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Maintenance Instructions

8.10.14

Kapitel/Chapter 7: Maintenance Instructions - Seite/Page 141

7.23.1 Replacement of the impeller

Fig. 7.23.1-1: Raw water cock

Close the raw water stop cock.

Representative picture

Fig. 7.23.1-2: Raw water pump

Raw water pump on the front side of the genset.

Representative picture

Fig. 7.23.1-3: Cover raw water pump

Remove the cover of the raw water pump by loosen the screws
from the housing.

Representative picture

Summary of Contents for 45i pms

Page 1: ...Panda_45i_PMS_System_eng R02 8 10 14 Fischer Panda GmbH Manual Panda 45i PMS Super silent technology 400 V 50 Hz 45 kVA...

Page 2: ...ding text and graphics Details are given to the best of our knowledge No liability is accepted for correctness Technical modifications for improving the product wit hout previous notice may be underta...

Page 3: ...8 10 14 Kapitel Chapter A Seite Page 3...

Page 4: ...Seite Page 4 Kaptitel Chapter A 8 10 14...

Page 5: ...ctions and hazards of generators 24 1 6 1 1 Protective conductor and potential equalisation 25 1 6 1 2 Protective conductor for Panda AC generators 25 1 6 1 3 Switch off all loads while working on the...

Page 6: ...and freshwater 47 4 3 3 Components of the fuel air intake and exhaust system 48 4 3 4 Components of the electrical system 49 4 3 5 Components of the lubrication system 50 4 3 6 Sensors and switches fo...

Page 7: ...6 6 installation 69 6 7 Installation of the water cooled exhaust system 70 6 7 1 Fischer Panda installation kit Exhaust System 70 6 7 2 Installation of the standard exhaust system 71 6 8 Installation...

Page 8: ...7 13 Replacing the Oil Pressure Switch 117 7 13 1 Replacing the oil pressure sensor optional component 118 7 14 Replacing a Thermoswitch 119 7 15 Replacing the V belt at Kubota 02 05 series 121 7 16 R...

Page 9: ...Inverter Panda PMGi 45 161 10 1 Safety instruction 162 10 2 Front side connection side 162 10 2 1 Socket pins of the PMGi 45 163 10 3 Left side 163 10 4 Settings for the use of iGenerators with power...

Page 10: ...ting functions 191 2 4 1 Set up menu 191 2 4 2 Setting the brightness of the backlight backlight and dimtime 192 2 4 3 The configuration menu config 193 2 4 4 The network ID 193 2 4 5 Saving settings...

Page 11: ...1 Cleaning the iControl2 controller 205 5 Warnings and error messages 207 5 1 Warnings 207 5 1 1 Examples of warnings on the display 207 5 1 2 Warning messages 208 5 2 Faults 208 5 2 1 Error messages...

Page 12: ...Seite Page 12 Kaptitel Chapter 1 8 10 14...

Page 13: ...Fischer Panda can supply Service Kits which are ideal for regular servicing tasks We only supply the highest quality components which are guaranteed to be the RIGHT parts for your generator Service P...

Page 14: ...ll quantities if inhaled swallowed or absorbed through the skin WARNING Important information This warning symbol draws attention to special warnings instructions or procedures which if not strictly o...

Page 15: ...to the danger of electric shock and draws attention to special warnings instructions or procedures which if not strictly observed may result in severe personal injury or loss of life due to electric s...

Page 16: ...er due to corrosive substances potential contamination of person Warning of substances that cause chemical burns upon contact These substances can act as contaminants if introduced into the body WARNI...

Page 17: ...les PPE Wearing safety goggles protects the eyes from damage Optical spectacles are not a replacement for the corresponding safety goggles MANDATORY INSTRUCTION Wear protective gloves PPE Wearing prot...

Page 18: ...bols are used throughout this manual to show which tool must be used for maintenance or installation Spanners W A F X width across flats of X mm Hook wrench for oil filter Screw driver for slotted hea...

Page 19: ...eral Instructions and Regulations 8 10 14 Kapitel Chapter 1 General Instructions and Regulations Seite Page 19 Clamp on ammeter DC for synchronous generators AC for asynchronous generators Torque wren...

Page 20: ...g these measures lies with those who undertake the installation of the generator in the final system 1 4 Customer registration and guarantee Use the advantages of registering your product you will rec...

Page 21: ...ces and ensure work safety Familiarise yourself with the equipment and its limits Keep the generator in good condition 1 5 3 Personal protective clothing PPE For maintenance and repair work on the equ...

Page 22: ...st fumes are vented appropriately leak proof system and that an adequate fresh air supply is available for the generator and the operator forced ventilation Check the system regularly for leakage and...

Page 23: ...from the batteries Ensure that the battery terminals are tightly connected and not corroded to avoid sparking Use an appropriate terminal grease Check the charge level with an adequate voltmeter or a...

Page 24: ...h water and soap and dry them with a soft cloth Immediately replace damaged or missing warning and instruction signs This also applies to the installation of spare parts 1 6 1 Special instructions and...

Page 25: ...The battery must always be disconnected if work on the generator or electrical system is to be carried out so that the generator cannot be started up unintentionally 1 6 1 3 Switch off all loads whil...

Page 26: ...is installed free from any influence due to friction and crushing 1 6 2 Recommended starter battery sizes Use only batteries approved by the manufacturer as starter batteries Use the battery capacity...

Page 27: ...da generator capsule the positive battery cable must be routed so that it is protected from heat and vibrations by means of an adequate conduit protective sleeve It must be installed so that it does n...

