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Installation Instructions

AGT 6000 PVMV-N 12V_24V - Chapter B: Installation Instructions

Page 45

B.2 Generator DC System-Installation

ATTENTION! Before the electrical system is installed, READ the SAFETY
INSTRUCTIONS of this manual FIRST! Be sure that all electrical installati-
ons (including all safety systems) comply with all required regulations of
the regional authorities. This includes lightnening conductor, personal
protection switch etc.

B.2.1 Installation Panda AGT 12 V System

Fig. B.2.1-1: Installation Panda AGT 12 V System - Schema

1

2

5

6

7

3

4

8

8

9

1. Generator
2. Battery block 12V
3. Battery monitor
4. Fuel pump
5. Remote control panel

6. Voltage control VCS
7. Starter battery 12V
8. Fuse
9. Battery switch

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Summary of Contents for AGT 6000 PVMV-N

Page 1: ...Panda AGT 6000 PVMV N Super silent technology 24V 6kW Fischer Panda GmbH ...

Page 2: ... the manufacturer Fischer Panda GmbH 33104 Paderborn reserves all rights regarding text and graphics Details are given to the best of our knowledge No liability is accepted for correctness Technical modifications for improving the product without previous notice may be undertaken without notice Before installation it must be ensu red that the pictures diagrams and related material are applicable t...

Page 3: ...3 6 Sensors and switches for operating surveillance 34 A 3 7 Components of the oil circuit 36 A 3 8 Externe Komponenten 38 A 4 Operating instructions 39 A 4 1 Preliminary remark 39 A 4 2 Daily routine checks before starting 40 A 4 3 Starting Generator 41 A 4 4 Stopping the Generator 41 A 4 5 Starting the Generator by a Failure bypass switch 42 B Installation Instructions 43 B 1 Generator Connectio...

Page 4: ...d of the generator to the actuator 81 D 1 7 Low Generator Output Voltage 83 D 2 Testing Generator Stator Windings 84 D 2 1 Testing Generator Stator Winding for Shorts to Ground 84 D 2 3 Measuring the Coil Inductive Resistance 86 D 3 Starting Problems 87 D 3 1 Fuel Solenoid Valve and Hubmagnet 87 D 3 2 Failure Bypass Switch 88 D 4 Troubleshooting Table 89 E Appendix 91 E 1 Maintenance Intervalls 91...

Page 5: ...r 118 A 2 General information 118 A 3 Operation instructions 119 A 3 1 Preliminary remark 119 A 3 2 Daily routine checks before starting 120 A 3 3 Starting Generator 121 A 3 4 Stopping the Generator 122 A 3 5 Starting the Generator by a Failure bypass switch 122 A 3 6 Installation of the Remote Control Panel 123 A 3 7 Fuse on control panel board 123 A 3 8 Installation assembly kit automatic start ...

Page 6: ......

Page 7: ... superiority in efficiency also ensures a fuel saving to the same extent The 100 water cooled Panda Aggregate are currently manufactured in the performance range from 2 to 100 kW in various versions Fast running motors are preferred for performances up to approx 30 kW Nominal speed 3000 rpm The heavier slow runners are preferred for the higher range The fast running aggregates have proved themselv...

Page 8: ...ial warnings instructions or procedures which if not strictly observed may result in electrical shock which will result in severe personal injury or loss of life This danger symbol refers to electric danger and draws attention to special warnings instructions or procedures which if not strictly observed may result in electrical shock which will result in severe personal injury or loss of life This...

Page 9: ...ance or installation Spanners X number of spanner Hook wrench for oil filter Screw driver for slotted head screws and for recessed head screws Multimeter multimeter with capacitor measuring Infrared temperature mesuring pistol Current clamp DC for synchron generators AC for asynchron generators X ...

Page 10: ...8 Socket wrench set Hexagon wrench keys ...

Page 11: ...into which the generator is to be installed in also corresponds to the regulations of the machine gui deline 98 37 EG This concerns among other things the exhaust system cooling system and the electrical installa tion The evaluation of the protection against contact can only be accomplished in connection with the respective system Likewise among other things responsibility for correct electrical c...

Page 12: ...t be used instead of the main switch which can be served manually which can be served then if necessary from different places The switches for the power relay are to mark accordingly as main switches DC battery with danger switch off Cooling of the rectifier block at the marine versions The retifier block is cooled with fresh water A normal cooling of the rectifier block is therefore only possible...

Page 13: ...rator A battery must always be connected to the inverter as a capacity Recommended capacity at 12V 240Ah at 24V 120Ah The screws at the electric rectifier may be pulled tight only with a torque wrench Torque 6 Nm The battery cable must be secured at the generator and at the batteries with appropriate safety devices The generator is also include into the CO2 fire extinguishing system ...

Page 14: ...sit imme diate a doctor Don t smoke in the near of the batteries Avoid naked flames or open fires In the area of batteries exists danger of explosions Pay attention that no tools fall on the battery poles if necessary cover them During the installation don t wear a wrist watch or arm jewels you can create under these circumstances a battery short circuit Burning of the skin could be the result Pro...

Page 15: ...ssible turn off the electrical power If you cannot turn off the electrical power pull push or lift the person to safety using a wooden pole rope or some nonconductive material After the injured person is free of contact with the source of electrical shock move them a short distance away and immediately start necessary first aid procedures 1 1 12 13 14 15 ...

Page 16: ...and lift chin Shout Are you OK Look listen and feel for breathing for 3 to 5 seconds 6 Give 2 Full Breaths Keep head tilted back Pinch nose shut Seal your lips tight around victim s mouth Give 2 full breaths for 1 to 1 seconds each 7 Check for Pulse at side of Neck 8 Phone EMS for Help Feel for pulse for 5 to 10 seconds Send someone to call an ambu lance 9 Begin Rescue Breathing 10 Recheck Pulse E...

