0.115 mm 0.15 mm

Idle gear 1 to cam gear Backlash 0.036 - 0.114 mm 0.15 mm

Idle gear 1 to injection pump gear Backlash 0.034 - 0.116 mm 0.15 mm

Idle gear 1 to idle gear 2 Backlash 0.033 - 0.117 mm 0.15 mm

Idle gear 2 to governor gear Backlash 0.030 - 0.117 mm 0.15 mm

Idle gear shaft to gear bushing

Idle gear 1 Clearance 0.020 - 0.054 mm 0.10 mm

Idle gear bushing I.D. 26.000 - 26.021 mm -

Idle gear shaft 1 O.D. 25.967 - 25.980 mm -

Idle gear 2 Clearance 0.020 - 0.054 mm 0.10 mm

Idle gear bushing I.D. 26.000 - 26.021 mm -

Idle gear shaft 2 O.D. 25.967 - 25.980 mm -

Idle gear

Idle gear 1 Side clearance 0.20 - 0.51 mm 0.80 mm

Idle gear 2 Side clearance 0.20 - 0.51 mm 0.80 mm

Piston pin bore I.D. 22.000 - 22.013 mm 22.03 mm

Piston ring to piston ring groove

Second ring Clearance 0.085 - 0.112 mm 0.2 mm

Oil ring Clearance 0.020 - 0.055 mm 0.15 mm

Piston ring gap Top ring 0.30 - 0.40 mm 1.25 mm

Second ring 0.30 - 0.40 mm 1.25 mm

Oil ring 0.25 - 0.40 mm 1.25 mm

Connecting rod Alignment - 0.05 mm

Piston pin to small end bushing Clearance 0.014 - 0.038 mm 0.15 mm

Piston pin O.D. 22.002 - 22.011 mm -

Small end bushing I.D. 22.025 - 22.040 mm -

Crankshaft Alignment - 0.02 mm

Crankshaft to crankshaft bearing 1 Oil clearance 0.034 - 0.114 mm 0.20 mm

Crankshaft journal O.D. 47.934 - 47.950 mm -

Crankshaft bearing 1 I.D. 47.984 - 48.048 mm -

Crankshaft to crankshaft bearing 2 Oil clearance 0.034 - 0.095 mm 0.20 mm

Crankshaft journal O.D. 47.934 - 47.950 mm -

Crankshaft bearing 2 I.D. 47.984 - 48.029 mm -

Crankshaft to crankshaft bearing 3 Oil clearance 0.034 - 0.098 mm 0.20 mm

Crankshaft journal O.D. 51.921 - 51.940 mm -

Crankshaft bearing 3 I.D. 51.974 - 52.019 mm -

Crankpin to crankpin bearing Oil clearance 0.029 - 0.091 mm 0.20 mm

Crankpin O.D. 39.959 - 39.975 mm -

Crankpin bearing I.D. 40.004 - 40.050 mm -

Crankshaft Side clearance 0.15 - 0.31 mm 0.50 mm

Cylinder liner I.D. 76.000 - 76.019 mm 76.15 mm

Cylinder (oversized) I.D. 76.500 - 76.519 mm 76.65 mm

SH15D

- 12 - - 13 -

(B) Lubricating System

(C) Cooling System

Item Factory specification Allowable limit

Engine oil pressure At idle speed More than 49 kPa -

(0.5 kgf/cm2)

At rated speed 196 - 441 kPa 147 kPa

(2.0 - 4.5 kgf/cm2) (1.5 kgf/cm2)

Inner rotor to outer rotor Clearance 0.06 - 0.18 mm -

Outer rotor to pump body Clearance 0.100 - 0.180 mm -

Inner rotor to cover Clearance 0.025 - 0.075 mm -

Thermostat Valve opening 69.5 - 72.5 ℃ -

temperature

(at beginning)

Valve opening 85 ℃ -

temperature

(opened

completely)

Radiator Water leakage No leak at specified -

test pressure pressure

137 kPa (1.4 kgf/cm2)

Radiator cap Pressure 10 seconds or more -

falling time 88 - 59 kPa

0.9 - 0.6 kgf/cm2

Fan belt Tension 7.0 - 9.0 mm/ 98 N (10kgf) -

- 12 -

SH15D

- 13 -

(D) Fuel System

(E) Electrical System

Injection pump Injection timing 0.30 - 0.33 rad. -

(3,000 min-1 (rpm)) (17 - 19˚)

before T.D.C.

