Ingersoll-Rand G 270 Users Manual And Maintenance Manual Download Page 1 | Manualshive

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Users guide and maintenance

manual for the generating sets

Réf. GPAO : 33501190701NE

Model(s) : G270

Control device

: Intellisys

Réf. constructeur : 33501190701

Revised (

10

-12)

Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and

Doosan

Company

or the

products

of

either.

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2
3
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»

Summary of Contents for G 270

Page 1: ...bcat Company from Ingersoll Rand Company in 2007 Any reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Com...

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Page 3: ...Users guide and maintenance manual All generating sets General considerations Safety instructions R f constructeur MUE IR A R f GPAO 33522051901 1...

Page 4: ...3 8 Risks related to moving the set 12 1 3 9 Recommendation for the operator and environment 13 1 4 Identifying sets 14 2 Installation 16 2 1 Unloading 16 2 1 1 Safety during unloading 16 2 1 2 Exampl...

Page 5: ...anual for the control unit User and maintenance manual for the engine User and maintenance manual and spare parts catalogue for the alternator Wiring diagrams supplied with the electrical generating s...

Page 6: ...other services The left and right sides can be seen from the back of the electrical generating set the radiator is at the front Our electrical generating sets have been designed so that damaged or wor...

Page 7: ...ating sets o tables of capacities lubricants and coolants and fuel tanks of different engines that may be fitted to the sets according to their configurations o general reference material for maintain...

Page 8: ...hts prohibited No smoking Entry prohibited to non authorised persons Exctinction by water prohibited Power When on a trailer earth the set before starting it Earth Emergency cut out Application of EU...

Page 9: ...ctions Never let anyone else use the generating set without having first given them the necessary instructions Do not run the engine without having refitted the protective covers Engine with turbochar...

Page 10: ...erstood how to use them before starting a procedure Only fit original spare parts Use tools that correspond to the work being carried out Clean all traces of oil or coolant with a clean cloth Never us...

Page 11: ...animals 1 3 3 Risks related to exhaust gases and fuels WARNING DANGER generating sets should not be operated in unventilated areas Always follow the local regulations in force regarding generating se...

Page 12: ...eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 1 3 5...

Page 13: ...es Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Never accidentally touch naked wires...

Page 14: ...ce the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 1 3 8 Risks related to moving the set Use lifting u...

Page 15: ...safety devices The presence of dangerous or combustible materials on premises where combustion apparatus is sheltered is limited to what is required for the operation The installations must be operat...

Page 16: ...are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documents contained in this manual Exa...

Page 17: ...Alternator 15...

Page 18: ...if not put down sufficiently strong and stable boards Remove the set as close as possible to its place of use or transport in a clear space with free access 2 1 2 Example of material crane slings lift...

Page 19: ...the frame making sure that only the cross beams are resting on the arms lift and handle the equipment carefully set down the generating set in its unloading position It is recommended to use a fork li...

Page 20: ...uld be available at all times for safety and maintenance reasons Ventilation of the generating set should not be affected if there are different objects close by It will cause abnormal heating and red...

Page 21: ...follows lock the wheels to stop the trailer from moving lift up the rear trailer supports and lock them release the parking brake release the locking levers for the draw bar arms and adjust the ring t...

Page 22: ...eed causes tyres to heat up therefore it is important to stop from time to time to check them Excessive heating can lead to a blow out and hence a serious accident When reversing do not forget to lock...

Page 23: ...cedures to be carried out check that the ground is strong enough for the assembly not to sink into it using the front wheel position the set as horizontally as possible engage the handbrake lower the...

Page 24: ...MAGED BLACK NO DAMAGE DAMAGE NOTED FIT TO OPERATE THE TESTER GIVES A POSITIVE RESULT REPLACE THE BATTERY THE TESTER GIVES A NEGATIVE RESULT CHECK THE BATTERY USING A MIDTRONICS WEGA OR SIMILAR TYPE OF...

Page 25: ...ternator maintenance manuals attached to this manual 6 1 Circuit capacities Mitsubishi engines Engines CIRCUIT AND TANK CAPACITY S4L2 SD series SL S4Q2 series SQ S4S series SS MODEL G 16 G 22 G 33 LUB...

Page 26: ...Y 3029TF120 4045TF120 4045HF120 6068TF220 6068HF120 153kW 1500rpm 6068HF160 183kW 1500rpm MODEL G 44 G 66 G 77 G 110 G 130 G 160 G 200 LUBRICATION in litres 6 13 5 13 5 21 5 21 5 31 5 COOLING in litre...

Page 27: ...ines ENGINES CIRCUIT AND TANK CAPACITY TWD 740 TAD 740 TAD 1032 TAD 1242 TAD 1631 MODEL G 220 G 270 G 330 G 440 G 550 LUBRICATION in litres 29 29 36 35 64 COOLING in litres 41 9 36 9 37 3 44 64 FUEL i...

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Page 31: ...User s manual Ingersoll Rand Control unit Intellisys Level 1 1 06F R f constructeur R f GPAO 33502013801...

Page 32: ...TION F FOR G GENERATING S SETS Access prohibited to unauthorized personnel Live installation potencial automatic starting Caution danger Caution toxic substances Caution risk of electric shock Caution...

Page 33: ...iometer v volts Adjusts the alternator voltage MICS A AMPG Device for electrical value display Control u unit Generating set programmable control ler Emergency S Stop The genset shuts down immediately...

Page 34: ...ing a single access code Option 4 of module 4 allowing operation at three different voltages 480V 208V and 240V may be fine tuned to reflect the customer s actual usage The low coolant level LED of th...

Page 35: ...4 4 Viewing t the e electrical v values 15 4 1 Voltages 15 4 2 Currents 16 4 3 Frequency and hours counter 16 5 Viewing t the e engine p parameters 17 6 Display l leds a and l lamp t test 17 7 Screen...

Page 36: ...to display the voltages Button to select Manu mode with LED Button to display the currents Button to test the LEDs except ON button LED 1 Oil pressure fault shutdown red LED on 2 Water T fault shutdo...

Page 37: ...ted to a specific use see tables below Note Alarm or Fault selection via programming Key A Alarm F Fault ana analog C Control T Transistor R Relay resistive Fig 1 1 C CB12 b board Fig 2 2 D Display m...