Page 17: ...The Panda Generator AGT 6000 PVMV N 12V_24V Chapter A The Panda Generator Page 15 A The Panda Generator A 1 Type plate at the Generator Fig A 1 1 Type plate Fig A 1 2 Discription type plate ...

Page 18: ...lternator 03 Thermoswitch at exhaust elbow 04 Water cooled exhaust elbow 05 Cooling water pipe exhaust elbow silencer 06 Compensator under heat isolation 07 Coolant hose for external expansion tank 08 Water cooled pre silencer 09 Oil filter 10 Oil pressure switch 11 Starter motor 12 Coolant intake from radiator 13 Generator housing with coil 14 Coolant output to radiator 15 Exhaust output 16 Conne...

Page 19: ... 03 Thermoswitch at silencer 04 Air suction housing with air filter 05 Voltage controller for alternator 06 Air suction hose to induction elbow 07 Actuator 08 Fuel solenoid valve 09 Pulley for internal cooling water pump and alternator 10 Electrical fuses blue 15A white 25A 11 Starter relay Ks 12 Pre glow relay K2 13 Relay fuel pump K3 14 Failure bypass switch 15 Speed sensor 16 Fuse 1 5A 17 Oil d...

Page 20: ... Main battery connection 06 Main battery connection 07 Passage for battery connection 08 Passage for battery connection 09 Fuel intake 10 Fuel output 11 Cable for fuel pump 12 Cable for remote control panel 13 Oil drain hose 14 Cable for VCS 15 Cable for Shunt 16 Cable for measuring voltage 17 Passage for starter battery 18 Passage for starter battery 19 Oil filter 20 DC alternator 21 Clamping dev...

Page 21: ...2V_24V Chapter A The Panda Generator Page 19 A 2 4 View from back side Fig A 2 4 1 Back side view 01 02 04 03 01 Coolant hose for external expansion tank 02 Exhaust output 03 Connection external expansion tank 04 Water cooled pre silencer ...

Page 22: ...ator under heat isolation 04 Water cooled exhaust elbow 05 Thermoswitch at exhaust elbow 06 DC alternator 07 Ventilation screw thermostat housing 08 Ventilation screw pre silencer 09 Thermoswitch at silencer 10 Air suction housing with air filter 11 Electric starter control unit 12 Voltage controller for alternator 13 Thermoswitch at cylinder head 14 Fuel solenoid valve 15 Stop solenoid 16 Ventila...

Page 23: ...of the generator without operating by remote control panel is not admissi ble As accessories option that operating by remote control panel can be equipped with an auto matic addition With this option the generator can be started by external signals e g battery guards A 3 2 Components of the cooling system Coolant intake This port is to be connected with the exter nal radiator From here the cold co...

Page 24: ...rew above the cooling water pump casing may not be opened whilst the generator is running If this occurs by mistake air will be drawn through the opening Extensive ventilation of the whole system is then necessary Fig A 3 2 4 Ventilation screw cooling water pump Ventilation screw thermostat housing The ventilation screw on the thermostat housing should occasionally be opened for control purposes S...

Page 25: ...xhaust elbow The manifold is cooled by means of the internal cooling system Fig A 3 2 6 Water cooled exhaust elbow Coolant pipe Coolant pipe from water cooled exhaust silencer to the water cooled pre silencer Fig A 3 2 7 Coolant pipe Water cooled pre silencer Fig A 3 2 8 Water cooled pre silencer ...

Page 26: ...t first filling or repair works Fig A 3 2 9 Ventilation screw silencer Return flow expansion tank The ventilation pipe leads from the water cooled silencer to the external expansion tank Fig A 3 2 10 return flow expansion tank Schlauchanschlussstutzen für externes Aus gleichsgefäß The external expansion tank is connected here Fig A 3 2 11 Connection external expansion tank ...

Page 27: ...supplied with an external electrical 12 V of DC fuel pump The fuel pump must be always installed in the proximity of the tank The electrical connections with the lead planned for it are before installed at the generator Since the suction height and the supply pressure are limited it can be sometimes possible that for reinforcement a second pump must be installed Fig A 3 3 1 External fuel pump 01 F...

Page 28: ...A 3 3 3 Fuel filter Fuel solenoid valve The fuel solenoid valve opens automati cally if START is pressed on the remote control panel The solenoid closes if the generator is switched to OFF position It takes a few seconds before the generator stops If the generator does not start or does not run smoothly i e stutters or does not attain full speed then the cause is fore mostly the solenoid 1 Fuel so...

Page 29: ...red the starting pro cedure Fig A 3 3 6 Glow plugs Stop solenoid for Motorstop Not at every genset interrupts the fuel flow by activating the stop lever Fig A 3 3 7 Stop solenoid A 3 4 Components of the combustion air Combustion air intake The sound cover is provided at the lower surface with drillings through which the combustion air can influx It must be consistently paid attention that the gene...

Page 30: ...housing with air filter Type Microstar LX266 Fig A 3 4 3 Air filter Combustion chamber intake elbow The figure shows the induction elbow at the combustion engine At the front of this induction elbow you can see the hose con nection between air suction housings and induction elbow The air filter must be chek ked if this hose pulls together at operation Fig A 3 4 4 Combustion chamber intake elbow ...

Page 31: ... cooled exhaust elbow Fig A 3 4 5 Water cooled exhaust elbow Compensator under heat isolation This part is because of the internal con struction elastic and comensates vibrati ons Fig A 3 4 6 Compensator under heat isolation Exhaust output Connect here a muffler Fig A 3 4 7 Exhaust output ...

Page 32: ...ery Electrical connections for control 01 Cable for fuel pump 02 Cable for remote control panel 03 Cable for VCS 04 Cable for shunt 05 Cable for measuring voltage Fig A 3 5 2 Electrical connections Starter motor 1 Starter motor and 2 Solenoid switch The Diesel engine is electrically started On the back of the engine is accordingly the electrical starter with the solenoid switch Fig A 3 5 3 Starter...