Injection timing 0.35 - 0.39 rad. -

(3,600 min-1 (rpm)) (20 - 22˚)

before T.D.C.

Injection pump (BG type) Injection timing 0.27 - 0.31 rad. -

(60 Hz/1,800 min-1 (rpm))

(15.5 - 17.5˚)

before T.D.C.

Pump element Fuel tightness - 13.73 MPa

(140 kgf/cm2)

Delivery valve Fuel tightness 10 seconds 5 seconds

13.73 - 12.75 MPa 13.73 - 12.75 MPa

(140 - 130 kgf/cm2) (140 - 130 kgf/cm2)

Injection nozzle Injection 13.73 - 14.71 MPa -

pressure (140 - 150 kgf/cm2)

Injection nozzle valve seatValve seat tightness

When the pressure is -

12.75 MPa (130 kgf/cm2),

the valve seat must be

fuel tightness.

Starter (planetary gear reduction type)

Commutator O.D. 30.0 ｍｍ 29.0 ｍｍ

Difference O.D. Less than 0.02 mm 0.05 mm

Mica Undercut 0.50 - 0.80 mm 0.20 mm

Brush Length 16.0 mm 10.5 mmStarter (Electromagnetic drive type)

Commutator O.D. 28.0 mm 27.0 mm

Difference O.D. Less than 0.05 mm 0.40 mm

Mica Undercut 0.50 - 0.80 mm 0.20 mm

Brush Length 16.0 mm 10.5 mm

Alternator

Stator Resistance Less than 1.0 Ω -

Rotor Resistance 2.9 Ω -

Slip ring O.D. 14.4 mm 14.0 mm

Brush Length 10.0 mm 8.4 mm

Glow plug Resistance Approx. 0.9 Ω -

SH15D

- 14 - - 15 -

2-3-3. TORQUE VALUES

(A) for Special use

(B) for General use

Section Item N ･m kgf ･mGenerator Rotor mounting bolt

End bracket mounting bolt34.3 - 44.119.6 - 27.4

3.5 - 4.52.0 - 2.8

Engine # Cylinder head cover screw 6.9 - 8.8 0.7 - 0.9# Cylinder head screw 63.7 - 68.6 6.5 - 7.0# Main bearing case screw 1 29.4 - 34.3 3.0 - 3.5# Main bearing case screw 2 49.0 - 53.9 5.0 - 5.5# Flywheel screw 53.9 - 58.8 5.5 - 6.0# Connecting rod screw 41.2 - 46.1 4.2 - 4.7# Rocker arm bracket nuts 21.6 - 26.5 2.2 - 2.7# Idler gear shaft screws 9.8 - 11.3 1.00 - 1.15# Fan drive pulley screw 235.4 - 245.2 24.0 - 25.0# Bearing case cover mounting screw 9.8 - 11.3 1.00 - 1.15

Starter "B" terminal nut 5.9 - 11.8 0.9 - 1.2Canopy Oil drain bolt 28.4 - 33.4 2.9 - 3.4

Note ; For "#"marked bolt and nut on the table, apply engine oil to their threads and seats before tightening.

Size N・m kgf・mM6 7.8 - 11.8 0.8 - 1.2M8 19.6 - 27.4 2.0 - 2.8M10 34.3 - 44.1 3.5 - 4.5M12 53.9 - 68.6 5.5 - 7.0

- 14 -

SH15D

- 15 -

1. Loosen the adjusting nut ① .2. Adjust the engine revolution to the set-up

rpm (see the below chart) by screwing the adjusting bolt ② .