Page 38: ...unisolated with 10A 240Vac built in power bus in 50 and 60Hz No voltage and frequency measurements 10 C Charge a alternator i input Charge alternator excitation and fault Starter hardware fail safe on...

Page 39: ...55011 Class A Immunity EN61000 4 2 EN6100 4 3 EN61000 4 4 EN61000 4 6 EN61000 4 8 ENV50201 CE mark UL listed CSA certified indication and fault shutdown for oil temperature low oil level water heater...

Page 40: ...tween the ATS and the user terminal block G means cable with a Green Yellow conductor Note for a remote start only a 2x1 5mm flexible cable is sufficient see overleaf External command mains sensing or...

Page 41: ...e minutes There the language used will be the one where the cursor was positioned Not until the appearance of the overview screen will it be possible to start the generating set however all inputs sta...

Page 42: ...of the input sensor and cabling If the fuel level analogue sensor is not available on the day tank there will be no display on screen see paragraph 5 This is the case for the Pacific range generating...

Page 43: ...start up possible When one of the three start up conditions changes from 0 to 1 for and or from inactive to active for a new message informs the operator then the generating set enters into an automat...

Page 44: ...battery discharges slowly electronics consumption in cases where the generating set is not equipped with a battery charger To avoid the battery from discharging and thus the generating set from not be...

Page 45: ...and neutral Press V again to bring up the first screen and so on Ph neutr V1 voltages V2 Volts V3 ext command 1 17 05 gen running 12 01 00 2 23 30 0 2 23 30 0 2 23 30 0 3 p phase w without n neutral...

Page 46: ...I1 current in phase 1 I2 current in phase 2 I3 current in phase 3 If you press A again nothing changes Phase I1 current I2 Amps I3 ext command 1 17 10 gen running 12 01 00 5 53 36 6 5 54 42 2 5 54 43...

Page 47: ...s Fahrenheit F Oil Pr PSI Oil T F WaterT F ext command 1 17 15 gen running 12 01 00 1 16 67 7 9 90 0 1 19 94 4 Screen 3 3 Press Engine a third time to get the following screen Press Engine again to br...

Page 48: ...ton Stop S Start A Auto A Auto T Test is associated with a LED The operation of these four LEDs is described in paragraph 2 The 0 and 1 buttons are each associated with a LED The Power button is assoc...

Page 49: ...Stop ext command 1 17 45 gen stopped 12 01 00 The message Fault m module 3 3 C CAN then appears on the second line see screen opposite Press Reset to reset the emergency stop fault the message disappe...

Page 50: ...32 26 6 Starting period attempt 1 on starter 1 ATS toggle delay Mains Stand by and Stand by Mains and closure confirmation of the Mains and Stand by contactors Motorised C B opening and closure Engin...

Page 51: ...be positio ned on the international language 3 M Modifying d display w with i international l language When the international language is selected on power up or during use The time and date are no l...

Page 52: ...ations refer to the user paragraph 5 The notations Bars and C are preserved For more information on the meaning of the notations refer to the user paragraph 5 A third screen can be accessed using the...

Page 53: ...lay para meter 104 of Timing menu is displayed next to this symbol and decrements automatically from the adjustment setting to 0 Example of screen showing system voltage is again available Two minutes...

Page 54: ...is displayed on the screen as follows XX Y Y XX is a number between 00 and 99 Y takes two values 0 to indicate an alarm 1 to indicate a fault same method used in Options menu Special case 1 for a sing...

Page 55: ...17 1 CB12 Option 5 module CAN bus impossible 18 1 CB12 Option 6 module CAN bus impossible 19 1 CB12 Spare RS485 communication 21 1 impossible CB CB12 Hardware watchdog impossible 22 1 CB CB12 Spare Sp...

Page 56: ...sible 57 1 module 4 Startup battery min voltage 58 0 impossible module 4 Startup battery charger 59 0 impossible module 4 MX coil impossible 60 1 module 4 Damping valve impossible 61 1 module 4 Starte...

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Page 59: ...e and maintenance manual Volvo Generating set and industrial engines 4 6 litre non EDC TAD 740 GE 1032 GE 1630 GE 1631 GE TWD 740 GE 1210 GE 1232 GE 1630 GE R f constructeur 7739614 R f GPAO 335220452...

Page 60: ...in both mobile and stationary applications in all conceivable service conditions This is not a coincidence After 90 years of manufacturing engines the name Volvo Penta has come to symbolise reliabili...

Page 61: ...ageable clutch 19 Operation at low loads 19 Stopping the engine 20 Before stopping the engine 20 Stopping 20 After stopping the engine 20 Emergency stop 20 Maintenance schedule 21 22 Maintenance sched...

Page 62: ...draw your attention to something that can cause damage product malfunction or damage to property NOTE Used to draw your attention to important information that will facilitate work or operations This...

Page 63: ...onal injury Engines are supplied without guards After the engine is installed all rotating and hot components must be protected where necessary for reasons of personal safety Starting lock If the inst...

Page 64: ...olvo Original re placement parts Components used in the fuel and electrical systems on Volvo Penta products are designed and construct ed to minimise the risk of fire and explosion Using non original...

Page 65: ...witches before working on the electrical system Isolate external power to the engine block heater battery charger or accessories mounted on the engine Batteries The batteries contain an extremely corr...

Page 66: ...e additional checks on the disengageable clutch if installed for the first few days It may be neces sary to adjust it to compensate for wear to the plates Fuel and oil types Only use the fuel and oils...

Page 67: ...actured of that type correspond to the certified engine This places special requirements for maintenance and service as follows The maintenance and service intervals recom mended by Volvo Penta must b...

Page 68: ...combustion and ex haust gas temperatures to appropriate levels In addi tion the emission of nitrous oxides is reduced The engines are equipped with an electrical starter element This facilitates star...

Page 69: ...uel line for tank connection 13 Injection pump 14 Muffler 15 Relay for electrical starter element 16 Electrical starter element 17 Air filter 18 Cable holder 19 Coolant pipe outlet 20 Fan guard 21 Rad...

