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Fischer Panda Panda 25i PMS, User Manual

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Fischer Panda Panda 25i PMS User Manual Download Page 111

Maintenance Instructions

20.7.15

Kapitel/Chapter 7: Maintenance Instructions   -   Seite/Page 111

7.12 Replacing the DC Alternator

NOTE:Representative procedure

The described procedure is representative for Fischer Panda 
generators. The original location of the item must be taken 
from the generator description of this manual. All 
replacements and repairs should be done by a trained 
person.

ATTENTION!

Ensure that the generator cannot be started up 
accidentally. Remove battery main switch.

For part numbers, refer to the spare parts catalogue.

Fig. 7.12-1: DC alternator

1. Open the capsule.

01. DC alternator 

Fig. 7.12-2: DC alternator

Figures similar!

2. Remove cable ties.

01

Summary of Contents for Panda 25i PMS

Page 1: ...Panda_25i_System_eng R04 20 7 15 Panda 25i PMS Super silent technology 230 V 50 Hz 25 kVA 400 V 50 60Hz 25 kVA 120 V 240 V 60 Hz 25 kVA...

Page 2: ...l 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 wit hout previous notice...

Page 3: ...generators 22 1 6 1 1 Protective conductor and potential equalisation 23 1 6 1 2 Protective conductor for Panda AC generators 23 1 6 1 3 Switch off all loads while working on the generator 23 1 6 1 4...

Page 4: ...raw and freshwater 46 4 4 2 The fuel and combustion air circle 47 4 4 3 Components of the electrical system 48 4 4 4 The lubrication oil circuit 49 4 4 5 Sensors and switches for operating surveillanc...

Page 5: ...ttery block 85 5 10 2 How to connect two 12V batteries to a 24V battery bank 88 5 10 3 Connection of the remote control panel See Panda iControl panel manual 89 5 11 Generator AC system installation 8...

Page 6: ...s 121 7 17 Replacing the Glow Plugs 124 7 18 Replacing the valve cover gasket at Kubota 02 series 126 7 19 Replacing the Water Pump at Kubota 02 series 127 7 20 Adjusting the valve clearance at Kubota...

Page 7: ...namic current limiter 164 10 7 2 Settings in the Victron VE Configure II Software Inverter 165 10 7 2 1 Assist current boost factor 165 10 8 Operation manual 166 10 8 1 Primary remarks Winter operatio...

Page 8: ...12 4 1 Set up menu 195 12 4 2 Setting the brightness of the backlight backlight and dimtime 196 12 4 3 The configuration menu config 197 12 4 4 The network ID 197 12 4 5 Saving settings and exiting t...

Page 9: ...2 1 Cleaning the iControl2 controller 209 15 Warnings and error messages 211 15 1 Warnings 211 15 1 1 Examples of warnings on the display 211 15 1 2 Warning messages 212 15 2 Faults 212 15 2 1 Error...

Page 10: ...Seite Page 10 Kapitel Chapter 1 20 7 15 Leere Seite Intentionally blank...

Page 11: ...rried out 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...

Page 12: ...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 13: ...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 14: ...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 15: ...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 16: ...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 17: ...eral Instructions and Regulations 20 7 15 Kapitel Chapter 1 General Instructions and Regulations Seite Page 17 Clamp on ammeter DC for synchronous generators AC for asynchronous generators Torque wren...

Page 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...ood the manual and that 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...

Page 31: ...service list Generator manual Spare parts catalogue Installation Service Guide Engine manual from the engine manufacturer Wiring diagram of the generator Optional components Optional components could...

Page 32: ...n the metal tab closures at the bottom of the transport box 5 Remove the sidewalls 6 Open the generator attachment 3 5 Opening the MPL sound insulation capsule Fig 3 5 1 Sound insulation capsule side...

Page 33: ...e GFK sound insulation capsule Fig 3 5 1 Lash closures GFK sound insulation capsule with lash closures Fig 3 5 2 Lash closures To open the lash closures pull the handle in arrow direction and lift the...

