AirMan PDS400S-6C3 Service Manual
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AirMan PDS400S-6C3 Service Manual

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Summary of Contents for AirMan PDS400S-6C3

  • Page 1 www.discount-equipment.com...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak,...
  • Page 3 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”...

  • Page 4: Table Of Contents

    Table of Contents Specification -------------------------------------------------------------------------------------- 1-1 1.1 Specifications ----------------------------------------------------------------------------------------------------------- 1-1 1.2 Set Value ----------------------------------------------------------------------------------------------------------------- 1-2 1.3 Outline Drawing -------------------------------------------------------------------------------------------------------- 1-3 1.4 Internal Components and Part Names ---------------------------------------------------------------------------- 1-5 1.5 Instrument Panel ------------------------------------------------------------------------------------------------------- 1-8 1.5.1 Indicator lamp･Warning / Emergency display --------------------------------------------------------------- 1-9 1.6 Capacity Control Device ---------------------------------------------------------------------------------------------- 1-10 1.7 Piping Diagram --------------------------------------------------------------------------------------------------------- 1-12 1.8 Fuel Piping --------------------------------------------------------------------------------------------------------------- 1-14...
  • Page 5 Table of Contents 3.10 Discharge Air Temperature･Separator Air Temperature･Engine Coolant Temperature Sensor (Thermister) - 3-29 3.11 Fuel Meter (Display) --------------------------------------------------------------------------------------------------- 3-29 3.12 Sending Unit ------------------------------------------------------------------------------------------------------------- 3-30 3.13 Fuel Air-bleeding Electromagnetic Pump (Type with built-in filter) ----------------------------------------- 3-31 3.14 Main･Safety Relay, MR･SR ----------------------------------------------------------------------------------------- 3-31 3.15 Electromagnetic Pump Relay, FR ---------------------------------------------------------------------------------- 3-32 3.16 Glow Relay, GR -------------------------------------------------------------------------------------------------------- 3-32 3.17 Starter Relay, SY ------------------------------------------------------------------------------------------------------- 3-32...
  • Page 6 Table of Contents 4.3 Operation of Emergency Switch ------------------------------------------------------------------------------------ 4-8 4.3.1 Discharge air temperature (or separator air temperature) is displayed abnormality-code and engine will stop ------ 4-8 4.3.2 Engine oil pressure is displayed abnormality-code and engine will stop -------------------------- 4-9 4.3.3 Engine coolant temperature is displayed abnormality-code and engine will stop ------------- 4-10 4.3.4 Engine RPM drop is displayed abnormality-code and engine will stop ---------------------------- 4-10 4.4 Others --------------------------------------------------------------------------------------------------------------------- 4-11...

  • Page 7: Specification

    1. Specification 1.1 Specifications Item unit PDS400S<SC>-6C3 ●Weight・Mass Overall length in.(mm) 172.0(4,370) Overall length (Bonnet only) in.(mm) 105.5(2,680) Overall width in.(mm) 77.8(1,975) Overall height in.(mm) 65.0(1,650) Tire To be locally procured 4,189<4,244> Net dry mass lb(kg) (1,900<1,925>) 4,652<4,707> Operating mass lb(kg) (2,110<2,135>) ●Compressor...

  • Page 8: Set Value

    1. Specification 1.2 Set Value Item unit PDS400S<SC>-6C3 ●Emergency stop devices °F(℃) Discharge air temperature 248(120) °F(℃) Coolant temperature 221(105) Engine oil pressure abnormality psi(MPa)[bar] 14.6(0.1)[1.0] Discharge air temperature at °F(℃) 248(120) separator Engine speed down 1,200 Discharge air temperature sensor Detection of disconnection disconnection Discharge air temperature sensor...

  • Page 9: Outline Drawing

    1. Specification 1.3 Outline Drawing...
  • Page 10 1. Specification...

  • Page 11: Internal Components And Part Names

    1. Specification 1.4 Internal Components and Part Names [Standard type] PC13022 PDS400S-6C3 Description Description Control panel Engine oil filter Auto-relief valve Engine Vacuum relief valve Exhaust pipe Pressure control valve Pressure sensor Intercooler Pressure regulator Oil cooler Solenoid valve for starting unloader (SV2)
  • Page 12 1. Specification 32 33 34 50 49 PC13023 PDS400S-6C3 Description Description Radiator Service valve Reserve tank Separator receiver tank drain valve Supply pump Compressor oil level gauge Air filter (For engine) Compressor oil filler port Vacuator valve (For engine) Sending unit...
  • Page 13 1. Specification [Aftercooler type] Only the special devices additionally or optionally attached to the standard machine are shown in the following figure. For the details of the other standard devices, refer to page 1-5 & 1-6. PC13024 PDS400SC-6C3 Description Description Aftercooler Drain port of aftercooler Drain separator...