Page 70: ...air filters 13 Relay for electrical starter element 14 Electrical starter element 15 Cable holder 16 Coolant pipe outlet 17 Radiator 18 Flywheel cover 19 Engine speed control 20 Instrument panel 21 S...

Page 71: ...ter full flow 13 Pipe for crankcase ventilation 14 Flywheel cover 15 Muffler 16 Air filter 17 Cable holder 18 Electrical starter element 19 Relay for electrical starter element 20 Double fuel filter 2...

Page 72: ...Prelift injection timing Identification plates TD TAD420 721 8 Empty 9 10 Manufactor identifikation code 11 Indication of standard and or regulation 12 Reduced gross power on site conditions items 14...

Page 73: ...gine Alternatively a lockable main switch can be used Instrument box 1 Oil pressure gauge Normally within the green field 300 500 kPa 2 Warning lamp Low engine coolant level acces sory 3 Engine coolan...

Page 74: ...the circuit with the main switch while the engine is running This could damage the genera tor Set the engine speed control to idle Disengage the disengage able clutch transmission Make a habit of chec...

Page 75: ...t 10 seconds Then warm up the engine at low speed and low load IMPORTANT Do not race the engine while it is cold NOTE Generating set engines automatically rev up to the pre set engine speed 1500 or 18...

Page 76: ...the fuel in jection system A fuel heater is recommended for extremely low temperatures Use a synthetic lubricating oil of a viscosity recommended for the prevailing temperature See chapter Lubrication...

Page 77: ...First connect the red jump lead to the auxiliary battery then to the discharged battery Then connect the black jump lead to the auxiliary battery then to a spot a short distance from the discharged b...

Page 78: ...d with an engine coolant level switch the engine stops automati cally and the acoustic alarm goes off The warning lamp lights If generator charging drops the warning lamp lights For other applications...

Page 79: ...ow This leads to soot deposits on valves piston crowns exhaust out lets and the exhaust turbine At low loads the temperature of combustion is so low that fuel is not burnt up properly This can lead to...

Page 80: ...rheating IMPORTANT This is especially important if the engine has been operated at high engine speeds and or loads After stopping the engine Inspect the engine and engine compartment for any leaks Clo...

Page 81: ...ilter should be replaced when the gauge remains in the red field after the engine has been stopped 3 When operating in extremely dirty conditions special air filters must be used AFTER THE FIRST 100 2...

Page 82: ...RS Valve clearance Adjustment not shown EVERY 2000 HOURS OR AT LEAST EVERY 12 MONTHS Air filter for air compressor Replace page 45 Charge air cooler Cleaning TAD engines 2 page 33 Coolant Anti corrosi...

Page 83: ...a running engine is dangerous Watch out for rotating components and hot surfaces Engine general Air filter Check replace The air filter should be replaced when the indicator re mains in the red field...

Page 84: ...ing the engine speed with the screw 3 If the engine speed is uneven the idle speed damping should be adjusted as follows 1 Remove the domed nut 4 and slacken off the locknut 5 Carefully turn the dampi...

Page 85: ...he screws A before tensioning the generator belts It should be possible to depress the belts 10 mm between the pulleys Worn belts which work in pairs should be replaced at the same time The fan belts...

Page 86: ...onths 1 Maintenance NOTE Mineral based and semi and fully synthetic oils may be used as long as they fulfil the above require ments If the 6 and 7 litre engines are equipped with low profile type oil...

Page 87: ...oil draining pump to suck up the oil 1 Clean the oil filter bracket thoroughly to avoid dirt ingress when the new filter s are installed 2 Run engine to normal operating temperature WARNING Hot oil an...

Page 88: ...coolant filter accessory must not be changed at the same time as the coolant It must be replaced 6 months after the first coolant replacement and then every six months See under heading Coolant filte...

Page 89: ...nti corrosion agents are harmful to health dangerous if ingested IMPORTANT Never mix antifreeze glycol and anti corrosion agents The two combined can produce foam and drastically reduce the coolant s...

Page 90: ...4 7 litre engines are self airing Therefore they have no bleed cock The locations of the drain and bleed cocks are displayed on the next page The engine must be stopped when filling Fill slowly so th...

Page 91: ...be removed Check that all the coolant has drained out Drain bleed cocks Location 4 7 litre engines Drain cock K on the left hand side of the cylinder block rear section Does not apply for engine 420...

Page 92: ...air cooler rear only TWD 16 litre engines Drain cocks K on the cylinder block above the starter motor under the rear edge of the coolant pump Charge air cooler front end only TWD Drain plugs P under t...

Page 93: ...brush Take care not to damage the cooling vanes Reinstall components IMPORTANT Do not use a high pressure hose Coolant filter Replace The coolant filter is only standard on 16 litre en gines For other...

Page 94: ...on a cold engine to avoid the risk of fire caused by fuel spilling onto hot surfaces Remove the filters Moisten the new filter gasket with a little oil Screw the filter into place by hand until the g...

Page 95: ...l injection pump often requires venting as well This is done by slackening off the fuel injec tion pump pressure equaliser 3 27 mm narrow U wrench Pump with hand pump 2 until fuel contain ing no air f...

Page 96: ...BL W blue white Is there automatic stop in the event of too low oil pressure with a non Volvo Penta oil pres sure switch that is open when the engine is off No Normally open Is the engine equipped wit...

Page 97: ...fuse may have tripped Reset the fuse by pressing on the button on the fuse IMPORTANT Always investigate the cause of an overload before resetting the fuse Main switch The main switch must never be tur...

Page 98: ...cting and disconnecting First connect the red battery lead to the battery terminal Then connect the black battery lead to the battery terminal When disconnecting the battery disconnect the lead black...

Page 99: ...Maintenance 18 Signal horn 46 Water level switch 720 models 52 Start button 52a Start relay 53 Interlocking button 54 Stop button 57 Charging control lamp 58 Oil pressure gauge 59 Water temperature g...

Page 100: ...A fuse output for automatic stop closes in the event of a fault 13 Relay for starter element 14 Starter element 15 Starter motor 16 Batteries 17 Generator 18 Engine speed rpm sensor 19 Engine coolant...

Page 101: ...colour BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Grey OR Orange VO Violet R Red SB Black W White Y Yellow The area of the battery leads de pends on the location of the battery Distan...