Page 34: ...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 35: ...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 36: ...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 37: ...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 38: ...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 exhaust...

Page 39: ...nda 25i PMS generator 20 7 15 Kapitel Chapter 4 Panda 25i PMS generator Seite Page 39 4 Panda 25i PMS generator 4 1 Type plate at the generator Fig 4 1 1 Panda 15000i PMS generator Fig 4 1 2 Type plat...

Page 40: ...03 04 05 02 06 07 08 10 09 12 14 11 13 01 Thermostat housing 02 DC alternator 03 Oil pressure switch 04 Oil filter 05 Exhaust out 06 Raw water injection pipe 07 Cooling water return pipe 08 Starter mo...

Page 41: ...take 02 Generator housing with coil 03 Sound cover base part 04 Oil dip stick 05 Generator terminal box 05 Impeller filter 06 Actuator 07 Housing with iControl electronic board DO NOT OPEN 08 Raw wate...

Page 42: ...ater intake 05 Fuel IN 06 Fuel OUT 07 Cable for fuel pump 08 Cable for iControl panel 09 Cable for generator output AC out to inverter 10 Cable for inverter control 11 Connection point for external ve...

Page 43: ...MS generator Seite Page 43 4 2 4 Back view Fig 4 2 4 1 Back view 06 02 01 05 03 04 01 Generator front cover 02 Sound cover base part 03 Connection from external expansion tank 04 Connection to externa...

Page 44: ...01 Air suction housing 02 Thermoswitch cylinder head 03 Suction hose air suction housing induction elbow 04 induction elbow 05 Stop solenoid 08 Ventilation screw internal cooling water pump 09 Ventil...

Page 45: ...ata 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 4 4 1 Panda iControl 2 panel Notice See remote...

Page 46: ...Panda 25i PMS generator Seite Page 46 Kaptitel Chapter 4 Panda 25i PMS generator 20 7 15 4 4 1 The cooling circuit raw and freshwater Fig 4 4 1 1 Cooling system...

Page 47: ...Panda 25i PMS generator 20 7 15 Kapitel Chapter 4 Panda 25i PMS generator Seite Page 47 4 4 2 The fuel and combustion air circle Fig 4 4 2 1 Fuel air intake and exhaust system...

Page 48: ...Panda 25i PMS generator Seite Page 48 Kaptitel Chapter 4 Panda 25i PMS generator 20 7 15 4 4 3 Components of the electrical system Fig 4 4 3 1 Electrical system...

Page 49: ...Panda 25i PMS generator 20 7 15 Kapitel Chapter 4 Panda 25i PMS generator Seite Page 49 4 4 4 The lubrication oil circuit Fig 4 4 4 1 Lubrication system...

Page 50: ...witch at engine The thermo switch at the engine is used for monitoring the engine tempera ture Fig 4 4 5 2 Thermo sensor at exhaust connection Thermo sensor at exhaust connection If the impeller pump...

Page 51: ...anda iControl panel manual 4 6 1 Daily routine checks before starting See Panda iControl manual 4 6 2 Starting generator See Panda iControl manual 4 6 3 Stopping the generator See Panda iControl manua...

Page 52: ...Seite Page 52 Kapitel Chapter 4 Panda 25i PMS generator 20 7 15 Leere Seite Intentionally blank Panda 25i PMS generator...

Page 53: ...l situation Damages caused by faulty or incorrect installation are not covered by the warranty 5 1 Personal requirements The described installation must be done by a technical trained person or a Fisc...

Page 54: ...ages 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 Only an electrician may carry out installation...

Page 55: ...xing the generator on a slippery surface with little mass i e plywood This acts as an amplifier of airborne sounds in the most unreasonable case An improvement can be achieved by reinforcing these sur...

Page 56: ...160 F The on board circuit must also be fitted with all essential fuses For the original location of the connection points see the generator description 5 4 Installation of the cooling system raw wate...

Page 57: ...ions Seite Page 57 Fig 5 4 2 3 Adapter Adapter Fig 5 4 2 4 Raw water filter Raw water filter Fig 5 4 2 5 Spiral coiled tube with metal spiral bead Spiral coiled tube with metal spiral bead Fig 5 4 2 6...