Page 33: ...d increases with increasing load Fig A 3 5 4 Actuator Speed sensor All Panda generators can be equipped with an external automatic start For the opera tion of this automatic starting system a separate speed sensor is necessary At some models the speed sensor is standard installed Fig A 3 5 5 Speed sensor Stop solenoid for Motorstop Not at every genset interrupts the fuel flow by activating the sto...

Page 34: ...ernal cooling water pump The 12V charge system may be used only for the generator own starter battery Fig A 3 5 7 DC alternator Charge control for DC alternator The voltage regulator for the 12V DCalter nator is on the back of the air suction hou sing The housing is formed for cooling purposes The voltage regulator may not be covered from the outside The surface must be accessible for the cooling ...

Page 35: ...ith fuses and power relais F1 fuse 15A for DC F2 fuse 25A for starter Ks relay for starter K2 relay for glow plugs K3 relay for fuel pump Fig A 3 5 10 Termianl block Time relay for stop solenoid Fig A 3 5 11 Time relay for stop solenoid Electric starter control unit Fig A 3 5 12 Electric starter control unit F2 F1 K2 Ks K3 ...

Page 36: ...at the cylinder head serves the monitoring of the generator temperature All thermo switches for the generators from Panda 6 000 upward are two pole and laidout as openers Fig A 3 6 1 Thermoswitch at cylinder head Thermoswitch at exhaust elbow Fig A 3 6 2 Thermoswitch at exhaust elbow Thermoswitch at silencer The coolant gets here the highest value Fig A 3 6 3 Thermoswitch at silencer ...

Page 37: ...h is built into the system The oil pressure switch is on the back of the engine before the electrical starter Fig A 3 6 5 Oil pressure switch Thermoswitch in the generator coil 01 Thermo switch 02 Housing 03 Temperatuesensor NTC 981S für Meßzwecke For the protection of the generator coil there are two thermo switches inside the coil which are for inserted parallel and safety s sake independently f...

Page 38: ...Normally the filler neck for the engine oil is on the top side of the valve cover At numerous generator types a second filler neck is attached additionally at the opera ting side Please pay attention that the fil ter necks are always well locked after filling in engine oil Consider also the references to the engine oil specification Fig A 3 7 1 Oil filler neck with capl Oil dipstick At the dipstic...

Page 39: ...lter Oil drain hose The Panda generator is equipped that the engine oil can be drained over an drain hose The generator should be always installed therefore that a collecting basin can be set up deeply enough If this is not possible an electrical oil drain pump must be installed Note Lubricating oil should be drained in the warm condition Fig A 3 7 4 Oil drain hose ...

Page 40: ...A 3 8 Externe Komponenten Battery monitor Fig A 3 8 1 Battery monitor Voltage control VCS The control printed board controls the signals which are given for the actuator for speed regulation On the VCS board are also adjustment possibilities for the control parameters Fig A 3 8 2 VCS ...

Page 41: ...for a maximum of 20 seconds without a pause A pre glow period of 5 6 seconds suffices for ambient temperatures above 20 C plus For lower temperatures the preglow period should be increased Tips regarding Starter Battery Fischer Panda recommends normal starter battery use If an aggregate is required for extreme winter conditions then the starter battery capacity should be doubled It is recommended ...

Page 42: ...immediately exchange the pump because the dripping water will be sprayed by the belt pulley into the sound insulated casing and can quickly cause corrosion 4 Check all electrical Lead Terminal Contacts are Firm This is especially the case with the temperature switch contacts which automatically switch off the generator in case of faults There is only safety if these systems are regularly checked a...

Page 43: ...ause of at least 60 seconds is required If the aggregate does not immediately start then the fuel intake should be checked to ensure it is flo wing freely For temperatures below 8 C check whether there is winter fuel 7 Check circuit voltmeter to test whether there is AC voltage and is within the tolerance rage Frequency and voltage The AC voltage should be within a tolerance of 3 Volt without load...

Page 44: ...down Before stopping the generator it is highly recommended that electrical devices e g refrigerating compressors air conditioning compressors etc are switched off because the voltage drops as the rotational speed rpm decreases as the engine comes to a halt Also see information regarding voltage control with automatic shut off for protection of consu mers when over or undervoltage occurs This is a...

Page 45: ...be available below and on the side of the generator in order to allow flow of cooling air The radiator may not be covered Untrained personnel should never open the generator B 1 2 Connections Fig B 1 2 1 Connections 01 02 03 04 05 06 07 08 10 11 09 12 01 Passage for main battery 02 Passage for main battery 03 Connection fuel intake 04 Connection fuel output 05 Cable fuel pump 2x1 5mm 06 Cable remo...

Page 46: ...tial problems after longer shut off the generator If the return pipe cannot put as immersion tube into the tank it should be absolutely ensured by a non return valve in the sucking in line that the fuel cannot flow back after shut off the generator Basically the Panda is airing out After the first line up or after longer downtime the notes Ventila tion of the Fuel System should be considered see D...

Page 47: ...ectrical installati ons including all safety systems comply with all required regulations of the regional authorities This includes lightnening conductor personal protection switch etc B 2 1 Installation Panda AGT 12 V System Fig B 2 1 1 Installation Panda AGT 12 V System Schema 1 2 5 6 7 3 4 8 8 9 1 Generator 2 Battery block 12V 3 Battery monitor 4 Fuel pump 5 Remote control panel 6 Voltage contr...

Page 48: ... installations have to be made on board B 2 2 Installation Panda AGT 24 V system Optional Fig B 2 2 1 Installation Panda AGT 24 V System Schema 1 2 5 6 7 3 4 8 8 9 1 Generator 2 Battery block 24V 3 Battery monitor 4 Fuel pump 5 Remote control panel 6 Voltage control VCS 7 Starter battery 12V 8 Fuse 9 Battery switch ...

Page 49: ...itch of the starter motor position 1 The negative cable of the battery is attached underneath the starter motor at the engine mount position 2 ATTENTION It must be guaranteed that first the cables are attached at the generator and then at the battery To avoid large voltage drops the battery should be installed as near as possible to the generator The positive terminal of the battery is attached at...