Page 102: ...erature switch accessory 3 Holding current relay operating current and in struments 4 Terminal block for engine cable harness 5 Terminal block for automatic stop and extra pow er output maximum 16 A 6...

Page 103: ...power output 16 A fuse and output for automatic stop closes in the event of a fault 7 Warning lamp high engine coolant temperature accessory 8 Warning lamp low engine coolant level access ory 9 Warni...

Page 104: ...kit for engagement of the starter element accessory 1 Time relay 2 Connector 8 pin 3 Ignition switch 4 Temperature switch access ory 5 Starter element 6 Indicator lamp engaged starter element 7 Batter...

Page 105: ...s of oil Disengagement bearing Lubricate sparingly so that no grease is squeezed out Use a grease recommended above Checking and adjusting WARNING Adjustments may only be made on a stopped engine The...

Page 106: ...pro tection against freezing If there is any possi bility the engine will be subjected to freezing temperatures the system must be drained Drain any water and contaminants from the fuel tank Fill the...

Page 107: ...Fault in the GAC unit generating set engines Fault tracing A number of symptoms and possible reasons for engine problems are described in the table below In case of faults or mishaps which you cannot...

Page 108: ...TWD740GE VE 6 7 28 795 TAD740GE 6 7 28 901 TAD741GE 6 7 28 901 TD100G 6 9 6 945 TD1030VE 6 9 6 945 TWD1031VE 6 9 6 975 TAD1030V 6 9 6 1062 TAD1030GE 6 9 6 1107 TAD1031 32GE 6 9 6 1107 TD121G 6 11 98...

Page 109: ...55 TWD740GE VE 1300 50 0 50 0 65 TAD740GE 1300 50 0 50 0 65 TAD741GE 1300 50 0 50 0 65 TD100G 550 50 0 40 0 70 TD1030VE 600 25 0 40 0 70 TWD1031VE 675 25 0 40 0 70 TAD1030V 600 25 0 40 0 70 TAD1030GE...

Page 110: ...40GE VE 300 500 min 150 TAD740GE 300 500 min 150 TAD741GE 300 500 min 300 TD100G 300 500 min 150 TD1030VE 400 600 min 150 TWD1031VE 400 600 min 150 TAD1030V 300 500 min 150 TAD1030GE 300 500 min 150 T...

Page 111: ...24 29 8 TAD740GE 24 29 8 TAD741GE 24 29 8 TD100G 21 25 9 TD1030VE 32 36 10 TWD1031VE 32 36 10 TAD1030V 30 34 8 TAD1030GE 32 36 10 TAD1031 32GE 32 36 10 TD121G 34 38 9 TWD1210V 34 38 9 TWD1211V 34 38 9...

Page 112: ...3 TD630VE 15 19 3 TWD630VE 15 19 3 TD71A 19 24 3 TID71A 19 24 3 TD730VE 19 24 3 TWD731VE 19 24 3 TWD1230VE 30 34 12 Oil change capacity for deep oil pan for large inclinations Designation Without oil...

Page 113: ...l pan soundproofed Designation Without oil filter litres With oil filter litres Volume difference MIN MAX TD630VE 20 24 6 TWD630VE 20 24 6 TD730VE 22 27 7 TWD731VE 22 27 7 TD1030VE 32 36 10 TWD1031VE...

Page 114: ...30G 37 75 88 TWD740GE VE 42 75 88 TAD740GE 37 75 88 TAD741GE 37 75 88 TD100G 27 82 95 TD1030VE 30 82 95 TWD1031VE 30 75 88 TAD1030V 38 82 95 TAD1030GE 38 86 96 TAD1031 32GE 38 86 96 TD121G 34 82 95 TW...

Page 115: ...0 8 29 5 0 8 6 st 0 29 TAD741GE 29 0 0 8 29 5 0 8 6 st 0 29 TD100G 26 0 0 8 26 5 0 8 4 st 0 38 TD1030VE 25 0 26 0 0 8 7 st 0 27 TWD1031VE 25 0 26 0 0 8 6 st 0 25 TAD1030V 27 5 0 8 28 0 0 8 5 st 0 30 T...

Page 116: ...710G 24 2x143 TD720GE 24 alt 12 2x110 2x88 TD720VE 24 alt 12 2x110 2x88 TAD720GE 24 alt 12 2x110 2x88 TAD720VE 24 alt 12 2x110 2x88 TAD721VE 24 alt 12 2x110 2x88 TAD730G 24 2x143 TWD740GE VE 24 2x143...

Page 117: ...TAD720VE 14 55 770 28 35 980 TAD721VE 14 55 770 28 35 980 TAD730G 28 60 1700 TWD740GE VE 28 60 1700 TAD740GE 28 60 1700 TAD741GE 28 60 1700 TD100G 28 55 1550 28 60 1700 28 80 2240 TD1030VE 28 55 1550...

Page 118: ...engageable clutch accessory Desigantion Type Gear ratio Size mm Weight kg AP S11A2 Single plate 1 1 292 11 1 2 66 AP D11A2 Double plate 1 1 292 11 1 2 83 AP T14A2 Triple plate 1 1 355 14 209 Technical...

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Page 122: ...7739614 1 English 04 2002...

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Page 125: ...EDITION JUNE2002 CPN 85623031 33519009601 ind1 GENERATOR PARTS LISTS GENERATOR MODEL G270...

Page 126: ...30 07 68 62 Fax 33 1 30 07 68 71 Organisatorische Bekanntmachung im Deutchland Ingersoll Rand Gmbh Unternehmensdetails Gewerbealle 17 Mulheim D 45478 Germany Telefon 49 208 99 94 400 Fax 49 208 99 94...

Page 127: ...Y 23 G270 ACCESSORY ASSEMBLY 24 M424 MISCELLANEOUS ASSEMBLY 25 RETENTION BUND M424 26 CANOPY M424 ASSEMBLY 28 CENTRAL LIFTING ARCH ASSEMBLY 29 PANEL WINDOW M404 407 ASSEMBLY 30 PANEL DOOR M424 425 ASS...