Page 58: ...waterline The Panda is equipped with a water intake pump mounted on the motor Since the intake pump is an impeller pump there are wearing parts which are likely to require replacement after a period o...

Page 59: ...r for many years without exchanging the old pump If the sealing ring is defective within the pump raw water runs into the sound cover of the genset A repair is then very expensive Replacement impeller...

Page 60: ...Installation Instructions Seite Page 60 Kaptitel Chapter 5 Installation Instructions 20 7 15 5 4 6 Raw water installation schema Fig 5 4 6 1 Raw water installation schema...

Page 61: ...itional hose and a connecting 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...

Page 62: ...rnal cooling 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 63: ...Seite Page 63 5 5 2 Scheme for freshwater circuit at two circuit cooling system Fig 5 5 2 1 Scheme for freshwater circuit at two circuit cooling system 1 Expansion tank 2 Exhaust manifold 3 Thermostat...

Page 64: ...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 5 6 1 1 Waterlock W...

Page 65: ...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 66: ...ust 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 67: ...the 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 w...

Page 68: ...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 69: ...eite Page 69 Fig 5 7 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 70: ...ally in tilted position by the waterlock moving out of the center line See the following pictures Fig 5 7 3 1 1 Ideal position of the waterlock In Fig 5 7 3 1 1 the waterlock is mounted in center unde...

Page 71: ...degrees Tilted position 45 degrees Fig 5 7 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 72: ...7 15 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 73: ...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 74: ...hat in a tilted position of 30 degrees you already face the highest risk of sea water sloshing into the combustion chamber Fig 5 7 3 2 4 Tilted position 45 degrees Tilted position 45 degrees Fig 5 7 3...

Page 75: ...istance between waterlock and the generator s center line 1000 mm Fig 5 7 3 2 5 waterlock 1000 mm next to center line Fig 5 7 3 2 6 Tilted position 15 degrees Tilted position 15 degrees Fig 5 7 3 2 6...

Page 76: ...ath 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...

Page 77: ...Installation Instructions 20 7 15 Kapitel Chapter 5 Installation Instructions Seite Page 77 Fig 5 8 0 1 Installation Scheme exhaust water separator...

Page 78: ...shortest 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 exh...

Page 79: ...allation Instructions Seite Page 79 Fig 5 9 1 1 Fuel hose Fuel hose representative picture Fig 5 9 1 2 No return valve No return valve representative picture Fig 5 9 1 3 Pre filter with water separato...

Page 80: ...e Fig 5 9 1 5 Quick connector for fuel lines Quick connector for fuel lines representative picture Fig 5 9 1 6 Hose clamps Hose clamps representative picture 5 9 1 1 The following items need to be ins...

Page 81: ...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 82: ...age 82 Kaptitel Chapter 5 Installation Instructions 20 7 15 Fig 5 9 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 valv...

Page 83: ...ed 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 period...

Page 84: ...tional fuel filters with water separator must be mounted outside the capsule in easily accessible places in the fuel lines between the tank intake fuel pump and the diesel motor s fuel pump Fig 5 9 3...

Page 85: ...Panda 6000 and higher normally provided with an alternator dynamo to charge the starter battery At generators without alternator dynamo it is needed to charge the starter battery with an external batt...

Page 86: ...in operation e g wheel exhaust elbow union tail pipe and the engine Do not lay the cable too tautly since otherwise it could be damaged Make a test run after the installation and check the laying of t...

Page 87: ...ge 87 Fig 5 10 1 3 DC Starter Motor DC Starter Motor All Panda generators are equipped with an independent DC starter motor 1 Solenoid switch for starter motor 2 Starter motor Fig 5 10 1 4 Connection...

Page 88: ...Fig 5 10 1 5 Connection starterbattery 24V schema 5 10 2 How to connect two 12V batteries to a 24V battery bank Fig 5 10 2 1 Installation starter battery The starter batteries have to be connected in...