Page 28: ...risk of skin burns Protect all battery contacts against accidental contact For battery banks Use only deep cycle batteries Starter batteries are not suitable Lead acid gel batteries are recommended T...

Page 29: ...by electrical shocks 5 Safety steps to follow if someone is the victim of electrical shock Do not touch the injured person while the generator is running Switch off the generator immediately If you ca...

Page 30: ...ds you by pulling slowly 4 Open Airway Tilt head back and lift chin Shout Are you OK 5 Check for Breathing Look listen and feel for breathing for 3 to 5 seconds 6 Give 2 Full Breaths Keep head tilted...

Page 31: ...rpose of the manual and description of the definitions of the trained persons operators users This manual contains the working instructions and operating guidelines for the owner and user of Fischer P...

Page 32: ...all hazard notes and safety instructions are respected The user must be instructed by the operator regarding his activity at the generator especially concerning the maintenance 3 3 Components of the...

Page 33: ...s catalogue Installation Service Guide d Engine manual from the engine manufacturer e Generator circuit diagram representative picture 3 4 Range of operation Reliable power supply on sailing boats 3 5...

Page 34: ...x 5 Remove the sidewalls 6 Open the generator attachment 3 6 Opening the MPL sound insulation capsule Fig 3 6 1 Sound insulation capsule side part To open the sound insulation capsule the closures mus...

Page 35: ...e GFK sound insulation capsule Fig 3 6 1 Lash closures GFK sound insulation capsule with lash closures Fig 3 6 2 Lash closures To open the lash closures pull the handle in arrow direction and lift the...

Page 36: ...loading of the generator For loading unloading the generator appropriate ring eye bolts shall be installed in the holes in the support rails The load bearing capacity of each ring eye bolt must at lea...

Page 37: ...orresponds with empty battery recharge For a 12 V battery the following applies 11 7 V lower open circuit voltage battery empty recharge battery 12 6 V upper open circuit voltage full battery trickle...

Page 38: ...s instructions Spray engine parts and V belt disks with preservative Clean air filter housing and spray with preservative metal housing only Close off intake and exhaust apertures e g with tape or en...

Page 39: ...n Cover alternator apertures Cleaning fluids and preservatives must not enter the alternator Risk of destroying the alternator Clean engine as per manufacturer s instructions Spray engine parts and V...

Page 40: ...ld engine stop lever in zero delivery position and crank engine manually several times Clean air filter housing with petroleum spirit check air filter and replace if necessary Remove covers from exhau...

Page 41: ...nda 45i PMS generator 8 10 14 Kapitel Chapter 4 Panda 45i PMS generator Seite Page 41 4 Panda 45i PMS generator 4 1 Type plate at the generator Fig 4 1 1 Panda 15000i PMS generator Fig 4 1 2 Type plat...

Page 42: ...view Fig 4 2 1 1 Right side view 01 03 04 05 02 06 07 08 10 09 11 12 01 Air filter 02 DC alternator 12V 03 Oil pressure switch 04 Raw water pump 05 Sound cover base part 06 Raw water hose 07 Starter m...

Page 43: ...4 2 2 1 Left side view 04 09 02 05 06 08 11 10 16 01 07 03 01 PMGi 45 with integrated icontrol board 02 Emergency Stop switch 03 Generator housing with coil 04 Sound cover base part 05 DC fuse 06 Actu...

Page 44: ...01 03 11 05 07 06 08 12 01 Fuel solenoid 02 Stop solenoid 03 Oil filter 04 Fuel in out 05 Cable for starter battery negative pol 06 Cable for starter battery positive pol 07 Raw water intake 08 passa...

Page 45: ...nda 45i PMS generator Seite Page 45 4 2 4 Back view Fig 4 2 4 1 Back view 05 03 02 01 02 03 01 PMGI Power out 02 Connection point Remote control panel 03 Connection point fuel pump 04 Generator back p...

Page 46: ...anda 45i PMS generator 8 10 14 4 2 5 View from above Fig 4 2 5 1 View from above 06 01 02 05 07 04 01 Air filter 02 Turbo charger 03 Suction hose air suction housing induction elbow 04 Exhaust out 05...

Page 47: ...14 Kapitel Chapter 4 Panda 45i PMS generator Seite Page 47 4 3 Details of function units 4 3 1 Remote control panel See Panda iControl manual 4 3 2 Components of the cooling system raw and freshwater...

Page 48: ...Panda 45i PMS generator Seite Page 48 Kaptitel Chapter 4 Panda 45i PMS generator 8 10 14 4 3 3 Components of the fuel air intake and exhaust system Fig 4 3 3 1 Fuel air intake and exhaust system...

Page 49: ...Panda 45i PMS generator 8 10 14 Kapitel Chapter 4 Panda 45i PMS generator Seite Page 49 4 3 4 Components of the electrical system Fig 4 3 4 1 Electrical system...

Page 50: ...Panda 45i PMS generator Seite Page 50 Kaptitel Chapter 4 Panda 45i PMS generator 8 10 14 4 3 5 Components of the lubrication system Fig 4 3 5 1 Lubrication system...

Page 51: ...itch at engine The thermo switch at the engine is used for monitoring the engine tempera ture Fig 4 3 6 2 Thermo sensor at exhaust connection Thermo sensor at exhaust connection If the impeller pump d...

