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SDMO R33C3, User And Maintenance Manual

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CONTENTS-1

CONTENTS

Chapter 1 
BASIC SAFETY PRECAUTIONS

Fire and explosions .............................1-1

Keep flames away............................................ 1-1
Keep engine surrounding area tidy and clean.. 1-1
Care for fuel, oil and exhaust gas leakage....... 1-1
Use explosion-proof lighting apparatus............ 1-1
Prevent electrical wires from short-circuiting.... 1-1
Keep fire extinguishers and a first-aid kit 
handy ............................................................... 1-1

Stay clear of all rotating and moving 

parts ....................................................1-2

Install protective covers around rotating 
parts ................................................................. 1-2
Check work area for safety .............................. 1-2
Stay clear of moving parts while engine is 
running ............................................................. 1-2
Lockout and tagout .......................................... 1-2
Keep engine stopped during servicing............. 1-2
Always restore engine turning tools after use .. 1-2
Changing the engine speed setting is 
prohibited ......................................................... 1-2

Be careful of exhaust fume 
poisoning .............................................1-3

Operate engine in a well-ventilated area.......... 1-3

Be careful of falling down ....................1-3

Lift engine carefully .......................................... 1-3
Do not climb onto the engine ........................... 1-3
Always prepare stable scaffold ........................ 1-3

Protect ears from noise .......................1-4

Wear ear plugs................................................. 1-4

Be careful of burns ..............................1-4

Do not touch the engine during or immediately 
after operation.................................................. 1-4
Do not open the radiator filler cap when the 
engine is hot..................................................... 1-4
Do not touch high pressure injection fuel......... 1-4
Refill coolant only after the coolant 
temperature dropped........................................ 1-4

Be careful when handling fuel, engine 
oil or LLC .............................................1-5

Use only specified fuel, engine oil and LLC ..... 1-5
Handle LLC carefully........................................ 1-5
Proper disposal of waste oil, LLC and 
coolant ............................................................. 1-5

When abnormality occurs....................1-5

Do not add coolant immediately after a sudden 
stop due to overheating.................................... 1-5
Avoid immediate restart after abnormal stop.... 1-5
Avoid continuous engine operation at low oil 
pressure ........................................................... 1-5
If belt breaks, stop engine immediately............ 1-5

Service battery .................................... 1-6

Handle the battery correctly ............................. 1-6

Other cautions..................................... 1-7

Never modify engine ........................................ 1-7
Observe safety rules at work site ..................... 1-7
Work clothing and protective gear.................... 1-7
Never break seals ............................................ 1-7
Perform all specified pre-operation inspections 
and periodic inspections................................... 1-7
Break-in the engine .......................................... 1-7
Warm up the engine before use....................... 1-7
Never operate the engine in an overloaded 
condition........................................................... 1-7
Conduct cooling operation before stopping the 
engine .............................................................. 1-8
Protection of the engine against water entry.... 1-8
Properly maintain the air cleaner and 
pre-cleaner ....................................................... 1-8
Use of tools optimum for each work................. 1-8
Avoidance of prolonged time of starter 
operation .......................................................... 1-8
Do not turn off the battery switch during 
operation .......................................................... 1-8
Cautionary instructions for transporting the 
engine .............................................................. 1-8

Chapter 2 
NAME OF PARTS

Engine external diagrams ................... 2-1
Equipment and instrument .................. 2-8

Starter switch ................................................... 2-8
Preheat indicator .............................................. 2-8
Water temperature meter and thermo unit ....... 2-9
Ammeter........................................................... 2-9
Hour meter ....................................................... 2-9
Stop solenoid ................................................. 2-10

Engine protection devices................. 2-11

Oil pressure switch......................................... 2-11
Thermo switch................................................ 2-11
Air cleaner indicator ....................................... 2-11

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Summary of Contents for R33C3

Page 1: ...User and maintenance manual for generating sets Translation of the original instructions R33C3 33504023701NE_2_1 ...

Page 2: ......

Page 3: ...port 33 3 4 1 Generating sets with and without an enclosure 33 3 5 Shipping 34 3 5 1 Generating sets with and without an enclosure 34 3 6 Air transport 34 4 Installation Connections 35 4 1 Unloading the generating set 35 4 1 1 Choosing the location 35 4 1 2 Safety during unloading 36 4 1 3 Unloading the generating set 36 4 1 3 1 Slings 36 4 1 3 2 Fork lift truck 37 4 1 4 Moving the generating set ...

Page 4: ...tarting 76 6 3 3 Switching off 77 6 3 4 Alarms and faults 77 6 3 4 1 Viewing alarms and faults 77 6 3 4 2 Activation of an alarm or fault 78 6 3 4 3 Activation of an alarm and a fault 79 6 3 4 4 Engine fault codes display 80 6 3 4 5 Horn reset 81 7 Maintenance schedule 81 7 1 Reminder of use 81 7 2 Maintenance safety instructions 81 7 3 Table of maintenance operations 82 7 4 Cover maintenance 83 7...

Page 5: ...n of the generating set control 17 Figure 10 Example of a generating set identification plate 20 Figure 11 Fluid retention container 21 Figure 12 Example of French signalling 33 Figure 13 Examples of problems that may be encountered 35 Figure 14 Points used for lifting and moving 37 Figure 15 TT earthing system 39 Figure 16 View of the front side 53 Figure 17 Description of the LEDs 54 Figure 18 V...

Page 6: ...and corrective maintenance or even total reconditioning of generating sets The left and right sides can be seen from the back of the generating set the radiator is at the front Note some user and maintenance manuals for engines fitted to generating sets cover control units and include the start up and shut down procedures for the engines As our generating sets are fitted with control units that ar...

Page 7: ...The safety pictograms present on the equipment are explained below Warning danger Important Electrical risk Important risk of explosion Important toxic materials Important rotating or moving parts Important pressurised fluids Important high temperature Important corrosive product Danger automatic start up Figure 1 Warning pictograms Entry prohibited to unauthorised persons Jet washing prohibited F...

Page 8: ...y charge must be checked Periodic maintenance compulsory Figure 3 Pictograms indicating compulsory operations Earth Battery isolating switch External fuel connections Diesel fuel Drain the fuel Inspection flap Fill the coolant Drain the coolant Mains supply connection prohibited before filling with water Fill the oil Drain the oil Retention container high level Drain the retention container Figure...

Page 9: ...tion valve Securing straps routing point Figure 5 Specific pictograms Wearing suitable protective clothing and goggles is compulsory Rinse any splashes of acid on the skin or in the eyes using clean water Consult a doctor immediately Wash contaminated clothing with water Figure 6 Pictograms relating to battery operations 7 242 ...

Page 10: ... documentation supplied with the equipment Information for personnel Regularly reiterate the safety and operating instructions to the operating personnel Contact your dealer if you have any questions regarding the equipment and any training requests for personnel Make the manufacturer s instructions available to the users if possible on site Protection for individuals and equipment Wear suitable c...

Page 11: ...e intervals will need to be reduced Check that the spare parts fitted on the equipment are supplied only by the dealer Handle the equipment according to best practices using techniques which do not risk damaging the equipment Replace any safety pictograms that are missing or illegible on the equipment Note the mounting bolts on the protective devices of the rotating parts are captive bolts equippe...

Page 12: ...ns in the country of use and the neutral system sold Ask a qualified electrician to intervene when there are specific cases requiring equipment to be connected to an existing electrical network Disconnect the power to the equipment equipment voltage battery voltage and network voltage before any installation or maintenance operation is performed Connect the equipment wires by respecting the wiring...