Page 50: ...able for the measuring voltage must be attached directly at the bat tery and may not attached to the output of the electric rectifier By the voltage drop between generator and battery the accurate voltage can only recieved direct at the battery A false link can lead to damage the battery 06 03 04 01 05 07 09 02 08 01 Measuring voltage 24V 02 Measuring voltage 24V 03 Actuator 04 Actuator 05 Battery...

Page 51: ...d if the synchronised voltage should be less than the battery shut down voltage The the battery monitor may only be connected directly to the terminals of the battery and not to the output of the generator for example B 7 The fan control see fan control datasheet Temperature controlled adjustable speed control for one or two stage DC Fan The fan regulator must be mounted an a dry and well aired lo...

Page 52: ...roperly the individual generated phases from the generator must be checked between each other between phase and ground the single phase or 4th phase also needs to be checked in this fashion 5 If the generator is protected by a ground connection then ALL electrical devices must also be connected to this common ground usu ground contacts are attached to the devices metallic housings The electrical s...

Page 53: ...lectrical connections to ensure that they correspond to the main circuit diagram The inspection and correct labelling is especially critical for terminals L1 L2 L3 L1 N for the 230V 50Hz model and for terminals L1 L2 L3 N 1 2 4 for the 60Hz 120V models The electrician is therefore obliged before installation to check whether the generator is earth free As long as this test has not been carried out...

Page 54: ...ard without a radiator Various radiators are available according to the customer s requirements these can be chosen according to the appro priate operating and installation situation The cooling system can also be assembled together with a normal commercial vehicle radiator B 9 1 Connection of the external radiator Fig B 9 1 1 ERadiator connection Schema 1 1 1 Generator 2 Radiatorr ...

Page 55: ...diator s place of installation into consideration The manufacturer cannot accept liability for the recom mendations given to the best of his knowledge As a precaution attention should always be paid that the air outlet for escaping warm is as large as possible The vehicle paint sprayer is often not in agreement with this but the person making the installation must make the aim clear The fitter mus...

Page 56: ...the performance ATTENTION The coolant pressure may however not exceed 0 7 bar Construction and position of the radiator The radiator can be assembled away from the generator in a well ventilated position Attention must be paid that the radiator emission direction is completely free of obstruction Turbulence is to be avoided There is often a clash between the streamline appearance of the chassis an...

Page 57: ...anged one time a year Fig B 9 1 2 Radiator fan Distance from the radiator to the unit The coolant water pump mounted on the generator is so laid out that a distance of up to 7 mtrs length from the radiator is possible The hose cross section must be laid out accordingly The minimal internal diameter amounts to 18mm Panda 4500 A hose must be used for both sides forward and back flow which is resilie...

Page 58: ...t be regularly checked in the interests of safety The antifreeze solution supplied from the factory provides protection to 15 C If lower temperatures are occasio ned during transportation or storage then the coolant must be drained The cooling system is however so arranged that the draining of the coolant is only possible in the assembled state when air under pressure is blown into the system Air ...

Page 59: ...ator An air separator must be fitted at all critical places in the circulation system in case a perfect automatic ventilation on account of obstacles in the pipe passage cannot be achieved A self actuating ventilation valve must be fitted to each air separator Monitoring the Temperature You are expressively advised to measure the temperature of the circulating coolant after installa tion Two remot...

Page 60: ... be a last resort It is only applicable if the generator tem perature exceeds the permissible value on account of inaccessible working conditions It must then be explained which measures are necessary to restore normal operating conditions Recording the temperature values Installation records are delivered with every handbook which must be completed after installation and returned to the manufactu...

Page 61: ...allation Instructions Page59 Fig B 9 1 3 Connection of the Generator to the Vehicle Cooling System 4 6 5 1 2 3 7 1 Exhaust pipe 2 Water cooled pre silencer 3 Combustion motor 4 Coolant expansion tank 5 Vehicle combustion engine 6 Vehicle radiator 7 Fan for radiator ...

Page 62: ...ystem which can then also operate as a Bypass No liability is assumed when a recommendation is made by the generator manufacturer to con nect the generator to the motor cooling system The person making the installation must also ensure in this case that all conditions of this type are considered It should also be considered that the vehicle thermostat or the thermo switch must be adjusted to the s...

Page 63: ...asier by pro ducing excess pressure by means of the above mentioned ventilation pipe The process is eased considerably in that a transparent ventilation hose draws in air this can also be carried out by mouth if done cautiously Meanwhile the coolant expansion tank should at the same time be refilled with water The generator can be started as soon as the drawn in water is seen in the ven tilation p...

Page 64: ...n diagram for vertical radiator 02 07 03 06 05 01 04 09 11 08 10 01 External fan control 02 Coolant expansion tank 03 Ventilation pipe 04 Ventilation screw 05 Fan for radiator 06 Radiator 07 Stop valve for coolant 08 Thermoswitch 09 Bucket with submerged pump 10 Water cooled pre silencer 11 Internal cooling water pump ...

Page 65: ... 01 08 09 11 12 02 10 13 01 Water cooled pre silencer 02 Water cooled exhaust elbow 03 Coolant expansion tank 04 External fan control 05 Dry silencer 06 Exhaust outlet 07 Pipe with connection for Thermoswitch 08 External cooling water pump 09 Stop valve for coolant 10 Pipe with connection for Thermoswitch 11 Radiator 12 Fan for radiator 13 Bucket with submerged pump ...

Page 66: ...r B Installation Instructions Fig B 9 1 6 Installation diagram for radiator on the roof 2 6 3 5 4 1 1 Ventilation pipe 2 Radiator horizontal 3 Coolant expansion tank integrated 4 T piece for Ventilation pipe 5 External cooling water pump 6 Bucket with submerged pump ...