3. Hold the position of the adjusting bolt by tightening the adjusting nut ① .

2-4. ENGINE REVOLUTION ADJUSTMENT

Set-uprpm

(no load)

50 Hz 60 Hz

52 ～ 53 Hz 62 ～ 63 Hz

① ②

3. TROUBLESHOOTING SH15D

- 16 - - 17 -

3-1. GENERATOR

NOTE : To replace the parts safely, be sure to remove the negative terminal of battery so as to prevent from short-circuiting the battery and the parts.

3-1-1. Evident Physical Defects (Overheating, Noise, Vibrations...)Fault Action Origin of fault

Excessive overheating of bearing (with or without abnormal bearing noise)

Disassemble bearing

* Excessive wear of the bearing or deterioration of the grease.

* Bearing race badly locked (moving in its housing) .

* Bracket misalignment.

Excessive overheating of generator frame

Check* Air inlets and outlets of

generator* Measuring equipment

(Voltmeter-Ammeter)

* Air flow (inlet-outlet) partially clogged or hot air is being recycled either from generator or prime mover.

* Generator over loaded.

Excessive vibration and humming noise coming from the generator.

Stop the gen-set and check the installation.

* Three phase generator is single phase loaded in excess of acceptable level.

Start up with no-load :if humming persists...

* Short-circuit in the generator stator.

Generator damaged by a significant impact which is followed by humming and vibration

Stop the gen-set immediately.

* Short-circuit in external circuit.* Break or deterioration in the coupling.* Break or twist in shaft extension.* Shifting or short-circuit or the main field

coil.* Bursting or unlocking of the fan.* AVR damaged.

Smoke, sparks, or flames issuing from the generator

Stop the set immediately.

* Short in external circuit (including wiring between generator and control panel).

* Object fallen into the machine.* Short or flash in stator coil.

- 16 -

SH15D

- 17 -

3-1-2. Voltage FaultsDefect Action Measure Origin of fault

No voltage at no load or start up

Check brush surface and wiring.

* The generator builds up in correct voltage.

* AVR faulty.

* Check the connection of the sensing leads to the AVR.

* Short or open circuit of the exciter coil (check the exciter coil).

* Open circuit of the rotor coil (check the resistance).

Voltage too high

Check each wiring connection.

Check resistance.* Short or open circuit of the pick-up

coil.* AVR faulty.

Voltage oscillation

Check each wiring connection.

Check resistance.

* Check speed for possible cycle irregularity.

* Check out put connections.* AVR faulty.

* Speed below nominal on load.* Open circuit of the exciter coil (check

resistance values). * Short circuit of the rotor coil (check

resistance).

Voltage correct on no-load, too low on load

* Check each wiring connection.

* Adjusting the engine revolution.

* Check resistance.* Check engine

revolution.

* AVR faulty.* Short circuit of the stator main coil or

exciter coil.* Short circuit of the rotor coil.* Engine revolution is low.

Voltage collapses during normal operation

Check the contact of brush and surface of slip ring.

* The output voltage does not return the nominal voltage

* Stator coil faulty (check the resistance). * Rotor coil faulty.

SH15D

- 18 - - 19 -

3-1-3. Engine Circuit Troubleshooting

1) Engine stops.

2) Charge fault lamp does'nt light when key

switch is turned on and engine is not running.

Does the engine stop approximately 10 second

after starting ?

Is the engine oilat the specified level ?

Does monitor showsoverheating ?

Is the cooling waterat the specified level ?

Does the charge fault lampoperate normally ?

Is the 10 A fuse intact ?

Stop at soonestafter starting

# Insufficient engine oil

# Engine breakdown# Insufficient fuel

# Defective oil pressure sensor# Defective water temperature sensor# Defective wiring# Over voltage

# Insufficient cooling water# Clogged radiator

# Insufficient cooling water

# Defective fan velt# Broken wiring# Short-circuited wiring

# Burnt out 10 A fuse

Engine Circuit Troubleshooting Sequence Chart

NO

YES

YES

NO

NO

NOYES

YES

YES

YES

NO

NO

- 18 -

SH15D

- 19 -

3) Charge fault lamp does not go off when engine is running.

4) Engine does not stop when key switch is OFF position.

# Incorrect fan belt setting

# Defective generator# Broken wiring# Short-circuited wiring

Is the fan belt normal ?