Page 13: ...xplosions DANGER FUELS FLAMMABLE PRODUCTS PRESSURISED FLUID RISK OF BURNS RISK OF FIRE RISK OF EXPLOSION 1 Before starting the equipment move any flammable or explosive products away petrol oil cloth etc 2 It is prohibited to put combustible materials on the hot parts of the equipment for example exhaust pipe 3 Avoid any contact with the hot parts of the equipment for example exhaust pipe 4 Use ap...

Page 14: ... filler cap 5 It is prohibited to cover the generating set with a fine layer of oil for anti rust protection Battery Smoking using a flame or producing sparks are forbidden close to batteries particularly when the batteries are being charged Supply gas concerns generating sets running on gas Request the user technical notes and LPG or NG safety data sheets from your gas supplier For any operation ...

Page 15: ...ath by inhalation if the concentration levels in the atmosphere are too high Corrosion inhibitor in the coolant contains alkali Read the instructions on the packaging Keep the product out of the reach of children Do not swallow it Avoid prolonged or repeated contact with the skin Never allow contact with the eyes In the event of contact with the eyes 1 Rinse immediately with plenty of water for at...

Page 16: ...oad being handled Note the lifting rings provided on the equipment are designed to handle the generating set alone If additional equipment is fitted to the generating set a study should be conducted in order to define the centre of gravity of the assembly and to check the correct mechanical performance of the structure and its lifting rings 1 4 7 Precautions for risks relating to noise HIGH SOUND ...

Page 17: ...n 2 1 Description Overview Figure 7 General description of the generating set 1 Acces to maintenance area 4 Acces to control unit 2 Lifting ring 5 Acces to power connections 3 Forklift grooves 6 Drawbar 6 2 4 1 3 5 15 242 ...

Page 18: ...ral description of the generating set Continuation 1 Protective grille 4 Alternator 2 Battery isolating switch 5 External fuel supply combined tap optional 3 Starter battery 6 Charging alternator 3 1 2 4 6 5 16 242 ...

Page 19: ...tion of the generating set control Note Photo presented with the Nexys control unit 1 Control unit 4 Working hours counter 2 Emergency stop 5 Power circuit breaker 3 Socket control panel 6 Connection terminal block 6 5 2 3 1 4 17 242 ...

Page 20: ...imited time period per year as per ISO 8528 1 an overload of 10 one hour every 12 hours is available as per ISO 3046 1 Term of use Standard reference conditions ESP PRP 40 40 Air Intlet Temp 1000m 1000m mA S L 60 relative humidity Engine data Manufacturer model MITSUBISHI S4S Z361SD Type 4 Cycles Naturally aspirated Cylinder configuration 4 XL Cubic capacity 3 33 L Rotation speed 1500 Rpm Max emer...

Page 21: ...NEXYS Standard specifications Frequency meter Voltmeter Ammeter Alarms and faults Oil pressure Coolant temperature Fail to start Overspeed Alternator min max Fuel level low Emergency shutdown Engine parameters Working hours counter Engine speed Battery voltage Fuel Level Air Preheating TELYS Standard specifications Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature ...

Page 22: ...umber 5 Year of manufacture 6 Rated output kVA and kW according to the ISO 8528 1 standard PRP main power ESP emergency power 7 Rated power factor 8 Maximum altitude of the site above sea level m for the rated power 9 Maximum ambient temperature for the rated power C 10 Rated frequency Hz 11 Generating set rotation speed RPM 12 Rated voltage V 13 Rated current A 14 Weight kg 15 CE marking 16 Non C...

Page 23: ...n to be collected Figure 11 Fluid retention container The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers via the drain port Note Never allow these ...

Page 24: ...ates and Canada JIS KK 2204 Japanese Industrial Standards Japanese industrial standards Respecting pollutant emissions The certification measures confirming that the legal emission value limits are respected are performed with certified fuels which conform to the standards and requirements stated above Resistance to low temperatures When the external temperature is low the fluidity of diesel fuel ...

Page 25: ...el of viscosity and density reduces engine power and increases fuel consumption Too high a level of viscosity and density seriously reduces the service life and operation of the fuel injection system In order to maintain adequate technical and environmental performance the viscosity and density must conform to the specifications indicated in the manufacturer s instructions for the engines fitted t...

Page 26: ... 15W40 or Kohler 5W40 according to the model of the engine Viscosity Viscosity is a measure of the flow resistance of a fluid The viscosity of an engine oil is expressed by 2 SAE Society of Automotive Engineers grades One grade for cold weather and one grade for hot weather The grade for cold weather appears before the letter W The 1st grade represents dynamic viscosity in cold weather namely the ...

Page 27: ...pical values given for information purposes TBN Total Base Number degree of alkalinity a measure of a lubricant s reserve alkalinity according to standard ASTMD 2896 This check makes it possible to assess the ability of the product to remain in service and to check the capacity of the lubricant to neutralise the acidity contained in the oil which may corrode the metallic elements of the lubricated...

Page 28: ...eness and service life of the cooling system High temperature feature promotes heat exchange Long term protection against overheating and corrosion under extreme conditions of use Compatible with the original fluid however it is recommended to drain the entire cooling system when replacing the fluid Specifications Specifications Units Characteristics Density at 20 C kg m 3 1053 3 pH pH 7 5 to 8 5 ...

Page 29: ...nerating sets must be transported by road in accordance with the regulations of the countries concerned When transporting generating sets in containers by road the following steps must be observed 1 Put a plastic cover over non enclosed generating sets during transportation 2 Select transport equipment trailer semi trailer etc suitable for this usage and having all the safety guarantees in terms o...

Page 30: ... compatible with the trailer Towing a trailer with a non compliant device bar cables lashing etc runs the risk of serious accidents Also check That there are no incipient ruptures or significant wear on the hitching system That the locking system is working properly IMPORTANT Jockey wheel for M3128 and M3129 type trailers Jockey wheel for M3126 and M3127 type trailers 28 242 ...

Page 31: ...e adjustable towbar handle to place the ring above the hitching system Tighten the nut to lock the towbar Fit the towbar safety pin 4 Attach the ring to the hitching system Lower the trailer by moving the jockey wheel away from the ground using its handle 5 5 Lock the jockey wheel in the towing position When in the towing position the jockey wheel must not obstruct the unlocking cable s movement t...

Page 32: ... MUST NOT be wound around the jockey wheel as this will disable emergency braking MUST NOT be taut or obstructed as this could activate emergency braking during towing MUST be routed as straight as possible and not be obstructed at any point MUST be sufficiently long to allow cornering IMPORTANT 7 Connect the electrical cable plug controlling the lamps indicators etc to the socket on the towing ve...

Page 33: ...e jockey wheel touches the ground Tighten the jaw of the tube 7 with its lever M3128 M3129 type trailers Remove the safety pin from the position lock 8 on the jockey wheel Remove the position lock 8 Place the jockey wheel in the bottom position Fit the position lock 8 Fit the position lock pin Lower the jockey wheel to the ground with its handle Support the load on the jockey wheel Lower the jocke...

Page 34: ...ng speed must be suited to the condition of the road and the handling of the trailer Maximal speed on road 140km h Driving at high speed causes the tyres to heat it is therefore important to stop from time to time and check them Excessive heating may cause a puncture and therefore a serious accident For reversing manoeuvres remember to lock the inertia brake Particular attention must be paid to th...

Page 35: ...specific rules governing rail transport When transporting generating sets in containers by rail the following steps must be observed 1 Put a plastic cover over non enclosed generating sets during transportation 2 Choose transport equipment appropriate for this usage and having all the safety guarantees both in terms of load bearing capacity and securing devices Front reflective devices white Side ...

Page 36: ...or packing 3 6 Air transport Containers must be transported by air in accordance with the specific rules governing air transport The UN has classified generating sets as dangerous goods listed under UN code 3166 class 9 Engine internal combustion flammable liquid powered Any air shipment of generating sets must be subject to prior declaration to the air freight company in accordance with form MOD3...