Page 67: ...tallation Instructions Page65 Fig B 9 1 7 Installation diagram with special air separator 2 7 6 1 4 5 3 1 Ventilation pipe 2 Coolant expansion tank 3 T piece for coolant expabsion tank 4 Water cooled pre silencer 5 Exhaust output 6 Special air separartor 7 Radiator ...

Page 68: ...10 2 Exhaust connection for mounting below the vehicle 3 2 1 4 5 6 7 8 1 Exhaust port 2 Generator 3 Roof outlet for exhaust pipe 4 Shock absorber 5 External pre silencer 6 Connection pipe 7 External silencer 8 Exhaust pipe 1 2 3 4 5 6 7 8 1 Generator 2 Exhaust port 3 Compensator 4 External pre silencer 5 Shock absorber 6 Connection pipe 7 External silencer 8 Exhaust pipe ...

Page 69: ...1 C 2 Oil Circuit Maintenance The laid down intervals must be heeded in order to avoid serious damage to the motor The first oil change should be carried out 35 hours after running time Thereafter every 100 hours SAE 30 is to be used for temperatures over 20 C and SEA 20 for temperatures between 5 C and 20 C Viscosity SAE 10W or 10W 30 is laid down for temperatures below 5 C Required oil See Table...

Page 70: ... countering use a second wrench Fig C 2 2 Pil drain screw Oil drain pump If discharging of the oil is not possible we recommend the employment of a hand pump which can be attached to the oil drain hose Afterwards the oil drain screw is closed again Fig C 2 3 Oil drain pump Oil filter change The oil filter can be loosen with an oil filter strap Fig C 2 4 Oil filter 13 ...

Page 71: ... only by hand Fig C 2 5 Oil filter gasket Open the oil filler neck After opening the cap of the oil filler neck the new oil is refilled Please wait instant before measure the oil level the oil must set off in the sump Fig C 2 6 Oil filler neck With the help of the engine oil dipstick the oil level is to examined The prescribed fil ling level may not exceed the Max mar king We recommend 2 3 oil lev...

Page 72: ...bypass switch and hold tight The electric fuel pump has to be running audibly By moving the failure bypass switch you can hear the solenoid valve of the generator star ting and stopping when the sound cover is taken off Fig C 3 1 Failure bypass switch After the fuel pump has been running 3 to 4 minutes because the failure bypass switch has been pushed down the bleeding screw of the solenoid valve ...

Page 73: ...has to be tightened again Fig C 3 3 Injection nozzle The injection line must be raised some mil limeters Main power switch OFF Fig C 3 4 Injection nozzle C 3 1 Exchange of the fuel filter The exchange of the filter depends on the contamination of the fuel should take place at least all 300 operation hours Before the exchange of the filter the inlet must be clamped Remove the hoses from the used fi...

Page 74: ... system If the coolant has been drained or if air has permeated into the cooling system by other reasons a careful ventilation of the cooling system is necessary This ventilation process has to be rerun ned several times Open ventilation screw at the internal coo ling water pump Fig C 4 1 Ventilation screw Open ventilation screw at the thermostat housing Fig C 4 2 ventilation screw ...

Page 75: ... the cooling water filler cap The coolant flows in very slow External Radiator If you notice that the coolant level don t falls anymore close bleed screws and start the generator Fig C 4 4 External radiator The generator should operate up to 60 Seconds Switch generator OFF Open coolant filler cap again and the bleed screw at the same time Pour in coolant again Fig C 4 5 Cooling water filler neck ...

Page 76: ...radiator should be vertically installed or even under the vehicle floor so that an external balance container is used filling up may only happen over this balance container and not over the radiator Now the cooling water is only filled over the external expansion tank This is connected by a hose with the gen set The external expansion tank should be filled in the cold condition only up to maxi mal...

Page 77: ...bout 85 C can be a reason for a reduced lifespan of the v belts It is possible that the softener in the rubber com pound lose their effect after a short operating time because the air in the sound insulated capsule can be relative warm and dry The v belt must be controlled in a very short time interval It can be happen to change the v belt after some weeks because of unfavorably conditions Therefo...

Page 78: ...tor Press the alternator to the direction of the thermostat housing Now the v belt can be changed type Gates XPZ 850 Stretch the v belt by pulling the return pul ley back Fig C 6 2 Alternator 12V The drive belt should be able to be pres sed approx 10mm with the thumb Tighten the fixing screws above and below the return pulley Fig C 1 V Belt For all maintenance and service requirements see the chec...

Page 79: ...ned so as not to overheat even under extreme conditions Note The exhaust gas will become sooty during peak load operation Effects of Short Circuiting and Overloading on the Generator The generator cannot be damaged by short circuiting or overloading Short circuiting and over loading suppress the magnetic excitation of the generator thus no current is generated and the voltage will collapse This co...

Page 80: ...voltage Such a voltage relay can be obtained from wholesale dealers or as a complete unit from PANDA dealers The circuit is always automatically cut off if the generator is stopped D 1 2 Adjusting Instructions for the Spindle of the actuator There are two independent regulation devices for the rev range of the generator Limited upward and downward With the regulation nuts at the spindle of the act...

Page 81: ...rev of the generator by turning the spindle of the actuator manually until the volt meter reach a value of 33V DC 7 Turn the limit stop screw tight against the limit stop point at the rev regulator lever 8 Protect the limit stop screw with the countering nut 9 Check again if the voltage of the generator is limited to max 33V without load The adjustment of the upper limitation of the rev serves an ...

Page 82: ...ator 6 Decrease the rev of the generator by turning the spindle of the actuator manually until the volt meter reach a value of 23V DC 7 Both nuts must be screwed tight 8 Check again if the lower voltage of the generator is limited to min 23V without load Adjusting the upper limitation 1 Proceed like before and tighten the countering nuts at a voltage of max 33V without load 2 Check again if the up...