Is the wiring normal ?

Is the wiring normal ?

Does the stop solenoidoperate normally ?

*Movement of stop solenoid Engine running : Solenoid ON Engine stop : Solenoid OFF

# Broken lead # Defective engine # Defective stop solenoid# Defective emergency relay

NO

YES

NO

YES

YES

YES

NO

NO

SH15D

- 20 - - 21 -

a) Engine stops. Engine Circuit Trouble Diagnosis

b) Engine stops.

Engine stops during operation.Engine starts, but stops after about 10 sec.

# Insufficient engine oil

# Oil pressure will not go up

# Insufficient cooling water

# Overheats when water temperature rises

# Oil pressure sensor failure

# Water temp. sensor failure

# Wiring short-circuit

Add more oil

Check the related point

Add more cooling water

Check the related points

Replace

Replace

Repair

Charge fault lamp does not light even with the key switch turned to "ON" when the engine is stopped.

Charge fault lamp is not off even when the engine is running.

Engine does not stop even after key switch to "OFF"

# Fuse 10 A burned out

# Charge fault lamp burned

# Wiring disconnection or short-circuit

# Generator failure

# Broken fan belt

# Wiring disconnection or short-circuit

# Emergency relay failure

# Stop solenoid failure

# Wiring disconnection

Replace

Replace

Replace

Replace

Replace

Repair

Replace

Replace

Replace

Oil pressure monitor lamp shows abnormal.

(Checking method) Are the oil pressure and water temperature monitor lamp normal ?

Water temperature monitor lamp shows abnormal.

Oil pressure and water temperature monitor lamps are normal.

Does not pass current.

(Checking method) Check the fuse for continuity with an ohmmeter.

- 20 -

SH15D

- 21 -

3-2. ENGINE

Symptom Probable Cause SolutionEngine Does Not Start No fuel Replenish fuel

Air in the fuel system Vent airWater in the fuel system Change fuel and repair or

replace fuel systemFuel pipe clogged Clean or replaceFuel filter clogged ReplaceExcessively high viscosity of fuel or engine oil at low temperature

Use the specified fuel or engine oil

Fuel with low cetane number Use the specified fuelFuel leak due to loose injection pipe retaining nut

Tighten retaining nut

Incorrect injection timing AdjustFuel camshaft worn ReplaceInjection nozzle clogged Clean or replaceInjection pump malfunctioning Repair or replaceSeizure of crankshaft,camshaft,piston, cylinder or bearing

Repair or replace

Compression leak from cylinder Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

Improper valve timing Correct or replace timing gearPiston ring and cylinder worn ReplaceExcessive valve clearance AdjustStop solenoid malfunctioning Replace

Starter Does Not Run Battery discharged ChargeStarter malfunctioning Repair or replaceKey switch malfunctioning ReplaceWiring disconnected Connect

Engine Revolution Is Not Smooth

Fuel filter clogged or dirty ReplaceAir cleaner clogged Clean or replaceFuel leak due to loose injection pipe retaining nut

Tighten retaining nut

Injection pump malfunctioning Repair or replaceIncorrect nozzle opening pressure AdjustInjection nozzle stuck or clogged Repair or replaceGovernor malfunctioning Repair

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to the specified levelPiston ring and cylinder worn or stuck Repair or replaceIncorrect injection timing Adjust

SH15D

- 22 - - 23 -

Symptom Probable Cause SolutionEither Black or Dark Gray Exhaust Gas Is Observed

Overload Lessen the loadLow grade fuel used Use the specified fuelFuel filter clogged ReplaceAir cleaner clogged Clean or replaceDeficient nozzle injection Repair or replace nozzle

Deficient Output Incorrect injection timing AdjustEngine's moving parts seem to be seizing

Repair or replace

Injection pump malfunctioning Repair or replace Deficient nozzle injection Repair or replace nozzleCompression leak Check the compression

pressure and repairGas leak from exhaust system Repair or replaceAir cleaner dirty or clogged Clean or replace

Excessive Lubricant Oil Consumption

Piston ring's gap facing the same direction

Shift ring gap direction

Oil ring worn or stuck ReplacePiston ring groove worn Replace pistonValve stem and guide worn ReplaceOil leaking due to defective seals or packing