Page 52: ...In order to be able to monitore the lubricating oil system an oil pressure switch is built into the system 4 4 Operation instructions See Panda iControl panel manual 4 4 1 Daily routine checks before...

Page 53: ...start device This means the generator can be started by an external signal To avoid an unexpected starting of the generator the starter battery must be disconnected before start working at the genera...

Page 54: ...manifolds This condition is particularly evident on standby generator set applications 5 3 2 1 The soot of the generator is due to the fact that The cylinder temperatures are too low to ensure complet...

Page 55: ...ped with various sensors temperatures switches The combustion engine is fur ther equipped with a oil pressure control switch which switches the motor off if the oil pressure sinks to a particular leve...

Page 56: ...l data sheet must be respected Respect the safety instruction in front of this manual 5 7 Stopping the generator see remote control panel data sheet Note The instructions and regulations of the remote...

Page 57: ...amages caused by faulty or incorrect installation are not covered by the warranty 6 1 Personal requirements The described installation must be done by a technical trained person or a Fischer Panda ser...

Page 58: ...e per sonal injury and death Electrical voltages above 48 volts battery chargers greater than 36 volts are always dangerous to life The rules of the respective regional authority must be adhered to On...

Page 59: ...n have resonance vibrations because of airborne sounds If this should be unavoidable then it is recommended that this surface is lined with 1 mm lead foil which will change the mass and the vibration...

Page 60: ...ections Connect all electrical wires within the capsule tightly to the motor and the generator This is also the case for fuel lines and cooling water lines ATTENTION Danger to Life High voltage The el...

Page 61: ...installation kit raw water Note The following additional components will be required for the specified installation You can purchase them as an installation kit or separately at Fischer Panda 1 2 3 4...

Page 62: ...10 14 Fig 6 4 2 1 Thru hull fitting with strainer Through hull fitting with strainer Fig 6 4 2 2 Sea cock Sea cock Fig 6 4 2 3 Adapter Adapter Fig 6 4 2 4 Raw water filter Raw water filter Fig 6 4 2...

Page 63: ...sailing at higher speeds more water will be forced into the inlet than the pump can handle and your generator will flood 6 4 4 Quality of the raw water sucking in line In order to keep the suction res...

Page 64: ...peller life span will be increased With the installation of a non return valve in the raw water inlet line which is under the waterline this problem can be restricted When starting the generator you s...

Page 65: ...Installation Instructions 8 10 14 Kapitel Chapter 6 Installation Instructions Seite Page 65 6 4 6 Raw water installation scheme Fig 6 4 6 1 Raw water installation schema...

Page 66: ...necting nipple Both hose ends must be led outside of the sound cover if possible 600 mm over the waterline in the mid ship line The valve is connected at the highest place to the two hose ends If the...

Page 67: ...e genset housing by the heat exchanger Fig 6 4 9 1 Installation scheme indirect cooling of the genset housing 1 Vent valve 2 Coolant connection block 3 Raw water pump 4 Exhaust manifold 5 Raw water fi...

Page 68: ...rnal cool ing water expansion tank This tank must be installed in such a way that its lower edge is at least 500 mm more highly arranged than the upper edge of the sound cover If this 500 mm should be...

Page 69: ...ge 69 6 5 2 Scheme for freshwater circuit at two circuit cooling system Fig 6 5 2 1 Scheme for freshwater circuit at two circuit cooling system 6 6 installation 1 Expansion tank 2 Exhaust manifold 3 T...

Page 70: ...aust System Note The following additional components will be required for the specified installation You can purchase them as an installation kit or separately at Fischer Panda Fig 6 7 1 1 Waterlock W...

Page 71: ...be installed at the lowest point of the exhaust system An optional noise insulated water lock can also be installed The exhaust hose descends from the capsule to the water lock Then the hose rises vi...

Page 72: ...st hoses play the decisive role If the waterlock is arranged in an unfavourable position the cooling water flowing back in the exhaust hose can rise so high that it reaches the exhaust stack Since at...

Page 73: ...e exhaust area when the ship is tilted b Position of the venting valve is too far from the ships center line The water reaches the exhaust area when the ship is tilted c The venting valve does not wor...

Page 74: ...h the emissions by the exhaust gas pressure When the engine is turned off the number of revolutions sinks quite fast By doing so the point is reached where the exhaust gas pressure does not suffice an...

Page 75: ...eite Page 75 Fig 6 8 3 0 1 Volume of the waterlock If there are any doubts a verification can easily be made by temporarily using a clear sighted hose 1 as exhaust hose In that way the cooling water l...

Page 76: ...ally in tilted position by the waterlock moving out of the center line See the following pictures Fig 6 8 3 1 1 Ideal position of the waterlock In Fig 6 8 3 1 1 the waterlock is mounted in center unde...

Page 77: ...degrees Tilted position 45 degrees Fig 6 8 3 1 4 In this case the water level rise so high that the distance constitutes only 325 mm Even when the water lock is mounted in the ideal spot at an extrem...

Page 78: ...10 14 Summary The preset minimum height of 600 mm must be regarded unconditionally and is only valid if the waterlock is mounted in its ideal position in center underneath the generator A higher posit...

Page 79: ...ave to be reckoned concerning motor yachts Here it is only necessary to regard that the volume of the waterlock is measured so large that it can take the entire amount of water flowing back and at the...

Page 80: ...hat in a tilted position of 30 degrees you already face the highest risk of sea water sloshing into the combustion chamber Fig 6 8 3 2 4 Tilted position 45 degrees Tilted position 45 degrees Fig 6 8 3...

