Copyright ©

Engine Electrical 1D-1

Engine
Engine Electrical
Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 1D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . 1D-2
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . 1D-3
General Description . . . . . . . . . . . . . . . . . . . . . 1D-3
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-6
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
General Description . . . . . . . . . . . . . . . . . . . . 1D-14
Service on the Machine: Starting System . . . 1D-15
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Torque Specifications . . . . . . . . . . . . . . . . . . . 1D-17
Main Data and Specifications. . . . . . . . . . . . . 1D-18
Preheating System . . . . . . . . . . . . . . . . . . . . . . 1D-22
Glow Plug Replacement . . . . . . . . . . . . . . . . 1D-22
Precautions on Service Work. . . . . . . . . . . . . 1D-22
A List of Defective Phenomena . . . . . . . . . . . 1D-22
Main Data and Specifications. . . . . . . . . . . . . 1D-23

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-2 Copyright ©
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound are not indicated in the illustration. The
correct torque value must be used when installing
fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-3
Engine Electrical

Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a self-rectifying
type with a built-in regulator.

4 5

7
8

2 1

WSJJ0028

Name
1. Lower Mounting Bolt 6. Sliding Piece
2. Nut 7. Adjusting Nut
3. Generator 8. Washer
4. Generator Adjusting Plate 9. Tension Adjusting Bolt
5. Bolt

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-4 Copyright ©
Maintenance Electrical Tests
The most common indication of charging system Before performing the following generator electrical
troubles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, check the not defective and generator belts are not slipping. Also,
battery first. Check if the battery is discharged because the battery must be fully charged for a valid test of the
of short circuit, or electrical components left turned on charging system.
for extended periods. Notice:
Keep the generator and all other electrical system To avoid damage to the vehicle electrical system,
terminals clean and tight. A loose or badly corroded always observe the following precautions:
terminal connection will create excessive resistance in • Do not polarize the generator.
the circuit and result in hard starting, dim lights, etc.
• Do not short across or ground any of the terminals
Inspect the generator system at regular intervals and
in the charging circuit except as specifically
correct any potential causes of trouble before machine
instructed herein.
performance is affected.
• NEVER operate the generator with the output
Diagnosis of Charging System terminal open-circuited.
Trouble in the charging system will be evidenced as one • Be sure the generator and battery have the same
or more of the following three conditions: ground polarity.
1. The battery discharge warning light will stay on. • When connecting a charger or other battery to the
2. An undercharged battery as evidenced by slow machine’s battery, connect negative to negative
cranking. and positive to positive.
3. An overcharge, or overvoltage, condition. 1. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “E” to
Undercharged Battery ground. The voltmeter should show 0 volts.
2. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “B” to
Inspection ground. The voltmeter should read at least 24 volts.
1. Accessories were not left turned on for extended 3. With the engine control switch “ON” and the engine
periods. not running, connect a voltmeter from white wire
2. Drive belt for proper tension. side of the connector to ground. The voltmeter
3. The ECM main relay has been stuck ON with the should show 24 volts.
key switch in OFF position. (Battery voltage is 4. With the engine control switch “ON” and the engine
consumed.) not running, the “charge” light should be on. This
4. Wiring and connections for corrosion or looseness. shows that the other circuit in the connection is
working.
Overcharge (or Overvoltage) condition
5. With the engine running and the headlight high
A charging rate in excess of 29.5-volts for a prolonged
beams (if equipped) turned on, read the voltage at
period may cause early electrical system failure.
the “B” post on the generator. The voltmeter should
Blown fuses, light bulbs burned out, and even battery
read at least 24 volts.
failure may result. If this condition exists, test the
generator as described under “Generator Output Test” 6. If steps 1 through 4 are not OK, check connectors
later in this section. in the harness for looseness or corrosion and
retest.
Noisy Generator 7. If step 5 voltage is low, substitute a known good
regulator and test again. If the voltage is still low,
bench test the generator.
Inspection
1. Drive pulley for looseness.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
Generator noise may also be caused by worn or
damaged diodes and/or starter.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-5
Engine Electrical

Generator

WSJJ0293

Removal
• Battery negative cable.
1. Electrical wiring at the generator.
2. Loosen the adjusting nut.
3. Loosen the ACG adjusting bolt.
4. Loosen the lower mounting bolt.