Page 128: ...OPTION WATER PREHEATING 53 EXPLOSIVE ATMOSPHERE OPTION AIR SHUT OFF VALVE VO TAD740 ASSEMBLY 54 SPARK ARRESTER INERIS DN125 ASSEMBLY 55 SINGLE BASE PLATE OPTION SINGLE BASE PLATE M424 ASSEMBLY 56 SOCK...

Page 129: ...TION JUNE2002 5 Item Part Number Description Quantity Units F01051 ENGINE FUNCTION TAD740 1 0 UN 010200 85422020 ENGINE VOLVO TAD740 SAE 2 11 5 1 0 UN Part numbers listed are the only parts used in th...

Page 130: ...STARTER 1 0 UN 301860 85401404 CHARGING ALTERNATOR 1 0 UN 302470 85426161 WATER PUMP REPAIR KIT 1 0 UN 301960 85401990 PRESSURE SWITCH 1 0 UN 302000 85402147 TEMPERATURE SWITCH 1 0 UN 302050 85402196...

Page 131: ...FLEXIBLE HOSE D25x32 1 0 ML 040180 85424034 OIL SUMP PUMP BRACKET VO 740G 1 0 UN 180910 85423242 PIPE UNION MAL MAL 3 4G 2 0 UN 180930 85423093 PIPE UNION ELBOW 90 MAL FEM 3 4G 1 0 UN 180950 85423044...

Page 132: ...PIPE UNION ELBOW 90 3 4BSP 1 0 UN 180860 85424893 BANJO SCREW 7 8SAE L45 1 0 UN 180910 85423242 PIPE UNION MAL MAL 3 4G 1 0 UN 181050 85417749 HOSE CLIP D25 40 1 0 UN 181160 85421758 GASKET D26x32 1...

Page 133: ...TY ASSEMBLY 1 0 UN 080330 85403848 AIR CLEANER CLAMP D330 2 0 UN 080340 85403863 RAIN CAP 1 0 UN 080350 85403921 AIR FILTER HEAVY DUTY 1 0 UN 080700 85423887 AIR FILTER BRACKET VO 740G 2 0 UN 080710 8...

Page 134: ...ETAIL 1 0 UN 300200 85400737 FILTER CARTRIDGE 1 0 UN 300210 85400786 FILTER CARTRIDGE 1 0 UN 300120 85501229 VACUATOR VALVE 1 0 UN 300230 85501294 DUST CUP 1 0 UN 080340 85403863 RAIN CAP 1 0 UN 18168...

Page 135: ...UN 160990 85407245 HOUSING ELECTRONIC REGULATION 1 0 UN 161000 85407336 ELECTRONIC REGULATOR BRACKET 1 0 UN 161020 85408706 STOP 1 0 UN 162520 85423366 RELAY 24V 10 20A 1 0 UN 160180 85408912 AUTOMOB...

Page 136: ...0G 1 0 UN 160270 85408078 COPPER BAR 5x25 1 0 UN 162520 85423366 RELAY 24V 10 20A 1 0 UN 162530 85413292 AUTOMOBILE RELAY BASE 1 0 UN 160180 85408912 AUTOMOBILE RELAY BASE 1 0 UN 162550 85423374 RELAY...

Page 137: ...Number Description Quantity Units F16004 85407484 OUTPUT CABLES ALTERNATOR ASSEMBLY 1 0 UN 160420 85406742 CABLE OUTLET PLATE 1 0 UN 160500 85406874 FOAM CABLE PROTECTION 2 0 UN Part numbers listed ar...

Page 138: ...EDITION JUNE2002 14 Item Part Number Description Quantity Units F02007 ALTERNATOR LS 462L ASSEMBLY 1 0 UN 020160 85416600 ALTERNATOR LS 462L 1 0 UN Part numbers listed are the only parts used in this...

Page 139: ...8877 N D E BRACKET 1 0 UN 302310 85425916 BEARING LSA 462 471 1 0 UN 319880 85509065 WAVY WASHER 1 0 UN 320610 85508927 WOUND EXCITER FIELD 1 0 UN 320620 85508968 WOUND EXCITER ARMATURE 1 0 UN 302210...

Page 140: ...1 2 WAY VALVE 1 0 UN 131070 85422947 RADIATOR FAN GUARD FRONT VO TAD740 1 0 UN 131080 85422954 RADIATOR FAN GUARD FRONT VO TAD740 1 0 UN 131090 85422962 RADIATOR FAN GUARD FRONT VO TAD740 1 0 UN 13110...

Page 141: ...E FILTER 1 0 UN 050460 85430551 3 WAY FUEL VALVE SEPARATOR FILTER BRACKET 1 0 UN 184920 85507937 BANJO CONNECTOR MALE D10 2 0 UN 184910 85507945 BANJO SCREW M16X150 L28 2 0 UN 183190 85509727 SPRING C...

Page 142: ...CARTRIDGE 1 0 UN 301370 85502946 SEPARATOR FILTER HOUSING 1 0 UN 301380 85502953 SEPARATOR FILTER BOWL GASKET 1 0 UN 301390 85502961 SEPARATOR FILTER BOWL RETAINER RING 1 0 UN 301400 85502979 SEPARAT...

Page 143: ...22 PLUG TANK 1 0 UN 050700 85622041 TANK 700L 1 0 UN 050120 85403509 LEVEL SENSOR ADAPTER 1 0 UN 110100 85404572 LEVEL SENSOR 1 0 UN 180130 85409068 SQARE FLANGE GASKET 1 0 UN 180140 85409076 ROUND FL...

Page 144: ...09222 PLUG TANK 1 0 UN 050420 85431120 FUEL FILTER 1 0 UN 050470 85496636 TANK 480L 1 0 UN 050120 85403509 LEVEL SENSOR ADAPTER 1 0 UN 110100 85404572 LEVEL SENSOR 1 0 UN 180130 85409068 SQARE FLANGE...

Page 145: ...1 0 UN 070120 85403723 BATTERY ISOLATOR SWITCH 1 0 UN 070180 85403731 STARTING BATTERY 12V 100Ah 450A 2 0 UN 161150 85417293 BATTERY CABLE 50mm2 L1000 RED 1 0 UN 161160 85417244 BATTERY CABLE 70mm2 L1...