Page 81: ...istance between waterlock and the generator s center line 1000 mm Fig 6 8 3 2 5 waterlock 1000 mm next to center line Fig 6 8 3 2 6 Tilted position 15 degrees Tilted position 15 degrees Fig 6 8 3 2 6...

Page 82: ...th the generator at least in reference to the ships center line Thus the waterlock is prevented from leaking very strongly when the ship is tilted The leaking of the waterlock leads to a rise of the w...

Page 83: ...Installation Instructions 8 10 14 Kapitel Chapter 6 Installation Instructions Seite Page 83 Fig 6 9 0 1 Installation Scheme exhaust water separator...

Page 84: ...hortest possible path in the through hull outlet For such long exhaust routes the exhaust hose diameter should also be increased f e from NW40mm to NW50mm in order to reduce the back pressure The exha...

Page 85: ...lation Instructions Seite Page 85 Fig 6 10 1 1 Fuel hose Fuel hose representative picture Fig 6 10 1 2 No return valve No return valve representative picture Fig 6 10 1 3 Pre filter with water separat...

Page 86: ...Fig 6 10 1 5 Quick connector for fuel lines Quick connector for fuel lines representative picture Fig 6 10 1 6 Hose clamps Hose clamps representative picture 6 10 1 1 The following items need to be i...

Page 87: ...p With the Fischer Panda generator is usually supplied an external electrical fuel pump DC The fuel pump must be installed close at the fuel tank The electrical connections is prepared at the generato...

Page 88: ...age 88 Kaptitel Chapter 6 Installation Instructions 8 10 14 Fig 6 10 1 2 Fuel system schema 5 2 3 4 1 6 1 Fuel tank 2 external fuel pump 3 external fuel prefilter with water separator 4 Non return val...

Page 89: ...ted higher than the tank in order to prevent fuel running back into the tank after the motor has been switched off which can lead to enormous problems if the generator is switched off for a long perio...

Page 90: ...commended to install an additional starter battery for the generator The generator is then independent from the remaining battery set This enables you to start the genset at any time with its own star...

Page 91: ...a distance to the battery of up to 300 mm 12 inch at maximum The cable from the battery to the safety device must be secured with protective pipe sleeve against chafing through For the connection use...

Page 92: ...starter Fig 6 11 1 2 Negative Battery Cable Negative battery cable The negative battery cable is connected to the engine foot Note The battery negative pole may not be connected with the boat ground o...

Page 93: ...nstallation Instructions Seite Page 93 Fig 6 11 1 4 Connection starterbattery 12V schema Fig 6 11 1 5 Connection starterbattery 24V schema 1 Generator 2 Battery block 3 Fuse 4 Battery main switch 1 Ge...

Page 94: ...connect two 12V batteries to a 24V battery bank Fig 6 11 2 1 Installation starter battery The starter batteries have to be connected in this order 1 cable of first battery Fig 6 11 2 2 Installation st...

Page 95: ...ltage Before the electrical system is installed READ the SAFETY INSTRUCTIONS of this manual FIRST Be sure that all electrical installations including all safety systems comply with all required regula...

Page 96: ...ion Instructions 8 10 14 Fig 6 12 0 1 Electrical installation example 6 12 1 Installation PMGi inverter See separate PMGi inverter manual 1 2 3 4 5 6 7 1 Generator 2 Electrical fuel pump DC 3 PMGi inv...

Page 97: ...efore before starting work at the generator Make sure that the generator is stopped and the starter battery is discon nected to guarantee that the generator cannot be inadvertently started Do not run...

Page 98: ...tions for safety reasons Warning Hot surface material Generator oil and antifreeze can be hot during after operation Risk of severe burns Instruction Personal protective equipment nec essary During In...

Page 99: ...f actuator trapezoid thread spindle 7 5 Maintenance interval For the maintenance intervals see the General information for vehicles generators which are attached to this man ual For generators with dy...

Page 100: ...e oil dipstick back into the check rail and wait for 10 seconds Pull the oil dipstick out of the check rail and read off the oil level at the lower end of the stick Fig 7 6 1 Oil dipstick Sample Oil d...

Page 101: ...service point immediately 7 6 1 Refilling Oil You require Engine oil 1 Check oil level as described under section 7 6 Checking oil level on page 99 2 Oil dipstick is pulled out of the check rail 3 Ope...

Page 102: ...nerator on a levelled surface with marine generators Change the oil when the ship is not lop sided Run the generator for about 10 minutes to ensure that the engine is warm Wait for 3 minutes so the oi...

Page 103: ...e oil drain screw by means of the open ended wrench from the oil drain hose rotating direction left Use a second open ended wrench to lock Make sure to do this over the container Use spanner size 17 m...

Page 104: ...Check oil level after every 2 litres with the oil dipstick 9 Check proper filling level See section 7 6 Checking oil level on page 99 When the proper filling level is reached screw in the oil cap agai...

Page 105: ...ttery Keep battery clean and dry Remove dirty clamps Clean terminal posts and and clamps of the battery and grease with acid free and acid resistant grease When reassembling ensure that clamps make go...

Page 106: ...Do not rest tools on the battery 7 9 Ventilating the fuel system Normally the fuel system is designed to ventilate air itself i e as soon as the electric starter motor starts operation the fuel pump...

Page 107: ...cloth or Kleenex tissue must be laid beneath the connection to prevent escaping fuel running into the capsule If the fuel runs out without air bubbles then the ventilation screw can be closed Only th...