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-6 Copyright ©
• Loosen the lower mounting bolt while holding the 2. ACG adjusting bolt
nut located on the back using a tool. 3. Adjusting nut
5. Drive belt
Tightening torque:
6. Generator
Adjusting nut 25 N.m (2.5 kg.m/18 lb ft)
4. Electrical wiring at the generator.
Installation
• Battery negative cable.
1. Generator
• Tighten the lower mounting bolt while holding the
nut located on the back using a tool.
Tightening torque:
Lower mounting bolt 51N.m (5.2 kg.m/38 lb ft)

Torque Specifications

N m(kg m/lb ft)

25 ( 2.5 / 18 )

25 ( 2.5 / 18 )

51 ( 5.2 / 38 )

WSJJ0205

Lep 9-94200EN Issued 02-06

 Copyright © 1D-7
Engine Electrical
Specifications Connector terminal

Isuzu Part No. 8980182040 Wire

Terminal symbol Lead wire color
specifications
Nominal output (V-A) 24-50
R R AEX 0.75f
Rated speed (rpm) 5000
L L AEX 0.75f
Regulator-type IC type
Regulated voltage (V) 28.5±1
Weight (kg) 9.5

1 2

WSHK0101
Name
1. R Terminal
2. L Terminal

Internal connections

SG L

IC
REGULATOR

WSHK0102

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-8 Copyright ©
Disassembly of generator

5
6
7
8 3 12

11
10
9 13
18

15
14

19

23
21
20
2
1

17

16
22
WSJJ0294

Disassembly Procedure
1. Screw 13. Collar
2. Cover 14. Ball Bearing
3. Through Bolt 15. Rotor Assembly
4. Rotor, Front Bracket Assembly 16. Screw
5. Nut, Washer 17. Field Coil Assembly
6. Pulley 18. Stator Assembly
7. Fan 19. Holder
8. Collar 20. Regulator Assembly
9. Screw 21. Bolt (B Terminal)
10. Retainer 22. Condenser
11. Ball Bearing 23. Rectifier Assembly
12. Front Bracket Assembly is the reverse order of disassembly.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-9
Engine Electrical
Inspection and repair of generator 3. Diode for initiating excitation, Resistor
Check for continuity between connector terminals
1. Diode
R and L with a tester (at Ω x 100 range). Normal
Check for continuity of forward and inverse
diodes and resistors show low resistance in
directions with a tester. Normal diodes show low
forward direction and high resistance in inverse
resistance in forward direction and high resistance
one.
in inverse one.
Judge that they are faulty other than those above.
Judge that they are faulty other than those above.

WSHK0106
WSHK0104
4. Field coil
2. Condenser
Charge the condenser with a tester (at Ω x 1000 • To judge the insulating condition of field coil,
range), and connect a tester lead inversely. Judge measure between the protrusion portions and core
it as normal if the needle on a meter deflects a little of the coil with a tester (at Ω x 1000 range). Judge
and returns to the original position. as faulty if it has continuity.
Judge that they are faulty other than those above.

WSHK0107
WSHK0105

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-10 Copyright ©
• Measure between the protrusion portions of field • Judge as normal if there is continuity between N
coil with a tester, and judge as normal if the lead of stator coil and three leads.
resistance is about 6.7Ω (20°C {68°F}).

WSHK0110
WSHK0108 6. Bearing
5. Stator coil • Check if the bearing rotates smoothly or has no
• To judge the insulating condition of stator coil, noise.
measure between the stator coil and core with a If the result of the inspection is unsatisfactory,
tester (at Ω x 1000 range). Judge as faulty if it has replace the bearing.
continuity.

WSHK0111
WSHK0109

Lep 9-94200EN Issued 02-06

 Copyright © 1D-11
Engine Electrical
Performance test
In the performance test of generator, connect as follows
and measure the regulated voltage and output current.
Actual wiring diagram for performance test of IC regulator built-in generator

2 3 SW 1 SW 2

V 1

6 7

WSJJ0295

Disassembly Procedure
1. Voltmeter 5. Clamp Tester Ammeter
2. R Terminal 6. Battery 24 V
3. L Terminal 7. Variable Resistor
4. Charging Lamp 24 V-3 W