  • Page 14: Instrument Panel

    1. Specification 1.5 Instrument Panel Each display of the operation panel is illustrated as follows. Read and fully understand the explanations and be sure to operate safely: Error code / Reset switch When this switch is pushed on while lamp is blinking / lighting, it shows error code.

  • Page 15: Indicator Lamp･Warning / Emergency Display

    1. Specification 1.5.1 Indicator lamp･Warning / Emergency display Turn the starter switch to “RUN” position. Then the lamp goes on. [Indicator lamp] Item Contents Measures Monitor When starter switch is placed to “RUN”, ― GLOW the lamp goes on and after preheating is finished, the lamp will be off.

  • Page 16: Capacity Control Device

    1. Specification 1.6 Capacity Control Device PC13052-3E Step Response Compressed air is sent into the unloader chamber through starting unloader solenoid valve SV1 to fully open the unloader valve. Further, as COM-NC for the solenoid valve SV2 is connecting, the spring chamber becomes negative pressure, and unloader valve fully closes at lower pressure.
  • Page 17 1. Specification Step Response When air consumption decreases and it exceeds the rated pressure, the pressure regulator operates to close the unloader valve. At the same time, the pressure sensor provided at the secondary side of pressure regulator detects and sends to engine controller the signal of engine speed lowering.

  • Page 18: Piping Diagram

    1. Specification 1.7 Piping Diagram [Standard type] 1-12...
  • Page 19 1. Specification [Aftercooler type] 1-13...

  • Page 20: Fuel Piping

    1. Specification 1.8 Fuel Piping PC13053E 1-14...

  • Page 21: Maintenance

    2. Maintenance 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;...
  • Page 22 2. Maintenance ⑪ Make sure to follow the tightening torque and clearance when reassembling the disassembled parts or components. ⑫ If the parts or components which are being disassembled are left untreated, ambient humidity or dirt may cause rust or corrosion. If it is unavoidably necessary to stop disassembling job on the way, make sure to protect them against rust and dirt.

  • Page 23: Tightening Torque

    2. Maintenance 2.2 Tightening Torque 2.2.1 General bolts and nuts tightening torque Fasten all the bolts and nuts with the specified tightening torque when assembling. Kind Low or Middle carbon steel bolt High tensile strength bolt (SS400B etc…) (SCM435 etc…) Strength and 8.8－12.9（7T－12T）...

  • Page 24: Tightening Torque Of Such Important Quality Parts As Bolts And Nuts

    2. Maintenance 2.2.2 Tightening torque of such important quality parts as bolts and nuts [Excerpted from HIS C-40940 (company standard)] Strength Tightening torque lbf ･ in.(N ･ m)[kgf ･ cm] classification Application parts & portions Coarse thread / fine thread Remarks Torque Bolt...
  • Page 25 2. Maintenance 1 Air-end ② ① 2 Mounting ③ ④ ④ 3 Coupling portion between comp. air-end and engine ⑤ ⑥ ⑦ COMP. SIDE ENG. SIDE PC12076...
  • Page 26 2. Maintenance 4 Lifting portion ⑧ PC13054 5 Pressure vessel and pipes ⑩ ⑨ PC13055 6 Undercarriage ⑬ PC14065...

  • Page 27: How To Adjust Regulator

    2. Maintenance 2.3 How to Adjust Regulator  When adjusting regulator system, install a silencer to the air delivery port and wear earplugs for protection of hearing damage. Operation with compressed air supply port opened is prohibited. D003 The speed regulator is already adjusted prior to delivery ex. works. Never change the setting of ●...