Page 37: ...lectrical distribution panel nuisance caused by the noise fuel supply burnt gas evacuation direction of these gases and the noise generated Incorrect ventilation and exhaust Building or terrain too rough Generating set incorrectly seated Impossible to open enclosure doors Impossible to fill with fuel Figure 13 Examples of problems that may be encountered 1 m min 35 242 ...

Page 38: ...e to its place of use or transport in a clear space with free access Example of equipment to be used crane slings lifting beam safety hook shackles Forklift truck 4 1 3 Unloading the generating set Before unloading or moving generating set check that the handling equipment used is able to bear the weight of the generating set shown on the generating set s identification plate IMPORTANT 4 1 3 1 Sli...

Page 39: ...generating set in its unloading position Figure 14 Points used for lifting and moving 4 1 4 Moving the generating set Whenever moving the generating set ensure suitable equipment is used e g sling forklift etc and identify those parts on the generating set which can be used to move it lifting eye no 1 forklift grooves no 2 tow bar no 3 1 3 3 2 37 242 ...

Page 40: ...generating set Fixed differential protection Adjustable differential protection Set the differential protection of the generating set 30 mA 30 mA 300 mA 300 mA No operation required terminal circuits protected No operation required terminal circuits protected Add differential protection set to 30 mA to the terminal circuit output s Add differential protection set to 30 mA to the terminal circuit o...

Page 41: ... the option for France only 4 2 2 2 TT system In the TT earthing system automatic power cut off via a Residual Current Device RCD is obligatory at the upstream part of the installation to ensure that personnel are protected additionally a maximum 30 mA device must be installed on outlet circuits Figure 15 TT earthing system The alternator neutral is earthed the grounds of the user equipment have t...

Page 42: ... those devices located downstream terminal circuits this means that continuity on clean circuits will be maintained in the event of a fault on one of the terminal circuits see the following point on setting the residual current device Example Risk of electric shock The generating set s differential relay is factory set with a current threshold of 0 03 A 30 mA and with an automatic time delay 0 s A...

Page 43: ...t s differential relay must be longer than that of the terminal circuit Type A AC differential relay Use Differential relay for which operation is guaranteed for residual sinusoidal alternating currents for continuous pulsed residual currents for continuous pulsed residual currents with a continuous component of 0 006 A with or without phase check independent of the polarity Setting 1 Use a screwd...

Page 44: ... setting potentiometer 1 and the micro switches 4 to 0 03 A 30 mA 2 Use a screwdriver to adjust the time delay using the setting potentiometer 2 and the micro switches 4 to 0s automatic 3 Test the residual current device using the Test button on the relay Risk of electric shock The generating set s differential relay is factory set with a current threshold of 0 03 A 30 mA and with an automatic tim...

Page 45: ...nnect the battery leads starting with the negative lead or use the battery isolating switch before carrying out any operations on the generating set DANGER 1 Open the door to the power section no 1 then the access door to the cable router flap and to the connection terminal box no 2 2 Connect the earth cable supplied to the terminal rep 3 on the generating set located on the connection terminal bo...

Page 46: ...nected to the generating set s earth connection and a galvanised steel earthing rod completely buried in the ground in an upright position This earthing rod must be at least 2 5 m long of which at least 1 m must be in the ground 4 2 3 Making the connections 4 2 3 1 Connections general information When connecting always comply with standard NFC 15 100 and the application guide NFC 15 401 in France ...

Page 47: ... 25 4 10 6 9 10 7 32 6 9 6 9 10 7 40 10 7 10 7 16 5 50 10 7 10 7 16 5 63 16 5 16 5 25 3 80 25 3 25 3 35 2 100 35 2 35 2 4X 1X50 0 125 1 4X 1X50 0 4X 1X50 0 4X 1X70 2 0 160 1 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 250 1 4X 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 400 1 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 630 1 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM Single ph...

Page 48: ...ve lead or use the battery isolating switch before carrying out any operations on the generating set DANGER 1 Open the door to the power section no 1 then the access door to the power connection cable router flap and to the connection terminal box no 2 2 Loosen the two knobs no 3 of the power connection cable router flap then slide the flap no 4 towards the outside of the generating set 3 Feed the...

Page 49: ...ive and neutral wires are correctly connected Our generating sets are factory set with a conventional direction of phase rotation A phase converter not supplied can be used to ensure correspondence of phases between the generating set and the installation IMPORTANT To limit the risk of falls caused by obstacles on the floor it is recommended to suspend cables and ventilation ducts As necessary ens...

Page 50: ...y disclaims all liability for any accidents caused by these phenomena However it is possible to install surge protectors considering that this assembly does not provide complete protection 5 Installation 5 1 Warnings concerning commissioning The inspections referred to in this section enable the electrical generator set to operate Specific skills are required to carry out these operations They mus...

Page 51: ... Check the levels see the engine s maintenance manual coolant oil fuel Open the oil filler tap if fitted to the generating set Check the starter battery or batteries connecting and charge see the paragraph entitled Starter batteries Check the starter battery charging system if fitted to the generating set 5 5 Checking the generating set after startup Off load tests Carry out the safety checks emer...

Page 52: ...r Make sure the following valves plugs and cocks are open or closed tightened properly Fuel feed valve Open Coolant drain cock plug Closed Tightened Oil drain valve Closed Checking the engine oil level Do not top up the oil if the oil level is not below the low level marker Important Pull out the oil level gauge and wipe it clean using a waste cloth Insert the oil level gauge fully into the oil le...

Page 53: ... out and you may be scald with it Warning Open the radiator filler cap and check the coolant level If the coolant level is low add coolant to the speci fied level Check for leaks in the cooling circuit Checking the air filter A clogged filter element limits the engine s air intake and a reduced air supply to the engine Important If the air filter is fitted with a dust control valve A press the tip...

Page 54: ...t at the bottom of the pre filter If necessary drain the pre filter using the following procedure Place a suitable container under the drain plug prefilter Undo the drain plug A at the bottom of the pre filter by two or three turns Collect the water and or sediment in the container When fuel starts to flow out tighten the drain plug Check that there are no leaks If necessary reprime the fuel circu...

Page 55: ...the module and RESET function Electronic card protection fuse Screen scroll button press successively to access the various screens which are available STOP button press to switch off the generating set START button press to switch on the generating set Normal operation LEDs and alarm and fault warning LEDs Slot reserved for panel fascia options Mounting bolt LCD for displaying alarms and faults o...

Page 56: ...uction to pictograms The pictograms are as follows Operating temperature Fuel Overspeed Non starting fault Starting on external command Preheating Air intake Oil pressure Battery Delay Figure 18 View of pictograms The fuel level pictogram is used to display the fault the alarm and the fuel level The operating temperature and oil pressure pictograms are used to display the fault and analog value Th...

Page 57: ... If the motor is equipped with an air preheating system there is a 10 second delay before the motor starts preheating activation period The following screen appears The third line displays the air preheating time remaining with pictograms representing a resistor and an hourglass If the motor is not fitted with an air preheating system or once the preheating delay has elapsed the engine starts up s...

Page 58: ...ault which caused the generating set to stop If one or more faults have appeared after the first fault they can only be displayed after the first fault has been reset press Reset as many times as the number of faults present Note an alarm can appear at the same time as a fault 6 2 5 Faults and alarms Details List of faults which will cause the generating set to stop and generate a pictogram Oil pr...

Page 59: ...fferential relay the generating set stops immediately also causing the main circuit breaker to be tripped 2 Insulation fault optional with an insulation fault causing the activation of the control unit performing insulation the generating set stops immediately Associated message Underspeed fault indicates an incorrect rotation speed below 1000 rpm Associated message Emergency stop or external emer...