Page 89: ...Disconnect the batteries in in reverse procedure 5 10 3 Connection of the remote control panel See Panda iControl panel manual 5 11 Generator AC system installation ATTENTION Danger to Life High volta...

Page 90: ...s cross sections are the minimum required sizes for a safe installation see section 9 2 Technical data on page 149 Fig 5 11 0 1 Electrical installation example Fig 5 11 0 2 Electrical installation par...

Page 91: ...d an unexpected starting of the generator the starter battery must be disconnected before start working at the generator Attention Danger to life Rotating parts inside of the generator Do not run the...

Page 92: ...ons 6 3 2 1 The soot of the generator is due to the fact that The cylinder temperatures are too low to ensure complete burning of all the fuel delivered A further result is that of abnormal carbon bui...

Page 93: ...ped with various sensors temperatures switches The combustion engine is further equipped with a oil pressure control switch which switches the motor off if the oil pressure sinks to a particu lar leve...

Page 94: ...et Note The instructions and regulations of the remote control panel data sheet must be respected Respect the safety instruction in front of this manual 6 7 Stopping the generator see remote control p...

Page 95: ...efore before starting work at the generator Make sure that the generator is stopped and the starter battery is disconnected to guarantee that the generator cannot be inadvertently started Do not run t...

Page 96: ...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 necessary During Ins...

Page 97: ...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 manual For generators with dyn...

Page 98: ...0 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 dipstick The oil level is to be checked by means of the...

Page 99: ...e Engine oil 1 Check oil level as described under section 7 6 Checking oil level on page 97 2 Oil dipstick is pulled out of the check rail 3 Open the oil filler cap 4 Fill in oil approx 1 2 litre and...

Page 100: ...erator 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 oil...

Page 101: ...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 102: ...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 97 When the proper filling level is reached screw in the oil cap agai...

Page 103: ...s Fig 7 8 1 1 1 Battery 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 t...

Page 104: ...rotective goggles 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 operati...

Page 105: ...id valve The button must continue to be pressed whilst opening the screw A large cloth or Kleenex tissue must be laid beneath the connection to prevent escaping fuel running into the capsule If the fu...

Page 106: ...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 107: ...icate 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 supp...

Page 108: ...s The original location of the item must be taken from the generator description of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cann...

Page 109: ...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 110: ...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 111: ...original location of the item must be taken from the generator description of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cannot be...

Page 112: ...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 113: ...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 114: ...Page 114 Kaptitel Chapter 7 Maintenance Instructions 20 7 15 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 115: ...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 116: ...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 117: ...tors The original location of the item must be taken from the generator description of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator c...

Page 118: ...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 119: ...r compounds may partially lose their effectiveness 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 che...

Page 120: ...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 121: ...l location of the item must be taken from the generator description of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator cannot be started...

Page 122: ...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 123: ...the screwdriver 1 into the hole in the heat ring seal 2 Rotate the screwdriver three to four times in each direction 3 When rotating the screwdriver slowly extract the heat ring seal 4 together with t...

Page 124: ...The original location of the item must be taken from the generator description of this manual All replacements and repairs should be done by a trained person ATTENTION Ensure that the generator canno...

Page 125: ...nstructions Seite Page 125 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 126: ...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 127: ...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 128: ...o 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 129 3 Rotate crankshaft 360 The valve is then closed as the cam shaft was...

Page 129: ...Cam follower 3 Push 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 V...

Page 130: ...n the air suction 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 A...

Page 131: ...131 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 132: ...sing by loosening the closure on the 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...

Page 133: ...over of the external expansion tank must be opened temporarily all other closures are now closed Sample picture Fig 7 20 4 2 Venting screw at the pipe socket 2 Open the venting screw at the pipe socke...

Page 134: ...g water is indeed circulating If there are air bubbles in the internal cooling water pump it is possible that the cooling water is not circulating The generator will heat up very quickly and switch of...

Page 135: ...ng system Schema Fig 7 20 6 2 Cooling 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...