  • Page 28: Maintenance And Adjustment Of Pressure Control Valve

    2. Maintenance 2.4 Maintenance and Adjustment of Pressure Control Valve (1) Procedure of maintenance In case that the discharge air pressure becomes lower than 51psi (0.35MPa) [3.5bar], it is necessary to adjust the pressure of the pressure control valve according to the following procedures. As it is possible that the O-ring has deteriorated or hardened, replace the O-ring even if the replacement cycle has not yet been reached.
  • Page 29 2. Maintenance  When disassembling the pressure control valve, remove the cover “4” after removing the cover “1” first without fail. If the cover “4” should be removed with the cover “1” fitted, the cover “4” will jet out by the tensile strength of the inside spring, and it could cause a serious accident.

  • Page 30: Change O-Ring Of Unloader

    2. Maintenance 2.5 Change O-ring of Unloader <Caution during O-ring replacement> Apply a thin coat of grease on the O-rings when ● replacing the O-rings“1”and“2”. ※ The piston “5”is threaded with an M5 tapping in the center area to enable attachment of an eye bolt, etc.

  • Page 31: Change Oil Separator

    2. Maintenance 2.7 Change Oil Separator When consumption of the oil is still unusual even after cleaning strainer in the scavenging orifice, ● change the oil separator with a new one. When replacing oil separator, be sure to replace gasket too. ●...

  • Page 32: Change Of Pellet Assembly Of By-Pass Valve

    2. Maintenance 2.8 Change of Pellet assembly of By-pass Valve By-pass valve fitted on this unit is of full bore type. While the unit is used for normal operation, it ● is not to perform periodical replacement of the Inner pellet assembly, but when such trouble as excessive rise of compressor oil temperature, it becomes necessary to replace it, in accordance with the following procedures.

  • Page 33: Clean The Strainer Provided Inside The Engine Feed Pump

    2. Maintenance 2.9 Clean the Strainer Provided inside the Engine Feed Pump To each 500Hr, remove the strainer“2”inside the ● joint bolt“1”fitted at the inlet side of the feed pump and clean it. Remove the strainer“2”by loosening the joint bolt ●...

  • Page 34: Manual Air Bleeding Method For Fuel Line System

    2. Maintenance 2.13 Manual Air Bleeding Method for Fuel Line System <Procedure> ① Place starter switch to “RUN” position to keep electromagnet pump functioning. ② Loosen “Air-bleeding plug” enough to move “Priming pump” (more than 20 times) till fuel comes out. ③...

  • Page 35: Clean Drain Separator (Aftercooler Type Only)

    ③ As it is possible that the O-ring“3”has deteriorated or hardened, replace the O-ring. ④ After finishing clean, assemble it in reverse procedure. PC13063E 2.16 Values of Various Adjustments of Engine Item Unit PDS400S-6C3 ISUZU CI-4JJ1XYCD-01 Engine model ISUZU CI-4JJ1XYCD-01G M11 bolt First stage 620(70)[7.1] lbf･in.

  • Page 36: Suction Control Valve (Scv) Replacement Procedure

    2. Maintenance 2.17 Suction Control Valve (SCV) Replacement Procedure 【Excerpted from ISUZU troubleshooting manual】 The suction control valve (SCV) is installed onto supply pump section of engine and controls pressure feed of fuel (discharge amount) to common rail. Refer to “3.18 Electronic Control Engine Component” for details. Supply pump Note: The illustration indicates the supply pump unit only in...
  • Page 37 2. Maintenance ④ Pull out the suction control valve (SCV). Note: ・If it is hard to pull it out due to the resistance on the O-ring, pull it out while rotating it from side to side. ・To prevent foreign matter from entering, do not put gloves on from the next work.
  • Page 38 2. Maintenance ⑧ After placing the O-ring, apply oil to it. Note: ・Use clean oil such as new engine oil. ・Do not let foreign matter on the O-ring. ⑨ Insert the suction control valve (SCV) into the pump housing. Note: Insert the suction control valve (SCV) by hand until it contacts the housing.

  • Page 39: Electronic Control System Of Engine

    3. Electric System 3.1 Electronic Control System of Engine 【Excerpted from ISUZU troubleshooting manual】 The engine control system is electronic control system which maintains optimum combustion status of engine all the time according to operating conditions. It consists of the following components. ①...
  • Page 40 3. Electric System (2) Injection pressure control Injection pressure is controlled by controlling the fuel pressure in the common rail. The appropriate pressure in the common rail is calculated based on the engine revolution speed and fuel injected amount, and proper fuel amount is injected by the control of the supply pump and it is sent to the common rail with pressure and being controlled.