Regulated voltage measurement of regulator Measurement of the output current

Close SW1 switch, and warm-up five to ten minutes at Close SW1 and SW2 switches, and raise the generator
approx. 1500 rpm in generator until an ammeter shows speed to 5000 rpm. While keeping the voltmeter
6 A or less. showing 27 V, measure the maximum value of output
After confirming that an ammeter shows between 2 and current with a variable resistor.
6 A, set the generator between approx. 3000 to 4000 In this time, judge as normal if the output current is 50 A
rpm. If an voltmeter shows between 27.5 and 29.5 V, or more.
the regulated voltage of regulator is normal.
If the ammeter shows 6A or more, charge the battery for Caution:
a while or replace it with full-charged battery. • Do not cut off battery circuit during generator
Replace the regulator if the voltmeter shows out of rotating.
range between 27.5 and 29.5 V. • Do not connect to L terminal if the charging lamp
(24 V-3 W) is not used.
Specified value of regulated voltage
Never connect L terminal and B circuit directly.
27.5 — 29.5 V (+25°C {77°F}) Diode for excitation may be broken.

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-12 Copyright ©
Handling of generator
Be careful with the following when handling a generator.
• Connecting the polarities of battery inversely
causes generator diode to be broken.
• While the engine runs, NEVER disconnect the
wiring of battery terminal and charging circuit.
• Wiring connection to terminal must be performed
properly according to terminal symbol.
• Do not perform megger test on semiconductor
device.
• Be sure to disconnect the battery terminal (−)
before inspection on equipment.
• Do not open/close the battery relay switch while the
engine runs.
• Disconnect the battery terminal when charging
from external source such as quick charge.
• Do not pour steam cleaner or water directly on it.
• After connecting to B terminal and E terminal,
tighten them to the following torque.
B terminal 4.9 N.m {50 kgf.cm/43 lb in}
E terminal 4.9 N.m {50 kgf.cm/43 lb in}
• Refer to “Belt Adjustment" for tension adjustment of
V-belt.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-13
Engine Electrical
Trouble and action

Action to
Trouble symptom Trouble location Trouble cause
be taken
Charging is Wiring and Open or short circuit, disconnection
Repair
impossible. ammeter
Generator Open circuit, short to ground, short circuit in each coil Replace
Broken diode Replace
Regulator Defective regulator Replace
Poor contact in terminal of regulator Repair
Insufficient Wiring Open or short circuit, looseness in connection Repair
charging
Generator Looseness of generator driven belt Repair
Layer or short circuit in field coil Replace
Layer or short circuit in stator coil Replace
Defective diode Replace
Poor contact in each terminal Repair
Regulator Defective regulator Replace
Poor contact in terminal of regulator Repair
Excessive Regulator Defective regulator
Replace
charging
Unstable charging Wiring Intermittent contact or nearly disconnected connection in
Repair
current wiring
Generator Looseness of generator driven belt Repair
Short circuit or nearly disconnected connection in field coil Repair
Short circuit or nearly disconnected connection in stator
Repair
coil
Poor contact in each terminal Repair
Regulator Defective regulator Replace
Poor contact in terminal of regulator Repair
Noisy generator Generator Improper installation of generator Repair
Defective bearing Replace
Contact of rotor core and stator core Repair
Defective diode Replace
Short circuit in stator coil Replace

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-14 Copyright ©
Starting System
General Description

Starter and Glow Plug Relays

The starter is a 4kw, reduction drive model.
The gear housing and armature end bearing housings
are aluminum. The brush ASM has replaceable
brushes. The commutator bars are mica insulated and
are undercut.
The starter circuit starts at the batteries. The battery
cable goes to the large terminal on the starter.
From that terminal wires lead to the engine control
switch and the starter relay.