Page 136: ...of the V belt is reduced It is possible that the plasticisers in the rubber compounds may partially lose their effectiveness even after a short operating time because the air in the sound insulated ca...

Page 137: ...ew Fig 7 20 3 Replacing the V belt 3 Push alternator towards the thermostat housing 4 Replace the V belt Quad Power XPZ 862 Fig 7 20 4 Replacing the V belt 5 The V belt is tensioned by pulling back th...

Page 138: ...e 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...

Page 139: ...peller Fig 7 22 1 1 Raw water cock Close the raw water stop cock Representative picture Fig 7 22 1 2 Raw water pump Raw water pump on the front side of the genset Representative picture Fig 7 22 1 3 C...

Page 140: ...entative picture Fig 7 22 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 lubricated with glycerin or wi...

Page 141: ...ator the starter battery must be disconnected before start working at the generator Warning Risk of injury Working at a running generator can result in severe personal injury Therefore before starting...

Page 142: ...ling operation installation and maintenance can result in severe personal injury and or mate rial damage Electrical voltages above 48 volts battery chargers greater than 36 volts are always dangerous...

Page 143: ...nly A high peak current is required to start many electrical devices especially electric motors and compressors from a still stand state In order to prolong the genset s life expectancy the nominal el...

Page 144: ...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 145: ...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 146: ...Generator Failure Seite Page 146 Kaptitel Chapter 8 Generator Failure 20 7 15...

Page 147: ...p 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 syste...

Page 148: ...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 149: ...y 1 25 l 1 25 l 1 25 l 2 8 l Fuel consumption approx 0 42 1 12 l approx 0 42 1 12 l approx 0 42 1 12 l approx 0 5 1 4l Oil consumption max 1 of fuel consumption max 1 of fuel consumption Oil specifica...

Page 150: ...9 3 kPa 93 Millibar 9 3 kPa 93 Millibar 9 3 kPa 93 Millibar 9 3 kPa 93 Millibar 9 3 kPa 93 Millibar Panda 6500 Panda 7 mini Panda 8000 Panda 8 mini Panda 9000 Panda 10000 Panda 9 mini Panda 12000 Pan...

Page 151: ...e running speed 2900 rpm 3000 rpm 3000 rpm 2900 rpm Valve clearance engine cold 0 2 mm Hydro Hydro 0 2 mm Cylinder head nut torque 63 7 68 6 Nm 68 Nm 68 Nm 25 Nm Compression ratio 22 5 1 22 16 22 16 2...

Page 152: ...m 70mm 70mm Max exhaust back pressure 10 7 kPa 107 Millibar 10 7 kPa 107 Millibar 10 7 kPa 107 Millibar 10 7 kPa 107 Millibar 10 7 kPa 107 Millibar Panda 7 5 4 Panda 9 4 Panda 12 4 Panda 17 4 Panda 22...

Page 153: ...3000UpM 1500 rpm Idle running speed 2900rpm 2900rpm 3100rpm 2900UpM 1800 rpm Valve clearance engine cold 0 16 0 20mm 0 2mm 0 2mm 0 2mm 0 2mm Cylinder head nut torque 58 8 63 7Nm 42Nm 42Nm 42mm 68Nm C...

Page 154: ...end cable cross size starter battery cable Length 4 meter max 70mm Max exhaust back pressure 10 7 kPa 107 Millibar Panda 45i Generator type Cooling water conduit Exhaust conduit mm Fuel conduit Freshw...

Page 155: ...gine oil is specified by the API standard American Petroleum Institutes The API designation is to be found on each engine oil bundle The first letter is always a C Panda PMS 60 MB 40 40 60 8 8 Panda P...

Page 156: ...the specificated engine oil Fig 9 6 1 2 1 Engine oil type Fig 9 6 1 2 Temp range of the SAE classes 9 7 Coolant specifications Use a mixture of water and antifreeze The antifreeze needs to be suitabl...

Page 157: ...ty is unknown or it may be inferior in quality Kerosene which is very low in cetane rating adversely effects the engine Chemical and physical properties Reserve alkalinity of 10ml ASTM D 1121 13 15 ml...