Page 108: ...es from the used filter and fasten them to the new filter The arrow on the filter housing indicates the direction of the fuel flow A clogged filter causes a decreased power output of the generator 7 9...

Page 109: ...ricate the sight glasses o ring with a heat resistant grease Specification Antiseize and screw the sight glass back into its mount right hand rotation 7 10 Checking the water separator in the fuel sup...

Page 110: ...The original location of the item must be taken from the generator descrip tion of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cann...

Page 111: ...c starter 3 Pull off rubber cap 4 Loosen hex nut with wrench with W A F 13 mm and remove the electric connections Fig 7 11 4 Electric starter 5 Loosen the lower attachment screw with a hex socket wren...

Page 112: ...r attachment screw is visible from up top view between engine and exhaust manifold 6 Slide the socket wrench fitted with both extensions under the exhaust manifold and insert in the hex socket screw L...

Page 113: ...original location of the item must be taken from the generator descrip tion of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cannot be...

Page 114: ...DP terminal red cable using a wrench with W A F 10 mm Fig 7 12 4 DC alternator 5 Remove nut and washer of the exciter terminal grey cable with a wrench with W A F 8 mm 6 Remove nut and washer of the c...

Page 115: ...osen bottom fixing screw of the DC alternator with a wrench with W A F 12 mm 01 9 Use a wrench with W A F 12 mm 02 for the counter nut Fig 7 12 7 DC alternator 10 Push the DC alternator toward the the...

Page 116: ...Page 116 Kaptitel Chapter 7 Maintenance Instructions 8 10 14 Fig 7 12 9 DC alternator 14 Loosen and remove the earthing strip with a size 5 mm socket wrench 15 Replace the DC alternator 16 To reinstal...

Page 117: ...that the generator cannot be started up accidentally Remove battery main switch For part numbers refer to the spare parts catalogue Fig 7 13 1 Oil pressure sensor 1 Open both connectors 01 on the oil...

Page 118: ...onnectors 01 on the oil pressure sensor Fig 7 13 2 Oil pressure sensor 2 Loosen and remove oil pressure sensor 6R3 using a wrench with W A F of 17 mm A large piece of cloth or absorbent tissue must be...

Page 119: ...ors The original location of the item must be taken from the generator descrip tion of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator c...

Page 120: ...7 14 3 Thermoswitch 3 Disconnect electric supply line of the thermoswitch Fig 7 14 4 Thermoswitch 4 Loosen thermoswitch with a wrench with W A F 22 mm Fig 7 14 5 Thermoswitch 5 Before installing the...

Page 121: ...r compounds may partially lose their effec tiveness even after a short operating time because the air in the sound insulated capsule can be both relatively warm and dry The V belt must therefore be ch...

Page 122: ...ing the V belt 3 Push alternator towards the thermostat housing 4 Replace the V belt Quad Power XPZ 862 Fig 7 15 4 Replacing the V belt 5 The V belt is tensioned by pulling back the alternator The V b...

Page 123: ...location of the item must be taken from the generator descrip tion of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cannot be started...

Page 124: ...he nozzle holder assembly 4 Wrench with W A F of 21 mm 3 Remove the copper seal 5 and the heat shield 6 4 Dismount the connector 2 from the glow plugs 3 5 Remove the glow plugs 3 For assembly Replace...

Page 125: ...the screwdriver 1 into the hole in the heat ring seal 2 Rotate the screwdriver three to four times in each direc tion 3 When rotating the screwdriver slowly extract the heat ring seal 4 together with...

Page 126: ...The original location of the item must be taken from the generator descrip tion of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cann...

Page 127: ...nstructions Seite Page 127 Fig 7 17 3 Glow plugs 3 Remove the glow plug connector Fig 7 17 4 Glow plugs 4 Loosen the glow plug using a socket wrench with a long size 10 mm socket Fig 7 17 5 Glow plugs...

Page 128: ...lacements and repairs should be done by a trained person Fig 7 18 1 De aerating hose 1 Remove de aerating hose Use Cobra pliers to open the Cobra clamp 2 Clean during reinstallation 3 Remove the cap n...

Page 129: ...7 19 1 Pulley 1 Drain cooling water from entire system 2 Remove V belts see Replacement of the V Belt in this manual 3 Remove all 4 screws on the pulley W A F 10 mm 4 Remove pulley 5 For reinstallatio...

Page 130: ...to be adjusted is fully open If necessary rotate back and forth to determine the dead centre See Fig 7 20 1 Valve open on page 131 3 Rotate crankshaft 360 The valve is then closed as the cam shaft was...

Page 131: ...sh rod 4 Adjusting screw 5 Counter nut 6 Rocker arm 7 Valve 8 Crankshaft Fig 7 20 2 Valve closed 1 Cam shaft 2 Cam follower 3 Push rod 4 Adjusting screw 5 Counter nut 6 Rocker arm 7 Valve 8 Crankshaft...

Page 132: ...housing by loosen the six screws on the housing cover Use spanner size 8 mm Fig 7 20 2 Opened air suction housing 2 Change the air filter mat 3 Close the suction air housing 7 20 2 Alternative replac...

Page 133: ...133 Fig 7 20 2 2 Air suction housing with pull out holder 2 Tip the two fasteners 90 Fig 7 20 2 3 Air suction housing with pull out holder 3 Pull the filter mat holder out Fig 7 20 2 4 Air suction hou...