Page 60: ...te the fault or alarm status of the engine or ECU A Machine Parameters The following parameters are available on the Murphy fault finding module working hours counter engine speed battery voltage engine speed coolant temperature oil pressure fuel economy air manifold temperature actual consumption active status codes status codes recorded coming from the engine MDDM20 parameter configuration for d...

Page 61: ...The following diagram shows the structure of the main menu and how to go to each parameter 59 242 ...

Page 62: ... aspects of the fault finding module display to be modified Changing the unit of measurement There are two display modes available for units English or metric To change your units of measurement use the and scroll buttons until you get to the sub menu Press the and arrows simultaneously if you want to retain the current designation Press one of the scroll buttons to show the second mode for displa...

Page 63: ...t that there are no active fault codes the following screen will appear Depending on the SPN FMI code refer to the attached List of engine fault codes and Engine user and maintenance manual for help on fault finding and maintenance Note that the manufacturer documents do not always stipulate the SPN used for example Volvo uses a set of codes called PID Parameter Identifier or SID System Identifier...

Page 64: ...odes to display the following screen will appear The purpose of programmed codes is to create a fault log which is used to determine recurrent faults and thereby carry out effective corrective and preventive maintenance on the engine also it not desirable to delete these when the generating set is in operation onsite Note that at the test bench outlets the EEPROM memory in which the programmed cod...

Page 65: ... the result of the following problems the CAN_Hi or CAN_lo bus or both are connected to an electrical ground or an external source of current data is being not transmitted at a standard baud rate This type of fault generally requires repairs to be carried out on the CAN BUS connection and therefore involves work on the engine wiring harness i e on the fault finding module extension Run Time Bus Er...

Page 66: ...el for scrolling through the menus and screens and selecting items simply by pressing the wheel 5 STOP button press to switch off the generating set 6 START button press to switch on the generating set 7 Power ON LEDs and alarm fault warning LEDs 8 Location of USB ports 9 Mounting bolt 10 LCD for displaying alarms and faults operating statuses electrical and mechanical quantities 11 ESC button for...

Page 67: ...shing red 3 Module on green on continuously Figure 21 Close up of USB ports 1 USB key connection HOST file transfer between USB key and TELYS and vice versa 2 Connection for microcomputer DEVICE file transfer between PC and TELYS and vice versa main module power supply 3 Protective cover 1 2 3 2 3 1 65 242 ...

Page 68: ...ms relating to dimensions measured are displayed as well as Alarm and Fault pictograms Zone 3 in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4 in this zone messages relating to the control of the generating set and the menus are displayed Note the information displayed on measurements alarms and faults as wel...

Page 69: ... mode AUTO mode Fixed TELYS in automatic mode AUTO Flashing For 5 seconds when switching from MAN to AUTO mode Flashing Genset starting Fixed Genset started Fixed Genset stabilised voltage and frequency Flashing impression of constant movement from left to right The genset is generating and in use Fixed Usage supplied Not used Fixed Synchronisation Flashing Fixed Genset synchronised or coupled 67 ...

Page 70: ...level fault alarm Alarm High temperature fault No preheating fault alarm Battery Min battery voltage flashing Max battery voltage flashing Battery charge indicator flashing bars Oil pressure temperature indicator Oil pressure Alarm Fault High or low oil level Alarm Fault High or low oil temperature Alarm Fault Emergency stop Emergency stop fault Overload or short circuit Tripping of circuit breake...

Page 71: ...nset started or genset stoppage in progress Screen No Pictograms Data displayed P2 Engine Speed Indication High temperature HT coolant temperature indication units as per settings menu Oil Pressure Indication units as per settings menu Oil Temperature Indication units as per settings menu Genset started Screen No Pictograms Data displayed P3 Operation default screen Fuel Level Indication Alternato...

Page 72: ... V1 single Voltage Indication Alternator Frequency Indication P7 Alternator V1 single Voltage Indication Alternator phase 1 Current Indication Alternator Frequency Indication P8 Alternator phase 1 Current Indication Alternator phase 2 Current Indication Alternator phase 3 Current Indication Alternator Neutral Current Indication P9 Total Active Power Indication Total Reactive Power Indication Total...

Page 73: ...screen is changed using the scrolling and validation wheel When the wheel is turned clockwise the screens scroll upwards and backwards The screens scroll in a loop Example in a 3P N network after screen 7 then screen 1 and in reverse 6 3 1 6 Display of messages in zone 4 The graphic zone zone 4 is used to display messages relating to the generating set s operation These messages are as follows Ini...

Page 74: ...MATIC OPERATION IMPORTANT IMMEDIATE START UP POSSIBLE 24 08 2005 13 12 Operation mode genset in AUTO mode ready to start Date and time depending on settings Screen No Screen Data displayed G 5 IMPORTANT AUTOMATIC starting 19min30 24 08 2005 13 12 Operation mode genset in AUTO mode with programmed start Countdown of micro disconnection delay OR EJP for France only Date and time depending on setting...

Page 75: ...ngs Generating set started Screen No Screen Data displayed G 8 Default screen AVAILABLE POWER 75 24 08 2005 13 12 Operating phase genset operating stable voltage and frequency Available power Date and time depending on settings G 9 AUTOMATIC STOP IN PROGRESS LOAD SUPPRESSION 1min30 24 08 2005 13 12 Operation mode operation in AUTO mode Power supply device opens motorised circuit breaker or changeo...

Page 76: ...NG IN PROGRESS 24 08 2005 13 14 Operation mode operation in AUTO mode Synchronisation of the genset with the grid or another genset Date and time depending on settings G 10 2 POWER TRANSFER 24 08 2005 13 16 Operation mode operation in AUTO mode Transfer of power from the generating set to the grid Date and time depending on settings G 10 3 POWER TRANSFER 24 08 2005 13 16 Operation mode operation i...

Page 77: ...ode operation in MAN mode AUTOMATIC start demand Generating set stop demand if a fault occurs or if STOP is pressed in AUTO mode Screen No Screen Data displayed G 13 MAN mode activated Do you want to switch to AUTOMATIC mode OK Esc Operation mode operation in AUTO mode genset running Warning message for switch to MAN mode if STOP is pressed or if a fault occurs G 13 1 The 51 Hz offset must be appl...

Page 78: ...3 12 Check the battery voltage Press START AIR PREHEATING 10 seconds 24 08 2005 13 12 If the engine is equipped with an air preheating system there is a delay adjustable before the engine starts preheating activation period If the motor is not fitted with an air preheating system or once the preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to start up the en...

Page 79: ...ning the key to OFF without forcing it to the OFF position 6 3 4 Alarms and faults 6 3 4 1 Viewing alarms and faults Alarms and faults are displayed as follows Alarms All alarms will cause the yellow LED to flash General alarm In conjunction with this LED a flashing pictogram appears on the LCD screen representing the circuit affected by the alarm and the associated indicator if present example me...

Page 80: ...g order of their appearance from the most recent to the oldest 6 3 4 2 Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed examples below FAULT ALARM Low coolant Level 06 10 06 10 30 OK HELP FAULT FAULT Emergency Stop 06 10 06 15 30 Esc RESET OK HELP Press OK on the scrolling and selection wheel to access the help message if it is a...

Page 81: ...and selection wheel examples below FAULTS 1 2 FAULT 25 12 05 15 30 Emergency Stop ALARM 25 12 05 15 30 Low Fuel Level 12 OK HELP Esc Press Esc to return to the previous screen Press OK to go to the HELP screen help on the highlighted fault Use the scrolling and selection wheel to scroll through the list of faults HELP Check Emerg Stop Pos Connector s Esc If the alarm is no longer active it is rese...