Page 146: ...1 0 UN 090120 85496750 40dB MUFFLER 1 0 UN 090570 85496842 EXHAUST PIPE D102 VOLVO 1 0 UN 090610 85496883 EXHAUST HOSE BRACKET 1 0 UN 090530 85622074 EXHAUST RAIN FLAP D140 1 0 UN 181020 85417798 HOSE...

Page 147: ...30810 85423960 ENGINE SUPPORT VO 6 7L LEFT RIGHT SIDE 2 0 UN 130820 85417392 RECTANGULAR ENGINE SHIM 7L VOLVO ENGINE 1 0 UN 130440 85497014 FRAME M424 1 0 UN 130880 85401875 ANTI VIBRATION MOUNT 0800d...

Page 148: ...ORY ASSEMBLY 1 0 UN 050420 85431120 FUEL FILTER 1 0 UN 144560 85509263 WBH LATCHE KEY 1 0 UN 182030 85503852 RECTANGULAR STICKER 1100x325 2 0 UN 181600 85428019 RECTANGULAR STICKER 450x600 2 0 UN 1819...

Page 149: ...2 0 UN 144570 85622124 RADIATOR UPPER PANEL M424 VO TAD740GE 1 0 UN 144580 85622132 RADIATOR LOWER PANEL M424 VO TAD740GE 1 0 UN 144590 85622140 RADIATOR LEFT RIGHT PANEL M424 VO TAD740GE 2 0 UN 1446...

Page 150: ...70 EDITION JUNE2002 26 Item Part Number Description Quantity Units F99017 RETENTION BUND M424 1 0 UN 132360 85622082 RETENTION BUND M424 1 0 UN Part numbers listed are the only parts used in this mode...

Page 151: ...G270 EDITION JUNE2002 27...

Page 152: ...UN 143440 85498343 CANOPY TOP ISOLATION BRACKET M424 4 0 UN 143550 85498475 SOUND SHIELD M424 1 0 UN 144670 85622116 SOUNDPROOF PANELS BATCH M424 1 0 UN 142920 85497824 LEFT FORWARD PLENUM PANEL M424...

Page 153: ...CENTRAL LIFTING ARCH ASSEMBLY 1 0 UN 142820 85497675 LADDER M424 1 0 UN 142830 85497683 LADDER PROTECTION PANEL M424 1 0 UN 144330 85509511 LIFTING FRAME 4500daN M424 CANOPY 1 0 UN 144340 85509529 LI...

Page 154: ...OR M404 405 406 407 1 0 UN 141330 85416790 DOOR STOP 1 0 UN 140330 85406148 CANOPY DOOR LOCK KEY LOCK 1 0 UN 140340 85406155 DOOR HINGE 2 0 UN 140350 85406189 ANTI VIBRATION MOUNT 140daN 15mm 1 0 UN 1...

Page 155: ...DOOR LOCK KEY LOCK 1 0 UN 140340 85406155 DOOR HINGE 2 0 UN 140350 85406189 ANTI VIBRATION MOUNT 140daN 15mm 1 0 UN 143670 85501765 STRIKER PLATE M400 CANOPY MCPS DOOR 1 0 UN 143690 85498640 TERMINAL...

Page 156: ...ber Description Quantity Units F16015 85407187 EMERGENCY STOP PANEL ASSEMBLY 1 0 UN 161080 85406726 SOCKET BRACKET CLOSURE PANEL 1 0 UN 161070 85407294 EMERGENCY STOP PANEL 1 0 UN Part numbers listed...

Page 157: ...Quantity Units F16216 85427862 R3000 BRACKET ASSEMBLY 1 0 UN 168330 85427177 RUBBER GROMET SUPPORT 2 0 UN 163330 85427193 INTELLISYS RACK BRACKET 2 0 UN 160520 85408391 RUBBER GROMMET D47 4 0 UN Part...

Page 158: ...s F16006 85407906 EARTH ROD WITH CABLE CANOPY ASSEMBLY 1 0 UN 160140 85408227 NEUTRAL EARTH SYSTEM CABLE 25mm2 L10000 Gr Ye 1 0 UN 160150 85408334 EARTH ROD L1000 1 0 UN 180120 85409191 CLIP ON BRACKE...

Page 159: ...UN 168210 85412161 INTELLISYS OPTION SPEED POTENTIOMETER 1 0 UN 168230 85427987 INTELLISYS OPTION ELECTRIC PACK 12V 1 0 UN 168240 85412278 INTELLISYS OPTION EARTH LEAKAGE RELAY 1 0 UN 168190 85412047...

Page 160: ...T 1 0 UN 166430 85508604 INTELLISYS CARD CB12 1 0 UN 166370 85504033 INTELLISYS WIRING LOOM C35S 1 0 UN 166440 85426112 FUSE CYLINDRICAL 12A 4 0 UN 166470 85426120 FUSE CYLINDRICAL 10A 1 0 UN 166450 8...

Page 161: ...161 INTELLISYS OPTION SPEED POTENTIOMETER 1 0 UN 302980 85504207 CLAMP D4 7 1 0 UN 303050 85504215 LOCK AXE SYSTEM 1 0 UN 166510 85503993 INTELLISYS WIRING LOOM C105 L540 1 0 UN 303070 85504223 POTENT...

Page 162: ...27987 INTELLISYS OPTION ELECTRIC PACK 24V 1 0 UN 302980 85504207 CLAMP D4 7 1 0 UN 303050 85504215 LOCK AXE SYSTEM 1 0 UN 166520 85504009 INTELLISYS WIRING LOOM C106 L560 1 0 UN 303130 85504264 POTENT...

Page 163: ...AGE RELAY 1 0 UN 303090 85504249 FLASK 1 0 UN 164080 85413482 FUSE CYLINDRICAL 5A 2 0 UN 166500 85503985 INTELLISYS WIRING LOOM C39 L2000 1 0 UN 303150 85504280 EARTH LEAHAGE RELAY 24V 1 0 UN 303110 8...

Page 164: ...17 INTELLISYS WIRING LOOM C3 L810 1 0 UN 166360 85504025 INTELLISYS WIRING LOOM C11 L460 1 0 UN 166380 85504041 EARTHING INTELLISYS WIRING LOOM 1 0 UN 166400 85412021 INTELLISYS DISPLAY LEXAN IR 1 0 U...