Page 134: ...right side of the housing 01 Closure Fig 7 20 3 2 Air suction housing 2 Open the combustion air housing by loosening the closure on the left side of the housing 01 Closure Fig 7 20 3 3 Air suction hou...

Page 135: ...ed Sample picture Fig 7 20 4 2 Venting screw at the pipe socket 2 Open the venting screw at the pipe socket of the internal cooling water pump until bubble free coolant escapes Close the vent screw no...

Page 136: ...it is possible that the cooling water is not circulating The generator will heat up very quickly and switch off because of overheating 7 20 4 1 Anti freeze in the cooling water circuit In the interes...

Page 137: ...ling water cap Some generators are equipped with an additional cooling water cap This only serves for the first filling at the factory This cap may not be opened when the generator is installed hot co...

Page 138: ...f the V belt is reduced It is possible that the plasticisers in the rubber compounds may partially lose their effec tiveness even after a short operating time because the air in the sound insulated ca...

Page 139: ...ew Fig 7 21 3 Replacing the V belt 3 Push alternator towards the thermostat housing 4 Replace the V belt Quad Power XPZ 862 Fig 7 21 4 Replacing the V belt 5 The V belt is tensioned by pulling back th...

Page 140: ...impeller if the cooling water sucking in way is relatively long or the supply is handicapped so that the cooling water sucking in range develops a negative pressure This can reduce first of all the p...

Page 141: ...peller Fig 7 23 1 1 Raw water cock Close the raw water stop cock Representative picture Fig 7 23 1 2 Raw water pump Raw water pump on the front side of the genset Representative picture Fig 7 23 1 3 C...

Page 142: ...ative picture Fig 7 23 1 5 Impeller Check to the impeller for damage and replace it if necessary Before the reinsertion into the housing the impeller should have been lubri cated with glycerin or with...

Page 143: ...orking at a running generator can result in severe personal injury Therefore before starting work at the generator Make sure that the generator is stopped and the starter battery is discon nected to g...

Page 144: ...allation of the elec trical connections for safety reasons Warning Hot surface material Generator oil and antifreeze can be hot during after operation Risk of severe burns Instruction Personal protect...

Page 145: ...ical demand on the system should not be more than 70 of the rated genset peak load Keep PEAK LOADING demand in mind when switching on electrical devices esp fridge compressors electric motors battery...

Page 146: ...lenoid valve is located in front of the injection pump It opens automatically if the START button is pressed on the remote control panel The solenoid valve is CLOSED when the generator main power is s...

Page 147: ...filter If the fuel filter is dirty change the filter element For replacing the filter element see section C 3 1 Replacing fuel filter on page 79 Fuel filter Fig 8 5 2 1 Fuel filter 1 Fuel filter eleme...

Page 148: ...Generator Failure Seite Page 148 Kaptitel Chapter 8 Generator Failure 8 10 14...

Page 149: ...clean if necessary Lack of fuel Check fuel supply Glow plugs not working correctly Check glow plugs and heating time Too much air in fuel lines Test fuel system for leakage Bleed air from fuel system...

Page 150: ...h tripped lack of cooling water Is indicated on the remote control panel Check cooling water system flow water pump inlet water filter extra heat exchanger coolant flow Lack of oil oil pressure sensor...

Page 151: ...42 1 12 l approx 0 42 1 12 l Oil consumption max 1 of fuel consumption Oil specification API CF API CF API CF Cooling water requirement for seawater cir cuit Marine generators only 10 12 l min 10 12 l...

Page 152: ...ni Panda 12000 NE Panda 14000 NE Panda 15000 NE Panda 18 NE Panda 24 NE Panda 30 NE Type D782 D902 D1105 V1505 V1505 TD Governor VCS VCS VCS VCS VCS Automatic start booster yes yes yes no no Cylinder...

Page 153: ...rox 4 9 13 1l approx 3 78 10 1l approx 6 3 16 8 l approx 6 7 17 9l Oil consumption max 1 of fuel consumption max 0 5 of fuel consumption Oil specification API CF API CF API CF 4 API CF API CF Cooling...

Page 154: ...Panda 30 4 Panda 30 4 Panda 40 4 Panda 50 4 Panda 70 4 Type Mitsubishi S DTS V3600 V3600 V3800 DI T BF4M 1013EC Governor VCS VCS VCS Mechanical GAC VCS Automatic start booster no no no no no Cylinder...

Page 155: ...1 22 1 Lubrication oil capacity 1 3l 2 8l 2 8l 3 7l 6 0l Fuel consumption approx 0 42 1 12l approx 0 7 1 8l approx 1 0 2 66l approx 1 3 3 6l approx 1 20 3 36l Oil consumption max 1 of fuel consumptio...

Page 156: ...conduit mm Fuel conduit Freshwater mm Seawater mm Supply mm Return mm Panda PMS 3 8 ND 12 12 30 8 8 Panda PMS 4 5 ND 12 12 30 8 8 Panda PMS 4500 SCB 12 12 30 8 8 Panda PMS 5000 SCE 12 12 30 8 8 Panda...

Page 157: ...erican Petroleum Institutes The API designation is to be found on each engine oil bundle The first letter is always a C API C for diesel engines The second letter is for the quality of the oil The mor...

Page 158: ...be regularly checked in the interests of safety Fischer Panda recommend to use the product GLYSANTIN PROTECT PLUS G 48 Engine oil type over 25 C SAE30 or SAE10W 30 SAE10W 40 0 C to 25 C SAE20 or SAE1...