Page 83: ...overloaded the voltage falls on account of a not adequate motor power under the nominal value The actuator stays at the upper keystroke and tries to rev up the diesel engine An internal regulation limits the current to the actuator nevertheless a longer overload can damage the winding of the actuator short of the winding The motor gets not strictly inoperative but it can happen that the cranking t...

Page 84: ...onstant overload of the generator Steps to check the voltage control by a disturbance 1 Switch off all electrical consumers 2 Disconnect the plug of the actuator 3 Turn the actuator manually to check if the adjusting nut is jamed to the limit stop points 4 Turn the actuator manually to check if the adjusting nut on the spindel runs faultless The spin dle has a clockwise rotating thread use a wrenc...

Page 85: ...gnal for the actuator is wired Change the VCS printed circiut board if the points above carries no clearance Check the limitation of the generator voltage The mechanical voltage limitation must be checked regularly The following steps have to be done 1 Disconnect the plug of the actuator 2 Switch off all consumers 3 Connect an electrical voltmeter 4 Start the generator 5 Turn the actuator manually...

Page 86: ...he individual windings connections If continuity is detected for any of the combinations the generator must be sent to the factory for inspection and repair If this is not possible the stator can be rewound by a qualified tradesper son technician Winding diagrams can be obtained from Fischer Panda GmbH Germany This test unfortunately is carried out at very low voltage 9V when a normal multimeter i...

Page 87: ...you meter together you should get a reading of 0 00Ohm When you isolate the probes the reading will be Overflow Please do this tests to check your meter Measure of the resistance within the individual windings The values should be very small It mainly depends on the relation between the values Some measuring instruments operate very inaccurately if the measured values are very small Resistance mea...

Page 88: ...erden Hierzu ist ein Spezialmeß gerät erforderlich mit dem die Induktivität einer Wicklung gemessen werden kann Die Induktivität wird in der gleichen Weise gemessen wie auch der Ohmsche Widerstand d h es werden die Wicklungsteile verglichen Der Wert wird in mH milli Henry angegeben Beachte Diese Werte hängen stark von der Messmethode ab z B Qualität des Messgerätes An alternative test method to ch...

Page 89: ...short period whilst in operation first remove the small retention screw and replace it immediately The motor should react immediately by revving high If the motor does not react sharply to the recon nection of the solenoid wire it is a sign that the solenoid valve could be faulty 2 Solenoid for engine stop The solenoid for engine stop is located at the injection pump 1 Energized to stop By pressin...

Page 90: ... an immediate restart facility of the generator should it cut out even if this was caused by over heating There is normally a requirement to wait until the motor has cooled down to the correct temperature This can last for several hours in certain cir cumstances since the generator is enclosed in a sound insulated casing which prevents heat loss Failure bypass switch Fig D 3 2 1 Failure bypass swi...

Page 91: ...t the motor is cooled by the circulating coolant BEWARE If the temperature is the reason for the generator cutting out when it is running under load then an immediate check must be made to determine the cause It could be a fault with the cooling system one of the fans the air intake or a fault with the external cooling system Continual use of the starter failure bypass switch should be avoided whi...

Page 92: ...Generator Failure Page 90 AGT 6000 PVMV N 12V_24V Chapter D Generator Failure ...

Page 93: ...X X Check all sensors switches a Coolant temperature sensor b Exhaust temperature sensor c Oil pressure sensor X X X X X X X X X X X Check all securing and fastening screws a All base mount screws b Exhaust manifold screws c Starter fixing d Connection screws generator engine X X X X X X X X X X X Check all electrical cables X X X X X X X X X X X Check battery X X X X X X X X X X X Idle run voltag...

Page 94: ...determined by SAE class SAE is for the union of American engineers Society of Automotives Engineers The SAE class of an engine oil only informs over the viscosity of the oil larger number more viscous lower number more highly liquidly e g to 0W 10W 15W 20 30 40 The first number shows the liquid of cold wea ther the second number refers to the fluidity with heat Complete yearly oils have usually SA...

Page 95: ...f safety Fischer Panda recommend to use the product GLYSANTIN PROTECT PLUS G 48 Engine coolant automotive industry Product description Product name GLYSANTIN PROTECT PLUS G48 Chemical nature Monoethylenglykol with inhibitors Physical form Liquid Chemical and physical properties Reserve alkalinity of 10ml ASTM D 1121 13 15 ml HCl 01 mol l Density 20 C DIN 51 757 procedure 4 1 121 1 123 g cm3 Water ...

Page 96: ...ine is running at the wrong speed Check the speed of the motor with a rev or frequency counter set the correct speed VCS voltage controler defective or wrong adjusted Check resp renew Actuator defective Check resp renew GENERATOR VOLTAGE FLUCTUATES Cause Solution 1 Fault or defect on the consumer side 2 A motor fault 1 Check if the power requirement of the consumer fluctuates 2 See Motor running i...

Page 97: ...G PROCESS Cause Solution Starter battery voltage insufficient Check battery Damaged bearing s piston seized Repairs need to be carried out by Kubota Service refer to Kubota motor manual Cooling water in combustion chamber 1 Turn generator OFF at control panel 2 Remove the glow plug see Kubota manual 3 Rotate the motor by hand carefully 4 Check if there is water in the oil and change both oil and f...

Page 98: ...use Solution Fuel solenoid valve or throttle shut solenoid is not swit ching off Check wire connections to solenoid Check valve functions as in the Inlet Fuel Solenoid Valve or in the trottle shut off solenoid sections Replace if necessary MOTOR STOPS BY ITSELF Cause Solution Lack of fuel Check fuel supply system Excess heat in cooling system thermo switch tripped lack of cooling water Is indicate...

Page 99: ...es dark motor overheats oil pressure drops oil light suddenly flashes Refer to respective section of manual and if necessary have repaired by Kubota Service or Panda represen tative TROUBLESHOOTING VCS SYSTEM Cause Solution Actuator does not move Check voltage supply and wire connections to actuator Motor connected Check connection to VCS Actuator sets throttle too high or too low Check that the w...