Replace

Fuel Mixed into Lubricant Oil

Injection pump's plunger worn Repair or replaceDeficient nozzle injection Repair or replace nozzleInjection pump broken Replace

Water Mixed into Lubricant Oil

Head gasket defective ReplaceCylinder block or cylinder head flawed Replace

Low Oil Pressure Engine oil insufficient ReplenishOil strainer clogged CleanExcessive oil clearance of crankshaft bearing

Replace

Excessive oil clearance of crankpin bearing

Replace

Excessive oil clearance of rocker arm ReplaceOil passage clogged CleanDifferent type of oil Use the specified type of oilOil pump defective Repair or replace

High Oil Pressure Different type of oil Use the specified type of oil Relief valve defective Replace

- 22 -

SH15D

- 23 -

Symptom Probable Cause SolutionEngine Overheated Engine oil insufficient Replenish

Fan belt broken or elongated Replace or adjustCoolant insufficient ReplenishRadiator net and radiator fin clogged with dust

Clean

Inside of radiator corroded Clean or replaceCoolant flow route corroded Clean or replaceRadiator cap defective ReplaceOverload running Reduce the loadHead gasket defective ReplaceIncorrect injection timing AdjustUnsuitable fuel used Use specified fuel

Battery Quickly Discharge

Battery electrolyte insufficient Replenish distilled water and charge

Fan belt slips Adjust belt tension or replaceWiring disconnected ConnectRectifier defective ReplaceAlternator defective ReplaceBattery defective Replace

4. DISASSEMBLY AND SERVICING SH15D

- 24 - - 25 -

4-1. EXTERNAL COMPONENT

Cover, Battery, Draining1. Place the generator on a firm and level

surface.2. Remove the maintenance doors ① and side

cover ② .3. Remove the battery cable (- and +), then

remove the battery.4. Open the coolant drain cock under the

radiator to drain the coolant.5. Remove the engine oil drain bolt to drain the

engine oil.6. Remove the fuel tank cap ③ .7. Remove the upper cover ④ .

Fuel Tank8. Reinstall the fuel tank cap ③ to the fuel tank ⑤ .

9. Turn the fuel valve ⑥ on the fuel filter to the OFF position.

10. Remove the fuel hoses and air bleeding pipe ⑦ from the fuel filter ⑧ .

11. Remove the fuel filter.12. Remove the fuel tank bands ⑨ , then remove

the fuel tank.

Fuel Tank Bracket13. Remove the maintenance cover ⑩ .14. Remove the ATS terminal ⑪ .15. Remove the fasteners ⑫ of the fuel tank

bracket ⑬ .16. Remove the fuel tank bracket.

②

③

④

①

⑨

⑤ ⑦

⑥

⑧

⑩

⑪ ⑬

⑫

⑫

- 24 -

SH15D

- 25 -

Front Cover, Control Panel17. Remove the generator harness terminals ⑭ .18. Disconnect the generator connectors ⑮ .19. Remove the generator brush holder ⑯ .20. Remove the front cover ⑰ .

Rear Cover21. Unscrew the bolts on the exhaust pipe ⑱ .22. Remove the upper and lower water hose ⑲ .23. Remove the air inlet pipe ⑳ .24. Remove the rear cover � .

⑮ ⑰

⑯

⑭

⑱

⑲

⑳

�

SH15D

- 26 - - 27 -

4-2. GENERATOR

Stator1. Remove the generator mounting nuts ① .2. Loosen the engine mounting nuts.3. Remove the stator harness ② .4. Place the jack under the generator front

housing ③ , then lift-up the generator slowly.5. Remove the bolts (M10× 205) ④ .6. Remove the generator rear housing ⑤ .7. Remove the stator assembly ⑥ not so as to

damage the coil.

Rotor8. Remove the rotor fixing bolts ⑦ .9. Remove the rotor assembly ⑧ not so as to

damage the coil.