Page 158: ...Tables Seite Page 158 Kaptitel Chapter 9 Tables 20 7 15...

Page 159: ...Inverter Panda PMGi 25 Art Nr 21 07 03 044P PMGi 25 230 V 21 07 03 065P PMGi 25 400 V 21 07 03 079P PMGi 25 2x120 V 240 V 21 07 03 045P PMGi 10000 15000 120 V 21 07 03 053P PMGi 15000 2x120 V 240 V Be...

Page 160: ...bove 48 volts battery chargers greater than 36 volts are always dangerous to life The rules of the respective regional authority must be adhered to Only an electrician may carry out installation of th...

Page 161: ...nerator 4 Air out grille 5 Cooling water out hot side 6 Cooling water in cold side 7 Socket for generator connection PMGi in 10 4 Alternative front side connection side PMGi 380 V Fig 10 4 1 Connectio...

Page 162: ...mination box with the socket 1 Do not cover the air out grille 3 1 Socket for Load PMGi out 2 PE N bridge 3 Air out grille 4 Socket for generator connection PMGi in 5 FP Bus socket connection to gener...

Page 163: ...i a fan is mounted The air holes and air grille should not be covered 01 Air holes Attention Inside of the PMGi are up to 550 VAC The cover of the PMGi should only be opened by special trained persons...

Page 164: ...r inverters of other brands 10 7 1 Settings in the Victron VE Configure II Software General Fig 10 7 1 1 Settings in the Victron VE configure II Software 10 7 1 1 Uninterrupted AC power UPS function D...

Page 165: ...n VE Configure II Software Inverter Fig 10 7 2 1 Settings in the Victron VE configure II Software 10 7 2 1 Assist current boost factor To reduce the action of the power inverter on the iGenerator the...

Page 166: ...The heat sink and the fan of the PMGi may become dirty as a consequence of the use of the generator and so the unit can loose a part of their heat transfer characteristic Every 6 months it is necessar...

Page 167: ...o mount the PMGi use the four fixing holes diameter 6 5mm Note See the safety instruction in your Generator and iControl Manual The rules of the respective regional authority must be adhered to Only a...

Page 168: ...e 168 Kaptitel Chapter 10 Inverter Panda PMGi 25 20 7 15 10 11 1 2 Cooling water scheme if the Radiator is higher than the Generator Inverter Fig 10 11 1 2 1 Cooling water scheme if the Radiator is hi...

Page 169: ...nverter Panda PMGi 25 Seite Page 169 10 11 1 3 Cooling water scheme if the Radiator is on the same level or lower than the Generator Inverter Fig 10 11 1 1 Cooling water scheme if the Radiator is on t...

Page 170: ...nverter Panda PMGi 25 Seite Page 170 Kaptitel Chapter 10 Inverter Panda PMGi 25 20 7 15 10 11 1 4 Cooling water scheme for PVK UK iGenerators Fig 10 11 1 4 1 Cooling water scheme for PVK UK iGenerator...

Page 171: ...anda PMGi 25 20 7 15 Kapitel Chapter 10 Inverter Panda PMGi 25 Seite Page 171 10 11 1 5 Cooling water connection schema Marine PMS Generator Fig 10 11 1 5 1 Cooling water connection schema Marine PMS...

Page 172: ...ctrical cabinet The Life wire and neutral wire will be connected to the RCD The PE will be connected to the PE of the electrical cabinet After installation the function of the RCD must be tested Fig 1...

Page 173: ...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 CurrentMaximum Coura...

Page 174: ...20 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 Stro...

Page 175: ...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 176: ...al 3x 17 4 A 400 Veff 52 A 230Veff 100 A 120Veff Stromst rkeMaximum CurrentMaximum CourantMaximum 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 Puiss...

Page 177: ...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 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 87 A 230...

Page 178: ...urrent Courant Stromst rkeNominal CurrentNominal CourantNominal 3x52 A 400V Stromst rkeMaximum CurrentMaximum CourantMaximum 65 A cos phi 0 8 400 V Leistung Power Puissance Nominal Nominal power Nomin...