Page 82: ...ents for example the injection system PID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to a specific component for example a sensor PPID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN PPID corresponds to PID but is only used by VOLVO FMI Fa...

Page 83: ...se The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule given as a guideline N B the environment in which the generating set is operating determines this schedule If the generating set is used in extreme conditions shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets...

Page 84: ...Check air cleaner Replace engine oil and oil filter a Inspect belt and adjust and belt tension Check and Clean radiator fins Add grease to link joints etc Replace fuel filter in line type fuel injection pump Inspect valve clearance Check glow plug Inspect starter Inspect alternator Retighten bolts and nuts on the engine a Clean nozzle tip Check and Clean fuel injection nozzle Inspect turbocharger ...

Page 85: ...6 months Every year Check General condition of the vehicle Tyre pressure Tighten the wheel nuts Efficiency of the automatic brake Efficiency of the parking brake Braking adjustment and distribution across all wheels Wear on brake linings and drums No play in the hubs Play in the clamping tube Play in the ball socket or ring Lubricate Braking control hinges and joints Stabilising Lubricate or greas...

Page 86: ...ercussions on an engine s operation and its service life Maintenance intervals will have to be shortened to accompany harsh operating conditions Shortening draining intervals among other things will enable you to change the oil more frequently which will tend to be choked with unburnt particles and contaminated with fuel Adding a load bench is generally used to limit low load phases and obtain the...

Page 87: ...istilled water carefully to avoid any splashes Wear protective goggles and rubber gloves when handling the battery adding water charging etc Note some batteries requiring no maintenance form the subject of specific instructions which must be respected After the battery has been topped up it must be recharged for at least 30 minutes 8 2 Checking the voltage acid density Every 2 months the following...

Page 88: ... increasing The power of the charger must be suitable for the battery to be charged and the charging time available Note if several batteries connected together are being recharged the following points must be checked Are the batteries connected in series Is the voltage chosen exact 1 battery x 12 V 3 x 36V batteries Adjust the charge current to the lowest battery The power difference between the ...

Page 89: ...arge the battery Battery exhausted or faulty Capacity too low Battery sulphated Replace the battery Battery terminals melted Incorrect electrical connection Battery cabling incorrect Tighten the ends of the battery cables or replace them if necessary and replace the battery One or two cells release a lot of gas at high charge Faulty cell s Replace the battery The battery discharges very quickly Ch...

Page 90: ...ting set is stopped until you are instructed to start up the generating set IMPORTANT Close the battery isolating switch to turn on the TELYS 2 Turn the supply switch of the TELYS 2 to the ON position Press the MENU key Using the knob select 3 SETTINGS and press the knob to confirm MENUS 3 4 1 ACTIONS 2 INFORMATION 3 SETTINGS 4 COUNTRY 12 OK Esc 88 242 ...

Page 91: ... or 60 Hz Return to the 3 SETTINGS screen and use the knob to select 35 NOMINAL VOLTAGE then press the knob to confirm Set the desired voltage then confirm using the scroll and confirm knob NOMINAL VOLTAGE 400 Vac Min 380 Max 480 12 OK Esc 3 SETTINGS 2 2 31 COMMUNICATION 32 FREQUENCY 33 VOLTAGE 34 50Hz 60Hz 12 OK Esc 50Hz 60Hz 50Hz 12 OK Esc 3 SETTINGS 4 7 34 50Hz 60Hz 35 NOMINAL VOLTAGE 36 PARAME...

Page 92: ... next to the TELYS 2 control unit Start up the generating set by pressing the START button Adjust the voltage after starting up the generating set using the 2003R08 potentiometer Warning when switching to 60Hz do not use sockets if fitted to the generating set IMPORTANT Configuration selector 90 242 ...

Page 93: ...ched off Important 9 3 Fuel supply valve The 3 way valve is used to select between the generating set fuel tank and an external fuel supply Valve in vertical position no 1 generating set supplied by the daily service tank Valve in horizontal position no 2 generating set supplied by the external tank EDF TT Ф 2 1 91 242 ...

Page 94: ...92 242 ...

Page 95: ...10 Appendix 10 1 Appendix A Engine user and maintenance manual 93 242 ...

Page 96: ...94 242 ...

Page 97: ...User guide and maintenance manual M MI IT TS SU UB BI IS SH HI I E En ng gi in ne e S SE ER RI IE E S SS S 99610 29120 01 07 2009 33522051001_3_1 95 242 ...

Page 98: ...96 242 ...

Page 99: ...to read this Oper ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance Never operate the engine or conduct maintenance work with out completely understanding this manual OPERATION MAINTENANCE MANUAL 199610 29120 97 242 ...

Page 100: ...n and maintenance information for engines from Mitsubishi Heavy Industries Ltd Please read this manual thoroughly before proceeding with operation inspection and maintenance work for correct use and servicing Failure to follow directions in this manual may result in serious accidents 98 242 ...

Page 101: ...gainst infringement of any patent Mitsubishi Heavy Industries Ltd will not be liable for any damages or consequential damages including but not limited to damages or other costs resulting from any abuse misuse misapplication of the engine and devices supplied from us Mitsubishi Heavy Industries Ltd will not be liable for any damages or personal injuries resulting from any modification without our ...

Page 102: ... Below warranty period shall begin on the date the engine is delivered to the first owner Warranted parts Mitsubishi Heavy Industries Ltd warrants the parts which will increase the emission of pollutants when they become defective The followings are examples Inlet Exhaust manifold Crankcase ventilation system Fuel system Fuel injection nozzle LIMITED WARRANTY Refer to LIMITED WARRANYT The followin...

Page 103: ...u are responsible for the performance of the required maintenance listed in your owner s manual Mitsubishi Heavy Industries Ltd recommends that you retain all receipts covering maintenance on your heavy duty off road engine but Mitsubishi Heavy Industries Ltd cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the heavy...

Page 104: ...tion e shall be warranted for the warranty period defined in Subsection b 2 A statement in such writ ten instructions to the effect of repair or repla ce as necessary shall not reduce the period of warranty coverage Any such part repaired or replaced under the warranty shall be warranted for the remaining war ranty period 3 Any warranted part which is scheduled for replacement as required maintena...

Page 105: ... valve and assembly D Turbocharger supercharger systems E Charged air cooling systems 3 Exhaust gas recirculation EGR system A EGR valve body and carburetor spacer if applicable B EGR rate feedback and control system 4 Air injection system A Air pump or pulse valve B Valves affecting distribution of flow C Distribution manifold 5 Catalyst or thermal reactor system A Catalytic converter B Thermal r...

Page 106: ...ts or devices and mount ing hardware D Pulleys belts and idlers E Emission control information labels F Any other part with the primary purpose of reducingemissions or that can increase emission during fail ure without significantly degrading engine performance e Mitsubishi Heavy Industries Ltd shall furnish with each new engine written instructions for the maintenance and use of the engine by the...

Page 107: ...e operated maintained and inspected only by qualified persons who have thor ough knowledge of engines and their dangers and who also have received risk avoidance training To prevent an accident do not attempt to carry out any operation other than those described in this man ual and do not use the engine for any unapproved purpose When the ownership of the engine is transferred be sure to provide t...

Page 108: ... could lead to serious accidents which could result in personal injury or death in the worst case Understand the directions well and handle engines with following directions Indicates an immediately hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a pote...

Page 109: ...W 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 75 cmHg Meter of water 1 kPa 10 197 cmH2O cmAq Engine speed 1 min 1 1 rpm Kinetic viscosity 1 mm2 s 1 cSt Abbreviations standards and others API American Petroleum Institute ASTM American Society for Testing and Materials ISO International Organization for Standardization JIS Japanese Industrial Standards LLC Long Life Coolant MIL Military Specificatio...