  • Page 41: Egr (Exhaust Gas Recirculation) Control

    3. Electric System 3.1.2 EGR (Exhaust gas recirculation) control EGR is a exhaust gas recirculation system. Part of the exhausted gas is mixed again together with intake air to control oxygen density in combustion chamber in order to soften combustion and to lower combustion temperature.

  • Page 42: Acceleration Control

    3. Electric System 3.1.3 Acceleration control Accelerator controller (control of output and engine speed) receives electric signal outputted from pressure sensor, and it controls electronic fuel injection system by outputting to engine controller (ECM). Pressure regulator The pressures at 2nd stage is converted into voltage and Pressure sensor outputted.

  • Page 43: Accelerator Controller

    3. Electric System 3.2 Accelerator Controller Part number:46870 54900 Terminal A (Female terminal) Connector CN5 Connector CN6 PC120013-1 With replacement of the acceleration controller, if engine speed is found different from specified ● speed, perform following adjustment. Adjusting screw for no How to adjust engine speed load speed 1.
  • Page 44 3. Electric System 1. List of functions (Connector CN6) Line Pin Name Connection Function color Engine controller (ECM) No.42 CN6-9 Power supply (DC5V) for accelerator sensor. terminal Based on the input voltage of CN6-16 terminal, change the resistance between CN6-10 and CN6-11 and then output it to Engine controller (ECM) No.63 CN6-10 engine controller.
  • Page 45 3. Electric System ●Pressure sensor / Accelerator controller Output – revolution speed list (for reference only) The voltage values in the following table are standard reference ones. They are different a little from actual ones during operation. Output voltage of pressure sensor Pressure sensor Regulator 2nd stage pressure Output voltage (DCV)

  • Page 46: Engine Controller (Ecm)

    3. Electric System 3.3 Engine Controller (ECM) Part number:44390 03700 CN3 terminal [81 pins] CN4 terminal [40 pins] SG09037...
  • Page 47 3. Electric System (1) General wiring diagram of engine controller (ECM) ・Some sensors are not connected to ECM depending on each model having its special specifications. ・Some sensors have input-output to ECM by signal of CAN communication. For the details, see engine wiring diagram of actual unit.
  • Page 48 3. Electric System (2) List of CN3 terminal function (81 pins) Line Pin No. Connection Function color CN3-1 Grounding CN3-2 Main relay (MR) Power supply CN3-3 Grounding CN3-4 Grounding CN3-5 Main relay (MR) Power supply No power exists during usual operation. When engine trouble, interior contact in engine controller (ECM) is “ON”, and it connects ground to sends power.
  • Page 49 3. Electric System Line Pin No. Connection Function color No power exists during usual operation. When engine cooling water temperature rises Emergency controller CN2-14 to emergency stop set temperature, the interior terminal contact in ECM becomes “ON” and connected to CN3-15 (Engine coolant temperature rise ground to send electricity to emergency...
  • Page 50 3. Electric System Line Pin No. Connection Function color Diagnosis tool connection terminal (CAN CN3-37 W/B Diagnosis tool No.14 terminal communication) With connection of diagnosis tool, it is possible to diagnose engine control system and to check CN3-38 W/G Diagnosis tool No.7 terminal system.
  • Page 51 3. Electric System Line Pin No. Connection Function color Barometric pressure sensor Power supply (DC5V) for barometric pressure CN3-61 VCC terminal sensor. CN3-62 Grounding Accelerator controller CN6-10 It controls regulator 2nd stage pressure CN3-63 terminal voltage conversion value and engine speed is controlled between full load and unload Accelerator controller CN6-10 CN3-64...
  • Page 52 3. Electric System (3) List of CN4 terminal function (40 pins) Line Pin No. Connection Function color It detects common rail pressure (fuel pressure). It detects fuel pressure in common rail and it converts it voltage signal and inputs it. It is used Common rail pressure sensor SP CN4-82 for fuel injection control.
  • Page 53 3. Electric System Line Pin No. Connection Function color Boost pressure sensor VCC CN4-95 Power supply (DC5V) for boost pressure sensor. terminal CN4-96 － CN4-97 Suction control valve (SCV) Grounding It inputs camshaft position (CMP) signal. CMP signal is caused when cam position of camshaft passes camshaft position (CMP) sensor.
  • Page 54 3. Electric System Line Pin No. Connection Function color Boost pressure sensor GND terminal CN4-109 Boost temperature sensor Grounding Crank angle sensor GND terminal CN4-110 W/L EGR DC motor W terminal Same as CN4-103 terminal. CN4-111 W/R EGR DC motor U terminal CN4-112 －...