2 3

WSJJ0029

Name
1. Starter 3. Ground Cable
2. Bolt

Maintenance Tighten the starter to engine mounting bolts and the

Keep the starter's exterior clean. Remove corrosion electrical cable retaining nuts.
from the terminals, leads, and connectors.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-15
Engine Electrical
Diagnosis of Starting System Service on the Machine: Starting System
No Cranking, No Sound Maintenance
• Discharged batteries. Check for the cause of the Keep starter terminals and all other terminals in the
discharged batteries. electrical system clean tight. A loose or corroded
• Sulfated battery terminals. Clean all the battery connection or terminal will cause excessive resistance
terminals and cable ends. in the system that will result in hard starting. At regular
• A starter that draws too much current. intervals, inspect the starting system to locate and
correct potential causes of trouble before the system
• Starter relay won't work. Attempt to start and listen
performance is affected. Starting motors do not require
for a “click” at the starter relay. If there is no “click,”
lubrication.
check the starter relay control terminals with a test
light. If the test light shows that power is getting to
the starter relay, check the ground circuit with the
test light. If the ground circuit is OK, replace the
starter relay.
• Engine control switch start circuit won't close.
With the engine control switch turned to start,
check the starter relay with a test light. If the test
light doesn't come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
• Starter relay power circuit isn't closing. Attempt to
start. Starter relay clicks. Check the secondary
terminals with a test light. If the test light lights on
the battery side only, replace the starter relay. If the
test light lights on both terminals, check for an open
at the starter.
• Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
cranking the engine. If voltage is OK, replace the
starter.

Slow Cranking, Magnetic Switch Clicks or Chatters

• Discharged batteries. Check for cause of
discharged batteries.
• Check the battery terminal for corrosion. Hint: Test
for warm terminals. Clean all the battery terminals
and connectors.
• Loose or dirty connections. Measure the cranking
voltage at the battery terminals. If the voltage is
less than 18 volts, load test the battery. If the
battery is bad, replace the battery. If the battery is
good, repair the starter.
If the voltage is 18 volts or more, measure the voltage
from the battery negative terminal to the engine block. If
the voltage is 0.5 volt or more, repair the ground cable
and connections.
If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the voltage
is 18 volts or more, repair the starter. If the voltage is
less than 18 volts, clean and tighten the positive cable
connections. If the voltage is still less than 18 volts,
replace the positive cable.

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-16 Copyright ©
Starter

The starter is a non-disassembled part as dip painting is applied to improve waterproof effect.

WSJJ0288

Output performance curve

S

B
M

WSJJ0289

Removal
1. Battery negative cable from the battery.
2. Cables and electrical leads from the starter.
3. Two mounting bolts.
4. Starter.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-17
Engine Electrical
Installation 3. Cables and electrical leads to the starter.
1. Starter 4. Battery negative cable to the battery.
2. Two mounting bolts.
Tightening torque:
Mounting bolt 97 N.m (9.9 kg.m/72 lb ft)

Torque Specifications

N m(kg m/lb ft)

97 ( 9.9 / 72 )

WSJJ0206

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-18 Copyright ©
Main Data and Specifications

Model (Manufacturer) Hitachi, Ltd.

Rating Voltage V 24
Power output kw 4.0
Time Sec. 30
Number of pinion teeth 11
Revolution direction (viewed toward pinion side) Clockwise
Weight (approx.) N {kg} 61.8 {6.3}
No load Current/Voltage A/V 120 or less/23
characteristic
Speed rpm 3500 or more
Load characteristic Current/Voltage A/V 250 or less/18.6
Torque N⋅m {kgf⋅m} 13.2 {1.3} or more
Speed rpm 1590 or more
Locking Current/Voltage A/V 1100 or less/10
characteristic
Torque N⋅m {kgf⋅m} 47 {4.8} or more

Lep 9-94200EN Issued 02-06

 Copyright © 1D-19
Engine Electrical
Connections (Hitachi, Ltd.)

S.S

S
P
B

C1 C2
M

Fc

Ar

3 4 1

WSJJ0292

Name
1. Starter Relay 3. Motor
2. Battery 4. Magnetic Switch

S.S Starter switch

Ar Armature
Fc Field coil
C1 Pressure coil
C2 Holding coil
P Contactor

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-20 Copyright ©
Inspection and repair of starter Handling of starter
1. Magnetic switch 1. Precautions on handling
Never perform operational check on magnetic • Improper gap between pinion and ring gear causes
switch as single unit. faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in})
Inspection of coil • Also, the front bracket is installed on the engine
• Check each continuity between S terminal and M side securely.
terminal, S terminal and case, M terminal and case • Be sure to turn off the battery switch before
of magnetic switch. If no continuity is present in removal/installation of stater.
either one of them, replace the starter since the coil • Tightening/inserting wiring must be performed
is open. properly. Improper work causes starting trouble due
to high contact resistance.
2. Precautions on starting
B S • Be careful with charging status of battery.
Insufficiently-charged battery causes starting
M
trouble.
• After checking engine starting, turn off the stater
switch immediately.
• One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.
• If the starter does not stop rotating when the starter
switch is turned off, turn off the battery switch
immediately. In this case, check the wiring, switch,
etc.