Page 165: ...02 41 Item Part Number Description Quantity Units F30055 85411676 INTELLISYS OPTION EMERGENCY STOP 1 0 UN 166490 85503977 INTELLISYS WIRING LOOM C11 L2000 1 0 UN Part numbers listed are the only parts...

Page 166: ...0 UN 166630 85410546 INTELLISYS WIRING LOOM 001 1 0 UN 166780 85411403 INTELLISYS WIRING LOOM 105 1 0 UN 166790 85509321 INTELLISYS WIRING LOOM 106 1 0 UN 166770 85410520 INTELLISYS WIRING LOOM 006 1...

Page 167: ...LOCK HOUSING M400B LOC ASSEMBLY 1 0 UN 161430 85417376 NEUTRAL EARTH SYSTEM CABLE 25mm2 L125 Gr Ye 1 0 UN 161540 85416881 COPPER BAR 5x25 2 0 UN 162360 85413706 INSULATION PIN 4 0 UN 183290 85409084 R...

Page 168: ...0 85416899 COPPER BAR 5x25 1 0 UN 161950 85417368 NEUTRAL EARTH SYSTEM CABLE 25mm2 L800 Gr Ye 1 0 UN 160770 85408342 INSULATION PIN 3 0 UN 160520 85408391 RUBBER GROMMET D47 5 0 UN 162410 85424679 CUR...

Page 169: ...5416923 COPPER BAR 10x30 1 0 UN 161730 85416931 COPPER BAR 10x30 1 0 UN 161740 85416949 COPPER BAR 10x30 1 0 UN 161750 85416956 COPPER BAR 10x30 1 0 UN 161760 85418069 PHASE ISOLATOR M400 4 0 UN 16236...

Page 170: ...424042 GLAND NUT PLATE TERMINAL CONNECTION M404 407 1 0 UN 162070 85424398 CIRCUIT BREAKER PROTECTION PANEL 1 0 UN 162080 85424596 ISOLATION PANEL MCPS 250 630A 1 0 UN 162170 85423804 CIRCUIT BREAKER...

Page 171: ...130 DOOR HINGE 3 0 UN 162060 85422749 TERMINAL CONNECTION PERSPEX DOOR M400 1 0 UN 160760 85407708 HINGE FIXING PLATE M214 3 0 UN 180460 85409225 1 4 TURN SCREW D9 2 0 UN 180470 85409233 CAPTIVE NUT F...

Page 172: ...Part Number Description Quantity Units F16036 COMPACT CIRCUIT BREAKER 100A I 630A ACCESSORIES 1 0 UN 162450 85408573 CIRCUIT BREAKER SHUNT RELEASE COIL 200 280VAC 1 0 UN Part numbers listed are the o...

Page 173: ...ASHER 8X18 8 0 UN 181760 85430619 PIPE UNION REDUCER MAL FEM 3 8G D10 4 0 UN 184900 85622660 PIPE UNION ELBOW 90 MAL FEM 3 8G 2 0 UN 181770 85430627 PIPE UNION MAL MAL D10 5 0 UN 181780 85430635 PIPE...

Page 174: ...START OPTION 1 0 UN 162460 85408581 AUXILARY CONTACT 1 0 UN 166670 85411163 INTELLISYS WIRING LOOM 035 1 0 UN 166650 85410835 INTELLISYS WIRING LOOM 013 1 0 UN 166870 85426948 INTELLISYS WIRING LOOM 0...

Page 175: ...UN 030320 85421287 WATER HEATING CONNECTION STANDING HANGER 1 0 UN 162400 85417491 RIGHT COWL 1 0 UN 180750 85421204 SPACER Th10 D15 1 0 UN 180900 85423267 PIPE UNION MAL MAL 1 2G 1 0 UN 180940 85423...

Page 176: ...cription Quantity Units F30077 85412062 INTELLISYS OPTION BATTERY CHARGER 24V 3A 1 0 UN 304380 85506665 CHARGER 1 0 UN 167440 85506541 INTELLISYS WIRING LOOM 022 024 1 0 UN 167450 85506558 INTELLISYS...

Page 177: ...LLISYS OPTION WATER PREHEATING 1 0 UN 167410 85506517 INTELLISYS WIRING LOOM 031 33 34 1 0 UN 167420 85506525 INTELLISYS WIRING LOOM 100 1 0 UN 167430 85506533 INTELLISYS WIRING LOOM 027 1 0 UN 304360...

Page 178: ...art Number Description Quantity Units F08028 85425072 AIR SHUT OFF VALVE VO TAD740 ASSEMBLY 1 0 UN 080720 85417657 AIR SHUT OFF VALVE D76 1 0 UN 162520 85423366 RELAY 24V 10 20A 1 0 UN 160180 85408912...

Page 179: ...OSPHERE OPTION Item Part Number Description Quantity Units F09038 85503357 SPARK ARRESTER INERIS DN125 ASSEMBLY 1 0 UN 090620 85503340 INERIS SPARK ARRESTER DN125 1 0 UN 181030 85417780 HOSE CLAMP D14...

Page 180: ...LATE OPTION Item Part Number Description Quantity Units F14021 85424976 SINGLE BASE PLATE M424 ASSEMBLY 1 0 UN 142770 85429694 HOOD UNDERSHEETING M424 1 0 UN 142780 85429751 HOOD UNDERSHEETING M424 2...

Page 181: ...0 TYPE 3 ASSEMBLY 1 0 UN 169090 85622678 INTELLISYS WIRING LOOM 135 1 0 UN 169100 85622686 INTELLISYS WIRING LOOM 136 1 0 UN 167670 85408300 SOCKET GERMAN 230V 16A 2S G 1 0 UN 165330 85622694 DIFFEREN...

Page 182: ...n Quantity Units F16150 85507275 SOCKET PANEL FR M400 TYPE 7 ASSEMBLY 1 0 UN 165330 85506087 DIFFERENTIAL SWITCH 2P 40A 30mA 1 0 UN 167810 85506111 SOCKET EC 110V 16A 2S G 1 0 UN 660170 85506459 MOULD...