Page 100: ...Appendix Page 98 AGT 6000 PVMV N 12V_24V Chapter E Appendix ...

Page 101: ...r head nut torque 42 Nm Compression ratio 23 1 Lubrication oil capacity 2 5 l Fuel consumption a a 0 35l kW electrical power the randomized values between 30 and 80 of the power rating ca 0 63 1 687 l Oil consumption max 1 vom Kraftstoffverbrauch Permissible max permanent tilt of engine a 25 que r zur Längsachse b 20 in Längsrichtung E 5 Technical Data Generator Generator Panda AGT 6000 PVMV N Per...

Page 102: ...Page 100 AGT 6000 PVMV N 12V_24V Chapter E E 6 Capsule Measurements ...

Page 103: ...CS AGT U I 72V 60mV F1RORE9627 012 212 80V VCS AGT U I 80V 60mV auf Anfrage on request 96V VCS AGT U I 96V 60mV auf Anfrage on request 115V VCS AGT U I 115V 60mV F1RORE9627 120 120V VCS AGT U I 120V 60mV F1RORE9627 144 144V VCS AGT U I 144V 60mV F1RORE9627 180 180V VCS AGT U I 180V 60mV auf Anfrage on request 300V VCS AGT U I 300V 60mV auf Anfrage on request 320V VCS AGT U I 320V 60mV auf Anfrage ...

Page 104: ...schreibung 1 Actuaror A Out for actuator 2 Actuator A Out for actuator 3 12V E Operation voltage 12V Automotive 4 0V E Operation voltage 12V Automotive 5 AC Controllamp A to 0V Optional 6 VCS on E 12V VCS is on open VCS is off 7 Mesurement voltage E Mesurement voltage from the generator 8 Mesurement voltage E Mesurement voltage from the generator 9 Mesurement current E Mesurement current from the ...

Page 105: ...VCS its like that there is no voltage The voltage control in this vase ist out of funktion It is necessary at the installation to check the right working of the VCS and a second overvoltage protection must be installed For the mesurement voltage a shieldet cable is needet it must be less than 3 mtr long The shield should be connected to ground at one side Note the safety instruction in the generat...

Page 106: ...VCS AGT U I Page 104 Chapter A VCS AGT U I VCS AGT UI_eng fm Fischer Panda Datasheet blank ...

Page 107: ...0_05 06 2007 Rev 1 2_24 02 2004 Replace Rev 1 0_24 02 2004 Rev 1 2_24 02 2004 Replaced by Fig A 1 Battery monitor A 1 Safety instructions See the safety instruction of your Generator and all other parts of your system Electrical power DANGER TO LIVE Electrical voltages above 48 volts battery chargers greater than 36 volts are always dan gerous to life The rules of the respective regional authority...

Page 108: ...ng polarity of the exit can lead to the destruction of the battery guard as well as attached devices The battery monitor is setup for a definied voltage i e 24V or 36V It is not possible to change these voltage charging rate max 7mADC output clamp 7 positive clamp 8 negative max operation voltage 35VDC max backward voltage 4VDC max operation current 10mADC output is electrically isolated from the ...

Page 109: ...of rotation of the trimmers Turn in the clockwise direction larger value By a drilling below clamp 1 is accessible with a small screwdriver a tracer which makes it possible for test purpo ses to switch between the two switching status back and forth This functioned however only if the battery voltage is within the adjusted borders Outside of the limit values the battery guard cannot be affected by...

Page 110: ...r Norm Urspr Ers d Ers f Blatt 1 Bl von 1 Zust Änderung Datum Name Zeichnungsnummer D 33104 Paderborn Otto Hahn Str 32 34 www fischerpanda de 49 0 5254 9202 0 Projektnummer Fischer Panda Generatoren Fischer Panda GmbH Bröckling 070042_00_00 070042_00_00 11 06 2007 RE 9517 batterymonitor switching on Output Panel clamp 13 Output Panel clamp 14 twisted and screened U Battery Voltage conrol 1 2 7 8 1...

Page 111: ...tic controller for DC fan Seite Page 109 Fischer Panda Datenblatt Datasheet A Intelligent stepless automatic controller for DC fan 23 04 2007 New layout of the Datasheet l Art Nr F1RORE0201V11 Bez Intelligent stepless automatic controller for DC fan Document Hardware Software Actual Rev 2 1_23 04 2007 Replace Rev 01_07 04 2004 ...

Page 112: ...r position In the middle Poti Freq Adjusting of the PWM frequency Desired to many customers a potentiometer was added for changing the PWM frequency A selection of the frequency between approx 1 7 and 3 5kHz is possible which can serve for the avoidance of unwanted oscillation resonances Ex factory a PWM frequency of 2 kHz is adjusted Function of the temperature sensors NTC resistance extern und i...

Page 113: ...If the temperature sensor for the output stage is defective or the feeder line to it interrupted cable break then this is indicated over the LED The fan controller continues working normally 3 Overheating of the output stage If the output stage of the fan controller becomes too hot then this switches itself off Please read in addition the description of the function of the internal temperature sen...

Page 114: ...mp 13 is the signal and at clamp 14 is ground A 1 4 Remote controlled switching on and off of the fan controller he fan controller can be switched on and or off over the connection ON clamp 9 If at connection ON lies the same voltage as at the connection BAT the fan controller is switched on If at connection ON lies no voltage the fan controller is switched off If this option is not needed then th...

Page 115: ...ge Main fuse flat fuse on the printed circuit board 12V operation 50A flat fuse 24V operation 30A flat fuse Output fuse plug fuse onthe terminal block each two pieces 12V operation 25A plug fuse 24V operation 20A plug fuse A 2 Technical Data Characteristics closed current electronics off 0 5mA closed current electronics on 10 15mA Benchmark figure of the temperature control fan start up 60 C 80 C ...