WSJJ0291

Contact Point Check

Measure the load current on starter. Replace it if voltage
drop between terminals B and M is 0.3 V or more per
100 A.

Caution:
Use a digital voltmeter to measure voltage drop. Using
an analog voltmeter may damage itself.

WSHK0117

Lep 9-94200EN Issued 02-06

 Copyright © 1D-21
Engine Electrical
Trouble countermeasure

Trouble symptom Trouble cause

Starter does not operate when 1. Full discharge of battery
starter switch is turned on. 2. Open circuit, poor contact
3. Poor contact in starter switch or improper tightening of terminal
4. Poor contact in starter relay or plug terminal
5. Short or open circuit in magnetic switch coil
Pinion moves forward but it does not 1. Insufficient capacity of battery
engage with ring gear. 2. Improper gap of pinion and ring gear
3. Wear of pinion or ring gear tooth edge
4. Dust on pinion shaft
5. Insufficient auxiliary rotation of armature due to insufficient thrust gap
of motor
Pinion engages and rotates motor 1. Slippage of clutch
but it does not run engine. 2. Breakage of reduction gear
Pinion engages but it does not run 1. Insufficient capacity of battery
engine. 2. Too high rotational resistance of engine
3. Improper tightening of wiring circuit terminal
4. Short circuit of armature or field coil
5. Contamination of commutator
6. Fatigue or wear of brush spring
7. Locking of bearing
8. Poor contact in magnetic switch
When turning starter switch off after 1. Retuning failure of starter switch contact
engine starts, starter does not stop. 2. Retuning failure of starter relay contact
3. Short circuit in magnetic switch coil

Lep 9-94200EN Issued 02-06

Engine Electrical 1D-22 Copyright ©
Preheating System
Glow Plug Replacement Precautions on Service Work
Adequate care should be taken as over-tightening the
Precautions during maintenance glow plug could lead to damage.
Adequate care should be taken as over-tightening the Explanations on functions and operation
glow plug could lead to damage.
The preheating system consists of the ECM, the glow
Removal Procedure relay, glow plugs and the glow indicator lamp. The
1. Remove the glow plug connector. preheating system is operated when the engine coolant
2. Remove the glow plug. temperature is low, and make the engine easy to start.
Glow plug check
• Use the circuit tester and measure the resistance
of the glow plug.
• If the measured value deviates from the specified
value, then replace the glow plug.
• Resistance value of glow plug is approximately less
than 6Ω.

Caution:
Use a set of glow plug from the same manufacturer.

WSJJ0207

Installation Procedure
1. Install the glow plug.
Tightening torque: 15 — 20 N⋅m
(1.5 — 2.0 kg⋅m/11 — 15 lb ft)
2. Install and tighten the glow connector with the
designated torque.
Tightening torque: 1.5 — 2.0 N⋅m
(0.15 — 0.20 kg⋅m/13 — 17 lb in)

A List of Defective Phenomena

• The glow indicator lamp does not light up.
• Preheating does not work.
• Preheating time is too long or too short.

Lep 9-94200EN Issued 02-06

 Copyright © 1D-23
Engine Electrical
Trouble Shooting

The glow indicator lamp does not light up.

Condition Possible Cause Correction

The glow indicator lamp does not Slow blow fuse has blown. Replace the slow-blow fuse.
light up. Fuse is unavailable. Replace the fuse.
Indicator valve is burnt out. Replace the indicator valve.
Engine control system is faulty. Refer to Engine Control System
section.

Preheating does not work.

Condition Possible Cause Correction

Preheating does not work. Slow blow fuse has blown. Replace the slow-blow fuse.
Defective or faulty glow plug relay Re-mount or replace the glow plug
connector contact. relay.
Engine control system is faulty. Refer to Engine Control System
section.

Preheating time is too long or too short.

Condition Possible Cause Correction

Preheating time is too long or too Thermo-sensor fault and break in Replace the thermo-sensor. Repair
short. circuit or short circuit. the circuit.
Fault in glow plug. Replace or tighten the glow plug.
Engine control system is faulty. Refer to Engine Control System
section.

Main Data and Specifications

Items Model
Preheating device model Glow plug
Glow plug rated voltage/ current (V-A) 23 – 3.5

Lep 9-94200EN Issued 02-06