Page 183: ...MANUAL PUMP 1 0 UN 132440 85622959 OIL SUMP PUMP BRACKET 1 0 UN 181550 85622967 PIPE UNION MAL MAL 3 4G 2 0 UN 180930 85423093 PIPE UNION ELBOW 90 MAL FEM 3 4G 1 0 UN 181270 85509677 FLEXIBLE HOSE D25...

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Page 185: ......

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Page 187: ...Users guide and maintenance manual Leroy Somer Alternators LSA 46 2 47 1 R f constructeur 2981 GB 4 33 a 04 00 R f GPAO 33522035901...

Page 188: ...ls Warning symbol for an operation which may damage or destroy the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Not...

Page 189: ...Special type of use 4 SERVICING MAINTENANCE 15 Safety measures Regular maintenance Checks after start up Cooling circuit Bearings Electrical servicing Mechanical servicing Fault detection Mechanical d...

Page 190: ...he alternator is identified by means of a nameplate fixed on the frame see drawing Make sure that the nameplate on the machine conforms to your order The machine name is defined according to various c...

Page 191: ...bes Space heaters 2 2 Mechanical characteristics Steel frame Cast iron end shields Ball bearings greased for life Mounting arrangement MD 35 single bearing with standard feet and SAE flanges coupling...

Page 192: ...t power supply max 140V 50 60 Hz rated overload current 10A 10s electronic protection overload voltage detection opening short circuit excitation overload current for 10 s then return to approximately...

Page 193: ...operation of 1 A 2 5 VA CL 1 See the diagram included with this manual Remote voltage adjustment potentiometer 470 3 W min adjustment range 5 range limited by internal voltage potentiometer P2 Remove...

Page 194: ...vent not only the recycling of hot air from the machine or engine but also exhaust fumes 3 2 Inspection prior to first use 3 2 1 Electrical checks Under no circumstances should an alternator new or ot...

Page 195: ...7 T12 T10 T4 T9 T3 T6 T11 T5 T2 T8 L2 V Voltage LM 1 2 voltage LL R 448 voltage detection 0 T3 220 V T2 L1 U L2 V L3 W NDE Winding 60 Hz 50 Hz 380 415 380 480 440 600 380 416 R 448 voltage detection 0...

Page 196: ...s Voltage L L Factory connection 3 phase N T1 T4 T3 T6 T5 T2 L1 U L3 W L2 V D L1 U L2 V L3 W L1 U L2 V L3 W NDE NDE LSA 47 1 6 WIRE LSA 47 1 6 WIRE N T3 T2 T1 T4 C11 C10 C12 T5 T6 L1 U L3 W 1 4 3 6 5...

Page 197: ...he machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram 3 3 5 Electrical checks on the AVR Check that all connections have been made properl...

Page 198: ...stments during tests must be made by a qualified engineer Take care that the drive speed specified on the nameplate is reached before commencing adjustment 1500 min 1 50Hz or 1800 min 1 60 Hz Do not t...

Page 199: ...ctive The voltage should drop by 2 to 3 If it increases swap the 2 incoming wires from the C T secondary n The no load voltages should be identical for all the alternators intended to run in parallel...

Page 200: ...ave a short circuit current so as to offer discriminating protection 3 5 3 Special type of use Field weakening The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxiliar...

Page 201: ...opped and checks carried out 4 2 4 Electrical servicing Cleaning product for the windings Do not use trichlorethylene perchlorethylene trichloroethane or any alkaline products Certain strictly defined...

Page 202: ...e bearing Bearing not fully locked abnormal play in the bearing cage End shields incorrectly aligned Abnormal temperature Excessive overheating of alternator frame more than 40 C above the ambient tem...

Page 203: ...ive speed Correct speed Check the AVR connections possible AVR failure Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low In...

Page 204: ...these systems should have characteristics which are compatible with the machine field excitation power see the nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field curre...

Page 205: ...cents respecting the polarity 4 6 4 Access to connections and the regulation system Access directly by removing the box lid 48 or the AVR access door 466 4 6 5 Replacing the NDE bearing on single bear...

Page 206: ...4 6 5 4 6 8 Reassembling the end shields Place the O ring seal 349 and the preloading wavy washer 79 in the bearing seat 36 Position shields 30 and 36 on the stator 1 Tighten screws 31 and 37 Reconnec...

Page 207: ...shaft extension 4 Mount the magnetised rotor on the adaptation shaft then using 2 M10 threaded rods screwed into the rotor slide the assembly onto the tie rod 5 Once the rotor is in position remove th...

Page 208: ...excitation current of the exciter field For 60 Hz machines the i exc values are approximately 5 to 10 lower 4 8 3 Voltage of auxiliary windings at no load LSA 46 2 Stator L N Rotor Field Armature M3...

Page 209: ...temperature probes PTC These are thermistor triplets with a positive temperature coefficient installed in the stator winding 1 per phase There can be a maximum of 2 triplets in the windings at 2 level...

Page 210: ...97 1 End plate 37 4 Fixing screw 320 1 Coupling sleeve 41 1 Cover front panel 321 1 Sleeve key 48 1 Cover top panel 322 3 Coupling disc 49 Cover screws 323 6 Fixing screw 51 1 Air intake louvre 325 Sp...

Page 211: ...t 28 1 Earth terminal 198 1 Voltage regulator AVR 30 1 DE shield 284 1 Circlips 31 6 or 4 Fixing screw 290 1 PMG housing 33 1 Fan guard 291 1 Adaptation shaft 34 2 Fixing screw 292 1 Magnetic rotor 36...

Page 212: ...26 INSTALLATION AND MAINTENANCE LSA 46 2 47 1 ALTERNATORS SPARE PARTS Ref 2981 GB 4 33 a 04 00 LEROY SOMER...

Page 213: ...27 INSTALLATION AND MAINTENANCE LSA 46 2 47 1 ALTERNATORS SPARE PARTS Ref 2981 GB 4 33 a 04 00 LEROY SOMER...

Page 214: ...MOTEURS LEROY SOMER 16015 ANGOUL ME CEDEX FRANCE Imprimerie MOTEURS LEROY SOMER RC ANGOULEME B 671 820 223...

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