Page 116: ...ominal voltage fan 24 VDC Maximum ratings Transformer operation 12V sieving in the power supply 10000µF 63V denpending on the load current data for secondary winding after rectfication sieving nominal load operating voltage continuity 11 VDC 14 4 VDC load operating voltage 15min 16 0 VDC maximum load operating voltage 3 sec 17 VDC idle speed operating voltage continuity 28 VDC maximum idle speed o...

Page 117: ...02 open main fuse 30A installed output fuse 20A installed For 12V operation the installed fuses must be exchanged against the provided fuses as described above The pre resistors for the operating voltage of control electronics must be configured like above described Assembly Vertical on standard rail pay attention to good ventilation At breach of specification can destroy one or more components of...

Page 118: ...Intelligent stepless automatic controller for DC fan Seite Page 116 Kapitel Chapter A Intelligent stepless automatic controller for DC fan RE0201_V1_UserDoc_r10_eng fm Fischer Panda Datenblatt Datasheet ...

Page 119: ...m Kapitel ChapterA Remote Control Panda 6 50 Seite Page 117 Fischer Panda Datasheet A Remote Control Panda 6 50 Art Nr F1WT1 95E730 Bez Remote Control Panel for Panda 6 50 Dokument Hardware Software Aktuell R02 02 07 2007 Replace R1 15 05 07 Fig A 0 1 Remote control panel ...

Page 120: ...control includes on switch pre heat starting and stopping generator functions The remote control panel is equipped with some new monitoring functions which increase the operational safety of the generator A failure message is shown over contacts which are normally closed If a connection is intermit ted a failure message is triggered The generator may not be run without the remote control panel Fig...

Page 121: ...ge and a sensor for speed pick up are additionally neces sary in addition to the automatic start option See Component Automatic Start A 3 Operation instructions A 3 1 Preliminary remark Pre heating the diesel motor The motor must be pre heated if the diesel motor is designed as a pre combustion chamber motor for indirect fuel injection A quick glow fitting is used for all Kubota diesel motors This...

Page 122: ...mmediately repaired especially the raw water impeller pump It is certainly possible that the raw water impeller pump will produce leaks depending upon the situation This can be caused by sand particles in the raw water etc In this case immediately exchange the pump because the dripping water will be sprayed by the belt pulley into the sound insulated casing and can quickly cause corrosion 6 Check ...

Page 123: ...s to be made then a pause of at least 60 seconds is required The generator can be started with the assistance of a pre heating device at temperatures as low as 20 C Please note that the gene rator can only be run at temperatures below 8 C with winter fuel and additional special additives 6 Press START button The electric starter may only be used for a maximum of 20 seconds Thereafter a pause of at...

Page 124: ...osi tion should overheating cause the generator to shut down because of overheating ATTENTION Before using the failure bypass switch it is important to check the oil level since the oil gauge is deactivated by the switch For a further reason it is important to switch off the generator electrical load before the generator is shut down Before stopping the generator it is highly recommended that elec...

Page 125: ... the fuse if it is defective 1 Fuse on the control panel board 630 mA slow to blow Fig A 3 7 1 Remote control panel back side A 3 8 Installation assembly kit automatic start optional F1WT5 95702 An automatic feature can be supplied as an accessory for all Panda generators Panda 8000 upwards This automatic feature consists of an additional board which can be installed into the back of the remote pa...

Page 126: ...ure to the remote control panel Fig A 3 8 1 Automatic start assembly kit Automatic Feature Assembly Assembling the automatic feature can be carried out by simply attaching the additional board to the standard remote control panel Attention must be paid that the standard plug forms a correct connection Ensure that the plug is centrally placed in the socket The board is then fixed to the remote cont...

Page 127: ...atic start kit Important information The generator can only be re started after 45 sec if the generator is stopped by means of the remote panel automatic stop control If the generator prematu rely starts the motor is again stopped after 10 sec running time The automatic starting process is disregarded if an automatic start is required and the remote control functions are switched off An automatic ...

Page 128: ...ooth and screwed in until it touches the tip of the tooth ATTENTION Ensure that when inserting the sensor that the sensor tip is not screwed into the root of the gear tooth The screw is subsequently turned anticlockwise by half a turn 0 3 to 0 8mm and held by a counter nut 1 Speed sensor on threaded seat 2 Engine Flywheel with gear teeth 3 Generator housing 4 Retention tightening nut ATTENTION For...

Page 129: ...control panel had been switched on A 4 Slave Panel optional The Slave Panel has the same buttons and function as the main panel To connect the slave panel with the main panel use the small adapter board delivered together with the slave panel For more details see slave panel datasheet Fig A 4 1 Slave panel A 5 Slave panel and automatik start togther optional To use the automatik start option toget...

Page 130: ...CMOS Inverter 1 2 3 1 2 3 R1 DC alternator setup J1 J2 link of 1 and 2 J1 J2 link of 2 and 3 P6 10 P12 P85 Relay NC normally closed only with inverter C MOS 4049 NO normally open without the chip for remote start circuit J1 J2 oil temp for generators up to 11 2000 voltage fault for generators from 11 2000 if no waterleak sensor is connected it has to be bypassed link 1 2 R68 6W R1 P25 with BOSCH D...

Page 131: ...chönberger Plan Bröckling Panel Slavepanel von 1 070030_00_00 070030_01_00 02 07 2007 Option Slave Panel 20 1 12V DC 2 air filter con 3 Fuel level 4 GND 5 Heat sig 6 Start sig 7 On sig 8 Off sig 9 main pan on 10 oil press 11 AC ok 12 T_engine 13 T_winding 4 air filter 5 fuel level 1 12V 5 oil press 12 T winding 11 AC Power fault 10 start relay 9 fuel relay 8 preheat 7 AC output ok 6 12V contrl 4 w...

Page 132: ...Remote Control Panda 6 50 Seite Page 130 Kapitel Chapter A Remote Control Panda 6 50 F1WT1 95E730 Panda 6 50 Fernbedienpanel_eng fm Fischer Panda Datasheet Intentionally Blank ...

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