  • Page 55: Emergency Controller

    3. Electric System 3.4 Emergency Controller Part number:46870 56600 PC13068E 3-17...
  • Page 56 3. Electric System 1. Exterior connection drawing PC12069E 3-18...
  • Page 57 3. Electric System 2. Warning / emergency display and emergency stop functions Item Indicator Sensor Actuation Detecting timing Time lag Discharge temp. H Thermister 239°F(115℃) Always 10.0 sec － Water temp. H Thermister 212°F(100℃) Always 10.0 sec － Negative Differential pressure Comp.
  • Page 58 3. Electric System 4. Engine speed drop PC12019E 5. Engine speed control PC13069E 6. Functions of each output relay Mark Name Function It goes ON when starter switch is ON. Discharge air temperature: Unload rotation command relay OFF in case of lower than 140°F(60℃) (Engine speed control) Discharge air temperature: ON in case of higher than 140°F(60℃)
  • Page 59 3. Electric System 7. Abnormal reset Turn “OFF” the starter switch. 8. Display function Item Unit Eng. speed ° Discharge temp. ° Water temp. Hour meter ×Hr When power is supplied, “Eng. speed” is indicated. Each time display selector swith is pressed, each indication will be selected. Every time the swith is pressed, the indication is changed in the order of 1→2→3→･・→1･・･.
  • Page 60 3. Electric System 10. List of functions (1) Connector CN1 Line Pin No. Connection Function color CN1-1 － CN1-2 － No power exists during usual operation. It is connected to the emergency stop circuit of engine controller (ECM). Engine controller (ECM) When the interior contact (RY3) becomes “ON”...
  • Page 61 3. Electric System Line Pin No. Connection Function color Starter switch [ACC] CN1-12 R/W terminal Power supply (Through 10A fuse) (2) Connector CN2 Line Pin No. Connection Function color Engine air filter CN2-1 Grounding Compressor air filter CN2-2 － When engine oil pressure abnormal signal is detected emergency controller interior contact (RY3) is made Engine controller (ECM) “ON”, power is sent to ECM CN3-7 terminal to make...
  • Page 62 3. Electric System Line Pin No. Connection Function color Detect the separator air temperature. The interior contact (RY3) of emergency controller is made “ON” when the discharge air temperature becomes higher than emergency stop set temperature and power is sent to ECM CN3-1 terminal to bring engine to Separator air temperature emergency stop, and to make the lamp flash when CN2-10 G/W...

  • Page 63: Alternator

    3. Electric System 3.5 Alternator ISUZU part number:898092-1122 Nominal DC24V-50A capacity PC12038E (1) List of functions Pin No. Line Connection Function (Terminal No.) color Starter motor B terminal Power for charging voltage. (Through 60A fuse) Detect voltage of ACC terminal and adjust the CN14-1(R) Starter switch ACC terminal current flowing to rotor coil...

  • Page 64: Starter

    3. Electric System 3.6 Starter ISUZU part number:898045-0272 Voltage DC24V Output 4.0kW Cable connection PC12039E (1) List of functions Terminal Line Connection Function color Starter switch B terminal For supplying power to starter which enables Battery + terminal starter pinion to turn. For supplying power to make starter pinion to spring out and also a little power to make pinion Starter relay C terminal...

  • Page 65: Solenoid Valve For Starting Unloader

    3. Electric System 3.7 Solenoid Valve for Starting Unloader 3.7.1 Unloader piston actuation:SV1 Part number:46811 27100 Clip Tube sss’y Coil ass’y Plunger ass’y O-ring Return spring Body (Rc1/4) (Rc1/4) ･Opened while electricity PC10037 is supplied (NC) Diameter of orifice φ4 Rated voltage DC24V Function...

  • Page 66: Air Filter Indicator (Engine / Air-End Common)

    3. Electric System 3.8 Air Filter Indicator (Engine / Air-end common) Part number:32148 03000 Operating 6.2kPa resistance Contact type A contact SC10016 3.9 Pressure Sensor (Secondary pressure of regulator detect) Part number:44328 20600 Trouble diagnosis of pressure sensor itself Check and confirm that output voltage between ②－③ is 0.5 ±0.1V when DC5V is applied between ①－③...