Page 110: ... or LLC 1 5 Use only specified fuel engine oil and LLC 1 5 Handle LLC carefully 1 5 Proper disposal of waste oil LLC and coolant 1 5 When abnormality occurs 1 5 Do not add coolant immediately after a sudden stop due to overheating 1 5 Avoid immediate restart after abnormal stop 1 5 Avoid continuous engine operation at low oil pressure 1 5 If belt breaks stop engine immediately 1 5 Service battery ...

Page 111: ...5 2 Engine oil deterioration mechanisms 5 2 Definition of properties of engine oil 5 3 Viscosity 5 3 Total base number 5 3 Total acid number 5 3 Water content 5 3 Flash point 5 3 Insoluble 5 3 Service Limits of engine oil 5 4 Chapter 6 COOLANT Recommended water for coolant 6 1 Long life coolant LLC 6 1 Genuine LLC 6 1 Other brand LLCs 6 2 Standard for other brand LLC 6 2 General demands of LLC 6 2...

Page 112: ...E Long term storage 9 1 Storing the engine in a non operable condition for 3 months or more 9 1 Preparation for storage 9 1 Maintenance during storage 9 1 Using the engine after storage 9 2 Storing the engine in an operable condition for 3 months or more 9 2 Operating the engine for maintenance 9 2 Chapter 10 TRANSPORTATION Lifting the engine 10 1 Chapter 11 TROUBLESHOOTING General precautions 11 ...

Page 113: ...Fig 6 1 GLASSY LLC 6 1 Fig 8 1 Belt and belt tension Inspect and Adjust 8 1 Fig 8 2 Fuel tank Drain water 8 2 Fig 8 3 Fuel filter Drain water 1 8 3 Fig 8 4 Fuel filter Drain water 2 8 3 Fig 8 5 Priming pump Handle 8 4 Fig 8 6 Fuel filter Bleed air 8 4 Fig 8 7 Fuel injection pump Bleed air 8 4 Fig 8 8 Fuel filter Bleed air 1 8 5 Fig 8 9 Fuel filter Bleed air 2 8 5 Fig 8 10 Fuel filter Replace 8 6 F...

Page 114: ... 9 1 Recommended rust preventive oil and corrosion inhibitor 9 1 Table 11 1 The starter does not crank or cranks slowly resulting in start failure 11 2 Table 11 2 The starter cranks but the engine does not start 11 2 Table 11 3 Output decrease 11 3 Table 11 4 Exhaust smoke is white or blue 11 4 Table 11 5 Exhaust smoke is black or charcoal 11 5 Table 11 6 Fuel consumption is high 11 6 Table 11 7 E...

Page 115: ...113 242 ...

Page 116: ...ngine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equipment Use explosion proof lighting apparatus When inspecting fuel engine oil coolant battery elec trolyte etc use a flameproof light An ordinary light ing apparatus may ignite gas and cause it to explode Prevent electrical wires from short circuiting Avo...

Page 117: ...es could result Lockout and tagout Be sure to lockout and tagout before starting inspec tion and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to OFF position and attach a Do Not Run or similar caution tag to the starter switch The starter switch ke...

Page 118: ... hangers provided on the engine using a cor rect sling During lifting process keep the engine in a well bal anced position by taking the center of gravity of the engine into consideration Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident If t...

Page 119: ...erature to lower sufficiently When opening the radiator filler cap open slowly to discharge the pressure inside the tank Also to avoid a risk of getting scalded by steam wear thick rubber gloves or wrap a cloth around the cap When closing the cap be sure to tighten securely The coolant is hot while engine is running and immedi ately after the engine stops If the cap is opened when the coolant is a...

Page 120: ...ke or other similar places Such a way of disposal is strictly prohibited by laws and reg ulations Dispose of waste oil LLC and coolant and other envi ronmentally hazardous waste in accordance with the applicable law and regulations When abnormality occurs Do not add coolant immediately after a sudden stop due to over heating If the engine stops suddenly or if you have no choice but stop the engine...

Page 121: ...lamp can cause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the battery switch to the Open OFF position or remove the plug from the negative terminal to cut off the electrical current Battery electrolyte contains dilute sulfuric acid Care less handling of the battery can cause the loss of sight and or skin burns Also do not consum...

Page 122: ...lance between fuel injection volume and governor operation or overrunning of the engine which could result in a serious accident Perform all specified pre opera tion inspections and periodic inspections Conduct the pre operation inspections and periodic inspections as described in this manual Failure to conduct the specified inspections may cause various engine problems damage to parts and serious...

Page 123: ...r or pre cleaner immediately cover the opening inlet port of air cleaner port in body for pre cleaner with plastic sheet or similar means to prevent foreign materials from entering the engine Clean the pre cleaner periodically The pre cleaner clogging can cause insufficient intake air or increasing in the exhaust temperature If the engine is equipped with a dust indicator con duct maintenance when...

Page 124: ... in line type fuel injection pump right view Fig 2 2 Engine right view Air inlet Stop solenoid Fuel injection nozzle Rear Flywheel Oil filter Oil level gauge Coolant drain plug Oil drain plug Fuel filter Governor Fan Water pump coolant inlet Fuel injection pump Fuel feed pump Crankshaft pulley Fuel inlet Front Front hanger Oil pan Belt Alternator Thermostat case Coolant outlet Front Rear hanger Oi...

Page 125: ...filter Oil level gauge Coolant drain plug Stop solenoid Rear Fuel injection nozzle Glow plug Fuel filter Governor Water pump coolant inlet Fuel injection pump Fuel feed pump Crankshaft pulley Fuel inlet Fuel return port Front Oil cooler Rear hanger Air inlet Front hanger Oil filler Flywheel housing Starter Oil pan Belt Alternator Thermostat case Coolant outlet Rear Front Turbocharger exhaust outle...

Page 126: ...eturn port Magnetic valve stop solenoid Oil drain plug Flywheel Oil filter Oil level gauge Coolant drain plug Air inlet Rear Fuel injection nozzle Fan Water pump coolant inlet Fuel injection pump Crankshaft pulley Fuel inlet Front Fuel filter Front hanger Oil pan Belt Alternator Thermostat case Coolant outlet Front Rear hanger Oil filler Exhaust outlet Flywheel housing Starter Rear 124 242 ...

Page 127: ... Water pump coolant inlet Fuel injection pump Crankshaft pulley Fuel inlet Oil drain plug Flywheel Oil filter Coolant drain plug Magnetic valve stop solenoid Rear Front Fuel injection nozzle Glow plug Fuel filter Oil level gauge Oil cooler Rear hanger Air inlet Front hanger Oil filler Exhaust outlet Flywheel housing Starter Oil pan Belt Alternator Thermostat case Coolant outlet Rear Front Turbocha...

Page 128: ...ter pump coolant inlet Fuel feed pump Fuel inlet Fuel return pipe Oil drain plug Flywheel Oil filter Oil level gauge Coolant drain plug Air inlet Stop solenoid Rear Front Fuel injection nozzle Fuel injection pump Fuel filter Front hanger Oil filler Coolant outlet Alternator Thermostat case Front Damper Belt Oil pan Rear hanger Oil filler Exhaust outlet Flywheel housing Starter Rear 126 242 ...

Page 129: ...Front Fuel return port Oil drain plug Flywheel Oil filter Oil level gauge Coolant drain plug Air inlet Magnetic valve stop solenoid Fuel injection nozzle Fuel filter Fan Water pump coolant inlet Fuel injection pump Fuel inlet Rear hanger Damper Front hanger Oil filler Oil filler Exhaust outlet Flywheel housing Starter Oil pan Belt Alternator Thermostat case Coolant outlet Rear Front 127 242 ...