Page 179: ...with the live wire The minimum requested feature for this fuse are the following Note The electrical Data reference to the General Specifications Do not submit the PMGi a temperature shock Umgebungste...

Page 180: ...Inverter Panda PMGi 25 Seite Page 180 Kaptitel Chapter 10 Inverter Panda PMGi 25 20 7 15...

Page 181: ...Panda iControl2_eng R07 20 7 15 Panda iControl2 Operating Manual Open loop and closed loop control system for Fischer Panda generators...

Page 182: ...Fischer Panda GmbH 33104 Paderborn reserves all rights regarding text and graphics in this document Details are given to the best of our knowledge No liability is accepted for correctness Please note...

Page 183: ...lts etc are covered and protected so that there is no danger to life and body If a sound insulation capsule will be produced at the place of installation then well placed signs must show that the gene...

Page 184: ...iControl2 Seite Page 184 Kaptitel Chapter 11 Safety instructions for the Panda iControl2 20 7 15 The flooding valve must be closed For PMS version only NOTE Also observe the safety instructions for th...

Page 185: ...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 12 1 1 Panda iControl 2 panel...

Page 186: ...y 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 187: ...rsion 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 12 3 2 The default displa...

Page 188: ...r system with 24 V starter system the starter battery voltage can not be displayed 12 3 3 Operating modes The Panda iControl2 controller offers different operating modes 12 3 3 1 Stand by mode After t...

Page 189: ...l Service on page 199 In the set up menu of the controller you can reset the service interval after performing maintenance Siehe Set up menu auf Seite 195 12 3 3 2 Start up mode The start up mode repr...

Page 190: ...xhaust 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 as...

Page 191: ...he inverter screen by actuating the cursor up button while in operation mode Fig 12 3 3 4 4 Inverter screen phase voltages This screen provides the latest inverter phase voltages You can access the in...

Page 192: ...rcuit board temperature The inverter will be switched off at a circuit board temperature of 75 C You can access the inverter screen by actuating the cursor up button while in operation mode 12 3 3 5 P...

Page 193: ...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 194: ...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 197 Note Manual start...

Page 195: ...Stop 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 12 4 3 Set up menu Set up...

Page 196: ...ce 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 ente...

Page 197: ...g the set up menu Save Exit After setting all parameters you can exit the set up menu with the menu item Save Exit Fig 12 4 5 1 Saving the values to the EEPROM In doing so all settings entered in the...

Page 198: ...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 199: ...t 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 necess...

Page 200: ...o 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 12 4 9 Selecting and saving a unit for the temperat...

Page 201: ...ompliance with the general safety instructions at the beginning of this manual Warning Automatic start up DANGER TO LIFE Improper operation can result in health impairment and death The battery must a...

Page 202: ...includes Tightly fitting protective clothing Safety shoes Safety gloves Hearing protection Safety goggles if applicable WARNING Switch off all loads All loads must be disconnected prior to working on...

Page 203: ...original 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 bet...

Page 204: ...Installation Seite Page 204 Kaptitel Chapter 13 Installation 20 7 15 13 3 Dimensions Fig 13 3 1 Housing of the Panda iControl2 panel...

Page 205: ...s 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 T...

Page 206: ...V servo 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 E...

Page 207: ...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 addit...

Page 208: ...Seite Page 208 Kapitel Chapter 13 Installation 20 7 15 Leere Seite Intentionally blank Installation...

Page 209: ...scope 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 14 2 Maintenanc...

Page 210: ...Seite Page 210 Kapitel Chapter 14 Maintenance 20 7 15 Leere Seite Intentionally blank Maintenance...

Page 211: ...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 Warni...

Page 212: ...Faults 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 213: ...sure 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 co...

Page 214: ...hecked 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...

Page 215: ...ive 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...

Page 216: ...Seite Page 216 Kapitel Chapter 16 Annex 20 7 15 Leere Seite Intentionally blank Annex...

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