  • Page 67: Fuel Meter (Display)

    3. Electric System 3.10 Discharge Air Temperature･Separator Air Temperature･ Engine Coolant Temperature Sensor (Thermister) ※Engine coolant temperature sensor, used in abnormal or alarm lamp and temperature display. SC14066 44364 08200 Sensor (～0154) Part number:44364 06500 Characteristic of temperature･resistance Temperature Resistance Temperature Resistance Permissible...

  • Page 68: Sending Unit

    3. Electric System Relation between indicator lamp (LED) and residual fuel level Remaining Indicator lamp Remark fuel gal.(L) Full tank 46(175) LED No.8 OFF (Green) 44(167) LED No.7 OFF (Green) 40(150) LED No.6 OFF (Green) 34(127) LED No.5 OFF (Green) 28(107) PC10033E LED No.4...

  • Page 69: Fuel Air-Bleeding Electromagnetic Pump (Type With Built-In Filter)

    3. Electric System 3.13 Fuel Air-bleeding Electromagnetic Pump (Type with built-in filter) Part number :43650 02500 ISUZU part number:898009-3971 Part number of filter ISUZU part number:898071-4010 PC12098 3.14 Main･Safety Relay, MR･SR Part number :44324 05800 ISUZU part number:898013-7900 Rated voltage DC24V NO circuit 10A Capacity of...

  • Page 70: Electromagnetic Pump Relay, Fr

    3. Electric System 3.15 Electromagnetic Pump Relay, FR Part number :44346 07500 ISUZU part number:582550-0300 Rated voltage DC24V Lamp load 150W Capacity of contact point Others 12.5A PC12043 3.16 Glow Relay, GR Part number :44346 15500 ISUZU part number:894460-7061 Rated voltage DC24V Rush current...

  • Page 71: Electronic Control Engine Component

    3. Electric System 3.18 Electronic Control Engine Component Engine component location diagram 【Excerpt ISUZU troubleshooting manual】 PC13072 Operation panel PC13074 1. Engine coolant temperature (ECT) sensor 10. EGR valve 2. Supply pump 11. Glow plug 3. Suction control valve (SCV) 12.
  • Page 72 3. Electric System 3.18.1 Supply pump The supply pump pressurizes fuel using engine output, and pressure-feeds fuel to common rail. The supply pump has suction control valve (SCV), fuel temperature (FT) sensor and feed pump. Feed pump Suction control Fuel temperature valve (SCV) (FT) sensor PC13091...

  • Page 73: Common Rail

    3. Electric System 3.18.3 Fuel temperature (FT) sensor The fuel temperature (FT) sensor is installed onto the supply pump, and the thermistor changes the resistance according to the temperature. The resistance is low when the fuel temperature is high, and is high when the temperature is low.

  • Page 74: Pressure Limiter

    3. Electric System 3.18.5 Pressure limiter The pressure limiter operates to release the pressure in common rail when the pressure becomes extremely high. Removal Do not replace the pressure limiter. Pressure Common If it is damaged, replace it as common rail assembly. limiter rail Common rail...

  • Page 75: Injector

    3. Electric System 3.18.7 Injector The injector is installed onto cylinder head section and is conrtolled by ECM to inject fuel. The ECM raises the voltage for operating injectors internally, energizes to injector, and regulates period of electric conduction of injector to control fuel injection amount and injection timing.

  • Page 76: Crankshaft Position (Ckp) Sensor

    3. Electric System 3.18.9 Crankshaft position (CKP) sensor The crankshaft position (CKP) sensor is installed onto engine block and produces the CKP signal when the convex portion of flywheel passes the sensor. The ECM distinguishes the cylinders by the CMP signal input from camshaft position (CMP) sensor, determines the crank angle and uses it to contorl fuel injection and calculate...

  • Page 77: Camshaft Position (Cmp) Sensor

    3. Electric System 3.18.10 Camshaft position (CMP) sensor The camshaft position (CMP) sensor is installed onto front of cylinder head and produces the CMP signal when the cam portion of camshaft passes the sensor. The ECM distinguishes the cylinders by the CMP signal input from camshaft position (CMP) sensor, determines the crank angle and uses it to contorl fuel injection and calculate...