Page 130: ...r Water pump Coolant inlet Fuel injection pump Magnetic valve Stop solenoid Oil filter Flywheel Oil drain plug Coolant drain plug Oil cooler Fuel injection nozzle Front Rear Relief valve Oil level gauge Turbocharger Air inlet Oil filler Oil filler Rear hanger Fuel return port Fuel inlet Front hanger Starter Coolant outlet Thermostat case Alternator Damper Belt Oil pan Exhaust outlet Front Rear 128...

Page 131: ...ved and inserted at this position To sotp engine turn the key to this position ON When the key is at this position power is supplied to the electric circuits After the engine starts the key is set to this position START When the key is turned to this position the starter cranks the engine and the engine starts When the key is released ti automatically returns to the ON position Fig 2 15 Starter sw...

Page 132: ...or 6 minutes and then inspect the cooling system Fig 2 17 Water temperature meter and thermo unit Ammeter It indicates the battery charging condition while the engine is running When the battery is charged the pointer swings to the positive side When the battery is discharged the pointer swings negative side Fig 2 18 Ammeter Hour meter It indicates the operating time of the engine When performing ...

Page 133: ... cut the fuel and consequently stops the engine Two types of stop solenoids are available RUN OFF ETS Energized To Stop type Not energized while the engine is running Energized by a stop signal to stop the engine RUN ON ETR Energized To Run type Energized while the engine is running and de ener gized to stop the engine Fig 2 20 Stop solenoid Stop solenoid ETR 131 242 ...

Page 134: ...s sure becomes abnormally low Fig 2 21 Oil pressure switch Thermo switch The oil pressure switch generates an alarm when the engine coolant temperature becomes high and reaches the specified temperature Fig 2 22 Thermo switch Air cleaner indicator The air cleaner indicator alarms with its red signal when air cleaner elements become clogged the differ ence in pressure between front air cleaner and ...

Page 135: ...133 242 ...

Page 136: ...l is about 10 to 15 mm 0 394 to 0 591 in above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water pour in carefully Fig 3 1 Battery electrolyte level Inspect Should an engine abnormality be observed during operation stop the engine and correct the problem or contact a dealer of Mitsubishi Heavy Industri...

Page 137: ...arks on the oil level gauge If the oil level is low add engine oil of the specified type 4 Install the oil filler cap after refilling 5 Check the oil pan and other area for oil leakage Fig 3 3 Oil filler and Oil level gauge When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not r...

Page 138: ... coolant up to the FULL level line Fig 3 4 Radiator filler cap Fig 3 5 Radiator coolant level Fig 3 6 Reserve tank coolant level Remove the radiator filler cap only after the engine has cooled to room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Never open the radiator filler cap while the...

Page 139: ...e The pressure gradually lowers to the normal level as the oil temperature rises External inspection during warm up Visually check the external view of the engine for fuel engine oil and coolant leakage or exhaust gas leak age from joints Before starting the engine check to make sure no one is near the engine and that tools are not left on or near the engine In a loud voice notify people in the ar...

Page 140: ...s during operation or immediately after shut down A hot engine can cause burns Always provide adequate ventilation in the engine room If air supply to the engine room is not sufficient the room temperature rises and can affect engine output and performance For the first 50 hours operate the engine under a light load for break in operation Operating the engine under heavy load or severe conditions ...

Page 141: ...rts and shorten the engine life Before stopping the engine idle the engine in low gear immediately until the engine temperature becomes normal except in an emergency Then perform cooling operation for 5 or 6 minutes before stopping the engine and inspect the whole engine Never accelerate the engine immediately before shutting it down Do not restart the engine immediately after abnormal shut down W...

Page 142: ...tank and also gives time for dust and water to separate and settle at the bottom of the tank Before refilling clean the areas around the caps thoroughly and remove the caps from the drum and tank Also clean your hands and the hose before refueling When using a hand operated pump be careful not to pump water or sediment accumulated at the bottom of the storage tank Be sure to use a strainer when fi...

Page 143: ... 2 0 mm2 s 0 0031 in2 s or more at 30 C 86 F 8 0 mm2 s 0 0124 in2 s or more at 30 C 86 F JIS K 2283 2000 ISO 3104 Sulfur content 0 2 weight or lower Except in cases the value is specified by the emission control JIS K 2541 2003 The content should be as low as the diesel fuel ISO 4260 ISO 8754 Water content and sediment 0 1 volume or lower JIS K 2275 1996 ISO 3733 Ash content 0 01 by mass or less 0...

Page 144: ...l tem perature 460 μm 0 02 in or less calculated wear scar diameter at WS 1 4 kPa 0 0143 kgf cm2 0 2031 psi ISO 12156 1 BDF Biodiesel fuel FAME Fatty Acid Methyl Ester BDF quality shall meet JIS K 2390 EN14214 or ASTM D6751 BDF blending of 5 by volume or less is approved Except in cases the value is specified by the emission control JIS K 2390 2008 FAME for mixture ASTM D 6751 EN 14214 Table 4 1 R...

Page 145: ...143 242 ...

Page 146: ... in compliance with the law When removing oil from the engine or oil can use an oil pump Do not suck oil with the mouth to siphon it Be sure to close the cap on the oil can after use Keep oil in a well ventilated area and out of direct sunlight Be sure to obtain the MSDS of the engine oil used and follow the instructions of the MSDS Use only the engine oils recommended in this manual Never use oth...

Page 147: ... can cause the wear of piston rings and cylinder walls Abrasion powder in the engine oil also accelerates deterioration as it can catalyze oxidation reaction Dust and dirt entered from outside deteriorate the en gine oil as well Contamination and deterioration pro cess accelerates with operation time Deterioration products and contaminants in the en gine oil if it is a small amount are harmless as...

Page 148: ...he engine oil oxidation or sulfurous acid or sulfuric acid derived by the combus tion of sulfur content of fuel or the oil becomes con taminated with imperfect combustion products An increase in the total acid number will result in cor rosion or wear of the inner parts of the engine such as cylinder liners or metal due to sulfur content and piston ring seizure due to sludge Water content Water in ...

Page 149: ...ming of engine oil replacement the stabiration of engine is required Refer to the following table for the determination of engine oil performance degradation If any of the following devi ate the limit replace the engine oil with new oil Table 5 1 Engine oil properties Properties Standard Test method Viscosity mm2 s in2 s 100 C 212 F 15 or more 30 or less of new oil JIS K 2283 2007 ISO 3107 ISO 290...

Page 150: ... does not meet the following specification Genuine LLC Mitsubishi Heavy Industries Ltd recommends the use of our genuine long life coolant GLASSY long life coolant Ethylene glycol type and Eco friendly prod uct PG GLASSY long life coolant Non amine type which are most appropriate coolant for diesel engine from Mitsubishi Heavy Industries Ltd Fig 6 1 GLASSY LLC Table 6 1 Water quality standards Ite...

Page 151: ...erning malfunctions caused by the use of LLC that does not meet the following specification General demands of LLC LLC shall be a homogeneous liquid Engine cooling system shall not receive troubles such as corrosions and precipitation products etc by LLC when the LLC is diluted to 30 to 60 density LLC shall be mixed with other LLC that satisfies this specification and shall not separate elements e...

Page 152: ... change Aluminum 0 30 mg cm2 Cast iron 0 15 mg cm2 Steel 0 15 mg cm2 Brass 0 15 mg cm2 Solder 0 30 mg cm2 Copper 0 15 mg cm2 External of test piece after the examination Not corrosion on surface excluding between test piece and spacer Discoloration is OK Bubbling while examination Not bubbling overflow Properties of liquid after the examination pH 6 5 to 11 0 pH change 1 0 Precipitation Maximum 0 ...