Page 159: ...esel fuel oil SAE J313 JUN87 according to ASTM D975 and EN 590 Do not use alternative fuel because its quality is unknown or it may be inferior in quality Kerosene which is very low in cetane rating a...

Page 160: ...Tables Seite Page 160 Kaptitel Chapter 9 Tables 8 10 14...

Page 161: ...Kapitel Chapter 10 Inverter Panda PMGi 45 Seite Page 161 Fischer Panda Datenblatt Datasheet 10 Inverter Panda PMGi 45 Art Nr xx xx xx xxx 400 V 50 Hz xx xx xx xxx 400 V 60 Hz Bez Panda PMGi 45 Documen...

Page 162: ...the motor is not running Electrical power DANGER TO LIVE Electrical voltages above 48 volts battery chargers greater than 36 volts are always dangerous to life The rules of the respective regional aut...

Page 163: ...yellow 2 Live L1 3 Live L2 4 Live L3 5 Neutral cable blue 6 PE N Bridge Attention Connecting one of the three Phase with the earth pin will destroy the PMGi 10 3 Left side Fig 10 3 1 Left side Inside...

Page 164: ...anda PMGi 45 PGMi 45_eng fm Fischer Panda Datenblatt Datasheet Attention Make sure that the connection between the generator and the PMGi is secured Never connect or disconnect the PMGi while the gene...

Page 165: ...adapted for the power inverters of other brands 10 4 1 Settings in the Victron VE Configure II Software General Fig 10 4 1 1 Settings in the Victron VE configure II Software 10 4 1 1 Uninterrupted AC...

Page 166: ...ettings in the Victron VE Configure II Software Inverter Fig 10 4 2 1 Settings in the Victron VE configure II Software 10 4 2 1 Assist current boost factor To reduce the action of the power inverter o...

Page 167: ...nnected to the PMGi after the output has reached the nominal 230V 50Hz and not to overload the PMGi some electronic devices such like air conditions need an higher start current May use a relay which...

Page 168: ...See Socket pins of the PMGi 45 on page 163 10 7 2 Electrical connection Only special trained persons are allowed to make the electrical connection When an extension cable is required be sure to use a...

Page 169: ...ted 10 8 Technical Data 10 8 1 General Data PMGi is part of the Panda i series generator Its not allowed to be used with other generators or applications 10 8 2 Generator Specification Storage tempera...

Page 170: ...V 20 C 40 C 5 V 20 C bis 40 C 5 V 20 C to 40 C 5 V 20 C 40 C Stromst rke Current Courant Stromst rkeNominal CurrentNominal CourantNominal 17 4 A 230Veff 17 4 A 230Veff 33 A 120Veff Stromst rkeMaximum...

Page 171: ...0 C to 40 C 5 V 20 C 40 C 5 V 20 C bis 40 C 5 V 20 C to 40 C 5 V 20 C 40 C Stromst rke Current Courant Stromst rkeNominal CurrentNominal CourantNominal 26 0 A 230Veff 53 A 120Veff 34 8 A 230Veff Strom...

Page 172: ...t rke Current Courant Stromst rkeNominal CurrentNominal CourantNominal 66 7 A 120Veff Stromst rkeMaximum CurrentMaximum CourantMaximum 83 3 A cos phi 0 8 120Veff Leistung Power Puissance Nominal Nomin...

Page 173: ...tMaximum 3x 21 7 A cos phi 0 8 400 Veff 52 A cos phi 0 8 230Veff 100 A cos phi 0 8 120Veff Leistung Power Puissance Nominal Nominal power Nominale 15 kVA 15 kVA 15 kVA Dauer Long term Continue 10 8 kW...

Page 174: ...omst rkeMaximum CurrentMaximum CourantMaximum 108 A cos phi 0 8 230 V 3x36 2 A cos phi 0 8 400 V 65 A cos phi 0 8 400 V Leistung Power Puissance Nominal Nominal power Nominale 25 kVA 25 kVA 45 kVA Dau...

Page 175: ...perate the short circuit protection a fuse must be put in series with the live wire The minimum requested feature for this fuse are the following Note The electrical Data refer to the system running i...

Page 176: ...Inverter Panda PMGi 45 Seite Page 176 Kaptitel Chapter 10 Inverter Panda PMGi 45 8 10 14...

Page 177: ...Panda iControl2_eng R07 8 10 14 Fischer Panda GmbH Panda iControl2 Operating Manual Open loop and closed loop control system for Fischer Panda generators...

Page 178: ...and graphics in this document Details are given to the best of our knowledge No liability is accepted for correctness Please note technical modifications aimed at improving the product may be implemen...

Page 179: ...tomatic start up WARNING The generator must not be operated with the cover removed If the generator is being installed without a sound insulation capsule it must be ensured that all rotating parts bel...

Page 180: ...e terminal then the positive terminal if work on the generator or electrical system is to be carried out so that the generator cannot be unintentionally started This applies in particular to systems w...

Page 181: ...most important data of the system as well as warnings and error messages The control panel is equipped with four buttons for operating the Panda iControl2 controller Fig 2 1 1 Panda iControl 2 panel 1...

Page 182: ...checked and cleaned The impeller fatigue increases if residual affects the raw water intake 5 Visual inspection Control fixing bolts check hose connectors for leakages control electrical connections...

Page 183: ...ion in default display Note Example Hardware version 2 iControl2 controller Generator type 01 Panda 5000i PMS Software version 2 0 iControl2 compatible with iControl Panel2 2 3 2 The default display s...