  • Page 78: Barometric Pressure Sensor

    3. Electric System 3.18.12 Barometric pressure sensor The barometric pressure sensor is installed into the operation panel and converts the barometric pressure into voltage signal. The ECM calculates barometric pressure by voltage signal and performs fuel injection amount correction (high-altitude correction) etc. by SG VOUT barometric pressure.

  • Page 79: Egr Position Sensor

    3. Electric System 3.18.14 EGR position sensor It is installed in EGR valve and detects the valve lift amount of EGR. Exhaust gas emitted from engine is mixed again with intake air and combustion temperature is lowered to reduce Nox and it is used as, EGR system sensor. EGR position sensor Conector terminal number, function (Reference value)

  • Page 80: Boost Pressure Sensor

    3. Electric System 3.18.15 Boost pressure sensor The boost pressure sensor detects boost pressure (intake air pressure) in intake manifold, converts the pressure into the voltage signal and sends it to ECM. Voltage becomes higher as pressure becomes higher, and lower as one dose lower.

  • Page 81: Troubleshooting

    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.

  • Page 82: How To Use The Failure Diagnosis

    4. Troubleshooting (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. ①Check the easiest thing or portion first.

  • Page 83: Failures Of Compressor And Engine

    4. Troubleshooting 4.2 Failures of Compressor and Engine 4.2.1 At start-up, starter rotates slowly Battery specific gravity too ※1 Faulty Check battery voltage and Re-charge and or supply low or electrolyte short or specific gravity water / replace performance degradation Normality Voltage: more than DC24V Gravity: more than 1.26...

  • Page 84: Engine Revolutions Will Drop Before Rises Up To Rated Pressure

    4. Troubleshooting 4.2.4 Engine revolutions will drop before rises up to rated pressure Adjustment Check adjustment of Faulty adjustment of Re-adjust pressure pressure regulator pressure Faulty adjustment Change pressure gauge for Adjustment Replace assembly Faulty pressure gauge replacement one, and re-adjust pressure gauge Faulty adjustment Faulty...

  • Page 85: Minimum Speed Not Available Even Upon No-Load Operation

    4. Troubleshooting 4.2.6 Minimum speed not available even upon no-load operation Faulty Unload adjustment screw adjustment rotation speed of the Faulty adjustment Re-adjust accelerator controller is sure has been adjusted Normality Approx. less than 2.1V Check pressure sensor Faulty pressure sensor Replace it output voltage (DCV) Normality...

  • Page 86: Oil Mixed Found In Delivery Air

    4. Troubleshooting No clogging Faulty Disassemble / clean or Check unloader valve Faulty unloader replace function (whether it closes) Normality Disassemble / check Faulty oil seal of Replace oil seal compressor air-end 4.2.8 Oil mixed found in delivery air Too much Arrange oil level to Check oil level inside Oil level too high...

  • Page 87: Discharge Air Is Insufficient

    4. Troubleshooting 4.2.10 Discharge air is insufficient Clogging is large Air filter clogging Clean or replace Check air filter for clogging Normality Faulty Disassemble / clean or Check function of unloader Faulty unloader valve replace valve Too long, narrow Normality and air leaking Normal -ity...

  • Page 88: Operation Of Emergency Switch

    4. Troubleshooting 4.3 Operation of Emergency Switch 4.3.1 Discharge air temperature (or separator air temperature) is displayed abnormality-code and engine will stop More than 104°F (40℃) Unsuitable place of Check ambient Relocation installation temperature Less than 104°F (40℃) Abnormality Normal -ity Check discharge Check resistance of...

  • Page 89: Engine Oil Pressure Is Displayed Abnormality-Code And Engine Will Stop

    4. Troubleshooting 4.3.2 Engine oil pressure is displayed abnormality-code and engine will stop Shortage Shortage of oil Check engine oil level Replenish or replace Proper Clogging Filter clogging Replace it Check engine oil filter Normality Faulty Check engine oil pressure Faulty oil pressure sensor Replace it sensor...

  • Page 90: Engine Coolant Temperature Is Displayed Abnormality-Code And Engine Will Stop

    4. Troubleshooting 4.3.3 Engine coolant temperature is displayed abnormality-code and engine will stop Shortage Check water quantity and Shortage of coolant and Replenish or replace quality in radiator bad quality Normality Faulty Tension not acceptable or Adjust or replace Check belt tension faulty belt Normality More than...