①②

③

④

⑤

④

⑥

⑦⑧

⑦

- 26 -

SH15D

- 27 -

4-3. SERVICING

(A) Terminal voltage for each part during No-load period

1. With the circuit breaker in the "ON" position, measure the voltage in each phase and each line.

2. If the factory spec. is not indicated, inspect the output circuit or the wiring harness (refer to the wiring diagram).

(B) Stator CoilMain Coil

1. Inspect the continuity between each stator coil harness terminal with a milliohm meter.

2. If the resistance is not as specified, replace the stator.

# Measurement is not possible with a regular tester.

Exciter Coil1. Inspect the continuity between the terminal

of the exciter coil connector.2. If the resistance is not as specified, replace

the stator.

Output voltage (factory spec.)

SH15D-R Line 220 V ± 13 V (U - V)SH15D-D Line 120 V ± 7 V (U - V, V - W)

240 V ± 14 V (U - W)SHT15D-R Line 220 V ± 13 V (U - O, V - O, W - O)SHT17D-S Phase 380 V ± 23 V (U - V, V - W, W - U)

ResistanceFactoryspec.

See page 9

ResistanceFactoryspec.

See page 9

Milliohm meter

Stator coil harnessterminals

Exciter coilconnector

SH15D

- 28 - - 29 -

Pick-up Coil1. Measure the coil between the terminal of the

pick-up coil connector.2. If the resistance is not as specified, replace

the stator.

Grounding of Stator coil1. Measure the insulation resistance between

each stator winding and lamination with a mega ohm meter.

2. Reading should be more than 1M Ω at DC 500V.

3. If continuous, after dry the stator with an appropriate way, measure the insulation resistance again.

If continuous still, replace the main stator or contact service.

(C) Rotor coil1. Measure the rotor coil resistance between

each rotor coil end with a milliohm meter.2. If the resistance is not as specified, replace

the rotor assembly.

# Measurement is not possible with a regular tester.

Grounding of Rotor coil1. Measure the insulation resistance between

each rotor coil and lamination with a mega ohm meter.

2. Reading should be more than 1M Ω at DC 500V.

3. If continuous, after dry the rotor with an appropriate way, measure the insulation resistance again.

If continuous still, replace the main rotor or contact service.

(D) Control panelAC ammeter

1. Inspect the continuity between each ammeter terminal with an ohmmeter.

2. Replace the ammeter if there is no continuity.

ResistanceFactoryspec.

See page 9

ResistanceFactoryspec.

See page 9

Milliohm meter

Rotor coilend

Ohmmeter

AC ammeter

Single phase models

Three phase models

- 28 -

SH15D

- 29 -

Circuit breaker1. Inspect the cont inui ty between each

upper and lower breaker terminal with an ohmmeter.

2. Confirm that there is continuity when the breaker switch in "ON".

3. If there is no continuity, it indicates that the contacts are faulty. Replace the breaker.

Current Transformer (CT for Ammeter)1. Test for continuity between each CT terminal

with an ohmmeter.2. Replace the CT if there is no continuity.

Lamp timer (for Glow plug)1. Remove the lamp timer from inside of the

panel.2. Connect the 12V battery ① , lamp timer ②

and bulb ③ as shown in the figure.3. The bulb ③ light up when contacting the lead

wire ④ with positive terminal of the battery ① and goes off approximately 5 seconds late, the lamp relay is proper.

Ohmmeter

Circuit breaker

Ohmmeter

Current Transformer

Lamp timer

① ③

②

④

SH15D

- 30 -

Oil pressure sensor1. The normal o i l p ressure sensor has

continuity when the engine is stopped and has no continuity while the engine is running.

2. Replace the sensor if it is defective.

Water temperature sensor1. Insert the water temperature sensor in the

engine oil, and continue the circuit when the oil temperature rises above than 115 ± 3℃ .

2. Check that the resistance is 0 ohm in case sensor is defective.

Emergency relay circuit1. When the engine is running at rated rpm,

connect the lead wires to the terminal of the oil pressure sensor or the water temperature sensor.

2. Also ground the other end of the lead wires to an unpainted portion of the engine frame.

(In normal operation)・The stop solenoid activates and the engine

stops automatically.

Oil pressure sensor

Water temperature sensor