Page 184: ...r system with 24 V starter system the starter battery voltage can not be displayed 2 3 3 Operating modes The Panda iControl2 controller offers different operating modes 2 3 3 1 Stand by mode After the...

Page 185: ...al Service on page 195 In the set up menu of the controller you can reset the service interval after performing maintenance Siehe Set up menu auf Seite 191 2 3 3 2 Start up mode The start up mode repr...

Page 186: ...exhaust system gases The cooling water cannot be pressed through the exhaust as long as the diesel motor does not run at sufficient speed This leads to severe motor damage Open the sea valve as soon a...

Page 187: ...he inverter screen by actuating the cursor up button while in operation mode Fig 2 3 3 4 4 Inverter screen phase voltages This screen provides the latest inverter phase voltages You can access the inv...

Page 188: ...is screen provides the latest inverter output voltage of the single phases with the matching conductor current and the circuit board temperature The inverter will be switched off at a circuit board te...

Page 189: ...an emergency stop switch for a regular stop of the generator The engine may overheat and can be damaged destroyed Note Manual start in autostart mode If the generator is manually started up and stopp...

Page 190: ...the On Off button To deactivate the autostart function the flag in the EEPROM must be reset with Disable Siehe Activating deactivating the autostart function Autostart auf Seite 193 Note Manual start...

Page 191: ...top button is used for confirming a selection in the set up menu If you confirm the row marked with the with the Start Stop button you will access the selected sub menu Fig 2 4 3 Set up menu Set up me...

Page 192: ...e menu screens are highlighted with the light bulb symbol The period after which the backlight is to switch to the dimmed level can be specified with the menu item dimtime In this screen you can enter...

Page 193: ...the set up menu Save Exit After setting all parameters you can exit the set up menu with the menu item Save Exit Fig 2 4 5 1 Saving the values to the EEPROM In doing so all settings entered in the su...

Page 194: ...ate the autostart function select Enable and again confirm your selection with the Start Stop button To deactivate the function use the menu item Disable The Panda iControl will then confirm your inpu...

Page 195: ...Stop button as well Note Manual start in autostart mode If the generator is manually started up and stopped while in automatic start mode it will switch to stand by mode for safety reasons If necessa...

Page 196: ...switch off the fuel pump manually For this purpose confirm the menu item Prime fuel again and switch off the fuel pump using the Start Stop button 2 4 9 Selecting and saving a unit for the temperature...

Page 197: ...ained technical personnel or by authorised workshops Fischer Panda Service Points only 3 1 1 Hazard warnings for installation Note Ensure compliance with the general safety instructions at the beginni...

Page 198: ...the cooling system MANDATORY INSTRUCTION Protective equipment required For installation work personal protective equipment is compulsory This includes Tightly fitting protective clothing Safety shoes...

Page 199: ...iginal Fischer Panda connecting cables Terminal Terminal description Cable colour Function 1 UBUS white WH Bus supply voltage 2 GND brown shielding BN Fischer Panda bus ground ground connection betwee...

Page 200: ...Installation Seite Page 200 Kaptitel Chapter 3 Installation 8 10 14 3 3 Dimensions Fig 3 3 1 Housing of the Panda iControl2 panel...

Page 201: ...connected to this jack The Fischer Panda CAN bus is connected to the 6 pin jack at the bottom right of the circuit board The configuration of the connectors is given in the subsequent tables Siehe Te...

Page 202: ...rvo motor red wire 12 OUT PWM servo motor yellow wire 13 OUT Booster optional depending on generator type 14 OUT Fuel pump 15 OUT Fuel pump 16 OUT Electric starter 17 OUT Electric starter 18 OUT Elect...

Page 203: ...company The operating company shall be instructed in the operation maintenance and hazards of the generator This applies to both the maintenance steps and hazards described in the manual and to additi...

Page 204: ...Seite Page 204 Kapitel Chapter 3 Installation 8 10 14 Leere Seite Intentionally blank Installation...

Page 205: ...cope of the overall generator cleaning The housing can be wiped off with a soft lightly dampened cloth In doing so it must be ensured that no moisture enters the jacks and the housing 4 2 Maintenance...

Page 206: ...Seite Page 206 Kapitel Chapter 4 Maintenance 8 10 14 Leere Seite Intentionally blank Maintenance...

Page 207: ...eaches a defined warning threshold The warnings are issued on the Panda iControl2 panel display via the cyclical display of the word HIGH or LOW alternating with the measured value e g the temperature...

Page 208: ...aults result in the generator shutting down If a fault occurs due to the battery voltage being too low the controller is completely shut down to prevent the battery from discharging too much Examples...

Page 209: ...re error BATTERY LOW Battery power too low Inverter overtime Inverter temperature too high Inverter overload Generator was overloaded message is also issued when the generator output cable is not conn...

Page 210: ...cked for firm seating or damage P8 P50 marine Cylinder head temperature Delay 90 C 5 s 95 C 5 s Winding temperature Delay 130 C 5 s 135 C 5 s Exhaust manifold temperature Delay 70 C 1 s 75 C 1 s P8 P5...

Page 211: ...Current consumption nominal 175 mA Current consumption stand by 2 5 mA Operating temperature 20 C to 85 C Storage temperature 30 C to 85 C Current sensor Hall element max 20A max tightening torque for...

Page 212: ...Seite Page 212 Kapitel Chapter 6 Annex 8 10 14 Leere Seite Intentionally blank Annex...

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