  • Page 91: Others

    4. Troubleshooting 4.4 Others 4.4.1 Abnormality-code is not shown, engine will stop (Starter switch is not set in contact, primary circuit of main relay (MR) is not connected properly, and blown fuse trouble is exempted) Check of electric conductance between Disconnected engine controller (ECM) Faulty wire connection...

  • Page 92: Explanation Of Trouble Diagnosis

    4. Troubleshooting 4.5 Explanation of Trouble Diagnosis Item Cause Remedy Faulty unloader Unloader valve cannot be open. Remove unloader assembly from compressor air-end, and disassemble it for inspection and replace O-ring. Check pressure sensor Engine speed is controlled by the proper Check output voltage (DCV) output voltage speed finally outputted to electro-control...

  • Page 93: Engine Trouble Diagnosis

    4. Troubleshooting Item Cause Remedy Check engine oil Oil pressure sensor detects voltage signal Check and confirm in pressure sensor which engine oil pressure is converted to accordance with the “4.6 and transmitted to engine controller Engine Trouble Diagnosis (ECM) → emergency controller. Function”.
  • Page 94 4. Troubleshooting 4.6 Engine Trouble Diagnosis Function With regard to this electronic governor engine (Common rail electronic control fuel injection engine), this engine itself is equipped with trouble diagnosis function. When it is in trouble, it is possible to check and confirm how the trouble is by monitor lamp blinking pattern (flash code). 4.6.1 Engine trouble diagnosis 1.
  • Page 95 4. Troubleshooting 2. Display of diagnostic trouble code (DTC) by diagnosis lamp Only when diagnostic trouble code (DTC) occurs during engine operation, diagnosis lamp is ON. During engine stop, diagnostic trouble code (DTC) displays both present and past diagnostic trouble code (DTC) by diagnosis lamp blinking pattern (flash code). 3.
  • Page 96 4. Troubleshooting Blinking Details Item to be detected pattern ECU charge circuit 1 fault (internal burnout, Charge circuit fault (bank 1) open circuit, etc.) ECU charge circuit 2 fault (internal burnout, Charge circuit fault (bank 2) open circuit, etc.) A/D conversion fault A/D conversion fault EGR position fault Open/short circuit/breakage of sensor or harness...
  • Page 97 4. Troubleshooting Blinking Details Item to be detected pattern Open circuit injection nozzle #3 drive Open/short circuit in electrical wiring No.3 system cylinder injection Open circuit injection nozzle #4 drive Open/short circuit in electrical wiring No.4 system cylinder injection Engine oil pressure sensor fault (low Open/short circuit/breakage of sensor or harness voltage fault) Engine oil pressure sensor fault (high...
  • Page 98 4. Troubleshooting 4.6.2 How to delete diagnostic trouble code (DTC) 1. Deletion of diagnostic trouble code (DTC) When diagnostic trouble code (DTC) is memorized in engine control module (ECM) in case of system trouble. Even after troubled parts have been repaired, memory of diagnostic trouble code (DTC) will not be deleted in this case.

  • Page 99: References

    5. References 5.1 Consumable Parts and Electrical Appliances Item Parts No. ●Element / Filter / Belt Air filter ASS’Y (For compressor) 32100 39700 Air filter element 32143 12500 Air filter ASS'Y (For engine) 32100 41001 Air filter element 32143 12700 Oil separator 34220 16500 34235 06000...
  • Page 100 5. References Item Parts No. ●Instruments on panel Starter switch 44322 02800 36141 18600 Pressure gauge (Isuzu part number:894402-5000) Engine diagnosis switch 46242 21800 Engine diagnosis lamp 46161 13700 ●Oil line By-pass valve ASS'Y 37200 11502 Pellet 37231 02100 O-ring 03402 25045 O-ring 03402 15025...

  • Page 101: Engine Wiring Diagram

    5.2 Engine Wiring Diagram PC13087E PC13088...
  • Page 102 This text book contains the most recent information available at the time of printing, and the contents of the list are based on information in effect at that time and are subject to change without notice. www.discount-equipment.com ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. Copyright(C)2014 HOKUETSU INDUSTRIES CO., LTD.

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