Page 153: ...n separation and gel Condition of parts Pump seal Not trouble while the examination Inside of pump case and blade Not remarkable corrosion Rubber adaptability 30 vol 115 C 239 F 360 Hr Silicon Tensile strength change 60 to 0 Elongation change 40 to 20 Volume change 0 to 40 Hardness change 20 to 10 Acrylonitrile butadiene rubber Tensile strength change 0 to 10 Elongation change 15 to 15 Volume chan...

Page 154: ...coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type For determining the accurate LLC concentration refer to the instructions for the LLC used Should coolant or LLC be accidentally consumed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention LLC is toxic Never dispose of coolant cont...

Page 155: ...re severe corrosion than when plain soft water is used This is a typical problem caused by the use of inap propriate LLC Examples of abnormali ties caused by LLC amine type Pitting of iron parts Amines are generally effective in suppressing the rust ing of ferrous metals but they are said to cause prob lems for copper parts Dissolved copper copper corrosion in the cooling system deposits on iron p...

Page 156: ...nance work regardless of rec ommended service intervals in the Maintenance schedule Note Appropriate service intervals vary depending on the usage and operating conditions as well as consumption of fuel oil and coolant Check the operating record of the engine to determine the most appropriate service intervals Feel free to consult a dealer of Mitsubishi Heavy Industries Ltd regarding service inter...

Page 157: ...place 8 6 Fuel system distributor type fuel injection pump Bleed air 8 5 Valve clearance Inspect Cleaning the fuel tank Every 500 service hours or Every 1 years Checking glow plug Every 1000 service hours Starter Inspect 8 18 Alternator Inspect 8 18 Bolts and nuts on the engine Retighten Every 1500 service hours Nozzle tip Clean Every 3000 service hours Fuel injection nozzle Check and Clean Turboc...

Page 158: ...Alternator side Adjust 1 Remove the belt cover 2 Loosen all retaining bolts of the alternator and ad justing plate 3 Move the alternator to adjust the belt tension 4 After adjusting the belt tension tighten all retaining bolts of the alternator and adjusting plate 5 Install the belt cover Fig 8 1 Belt and belt tension Inspect and Adjust If defects such as cuts or surface separations are found duri...

Page 159: ...n the drain cock of fuel tank and drain fuel at least 1 to 2 L 0 3 to 0 5 U S gal 3 Make sure that water and particles of foreign mate rials discharged with fuel Close the drain cock Fig 8 2 Fuel tank Drain water When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not remove the s...

Page 160: ...el by pushing down on the priming pump about seven strokes to facilitate draining 4 After draining tighten the drain plug securely 5 After drain the fuel filter bleed the fuel system For bleeding air from fuel system refer to Fuel system distributor type fuel injection pump Bleed air 8 5 Fig 8 4 Fuel filter Drain water 2 When handling fuel make sure there are no open flames or other fire hazards n...

Page 161: ...fuel flow from the air vent plug becomes free of bubbles push and turn the priming pump clockwise to lock 3 Tighten the air vent plug on the fuel injection pump Fig 8 7 Fuel injection pump Bleed air When fuel overflow from the air vent plug wipe thor oughly with a cloth Spilled fuel causes fire hazard After bleeding lock the priming pump securely If the cap is not locked tightly the priming pump c...

Page 162: ...rns 2 Apply a cloth to the air vent plug Fig 8 8 Fuel filter Bleed air 1 3 Repeat pumping until the fuel flow from air vent plug becomes free of bubbles 4 Repeat pumping until the fuel flow from air vent plug becomes free of bubbles Fig 8 9 Fuel filter Bleed air 2 When handling fuel make sure there are no open flames or other fire hazards near the engine When fuel overflows from the air vent plug ...

Page 163: ...uel filter in line type fuel injection pump Replace 8 6 9 Start the engine and let it idle for several minutes 10 Make sure that there is no fuel leakage during the engine operation If fuel leakage is found loosen the fuel filter and check the gaskets for damage If there is no damage retighten the fuel filter Fig 8 10 Fuel filter Replace Fig 8 11 Fuel filter When handling fuel make sure there are ...

Page 164: ...r installing the new fuel filter bleed the fuel sys tem Note For bleeding fuel system refer to Fuel system distributor type fuel injection pump Bleed air 8 5 12 Start the engine and let it idle for several minutes 13 Make sure that there is no fuel leakage on mount ing sureface of fuel filter element If fuel leakage is found loosen the fuel filter and check the gaskets for damage If there is no da...

Page 165: ...il or changing the oil filter wear gloves Hot engine oil and parts may cause burns Do not dump waste oil It is forbidden by law For disposal of waste oil consult a dealer of Mitsubishi Heavy Indus tries Ltd Change engine oil and the oil filter at the same time Also checking and analyzing the oil properties is recommended when changing the engine oil Do not reuse the oil filter element as it is a p...

Page 166: ...he gauge again 7 The proper oil level is between the high and low marks on the oil level gauge If the oil level is low add engine oil of the specified type 8 Check the oil pan and other area for oil leakage Repair any oil leakage found 9 Run the engine with starter for approx 10 seconds while pulling the stop lever and feed engine oil to all parts of engine Stop the operation for 1 minute then rep...

Page 167: ...nting surface of oil filter with a waste cloth 5 Check the new oil filter for proper seating of gasket 6 Apply clean engine oil to gasket 7 Install the oil filter When the filter gasket contacts the mounting surface of filter tighten the filter with specified torque Fig 8 15 Oil filter Change Fig 8 16 Oil filter Do not use a dented filter cartridge Filter damage or fule leakage may occur while eng...

Page 168: ...r the engine has cooled to room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it Coolant containing LLC drained from the engine is toxic Never dispose of coolan...

Page 169: ...For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICA TIONS 12 1 3 Pour in water soft water with minimal impurities such as tap water slowly to FULL level line 4 Check the radiator and other parts for coolant leak age If any coolant leakage is found repair it 5 When coolant reaches FULL level line close the radiator filler cap securely 6 Run the engine with starter ...

Page 170: ... and cracks To clean the radiator fins blow compressed air from the opposite direction of the normal air flow Fig 8 22 Radiator fins Clean When handling compressed air wear safety goggles a hardhat gloves and other necessary protective gear Works without wearing proper protective gear could result in serious injuries 168 242 ...

Page 171: ...side Hold the compressor wheel nut by hand and turn the wheel to check for looseness or abnormal noise Replace the turbocharger if looseness or abnormal noise is found Note When removing and inspecting turbocharger contact a dealer of Mitsubishi Heavy Industries Ltd Fig 8 24 Turbocharger Inspect Checking procedure described below is a commonly used procedure Some application may be equipped with d...

Page 172: ... detergent 2 Rinse the pre cleaner with fresh water 3 After drying thoroughly inspect the pre cleaner for defect If any defect are found replace the pre cleaner with a new one 4 After cleaning inspecting or changing the pre cleaner reinstall it to the silencer Fig 8 25 Pre cleaner Clean Never service the pre cleaner while the engine is running Servicing the air cleaner while the engine is running ...

Page 173: ...ng the air cleaner element press the reset button to reset the indicator Fig 8 26 Air cleaner element Remove Fig 8 27 Air cleaner element Clean and Check Fig 8 28 Air cleaner Check When handling compressed air wear safety goggles a dust mask a hardhat gloves and other necessary protec tive gear Works without wearing proper protective gear could result in serious injuries Never service the air clea...

Page 174: ...ravity of battery electrolyte Check If the specific gravity measured at 20 C 68 F is lower than 1 22 then charge the electrolyte Fig 8 30 Specific gravity of battery electrolyte Check If battery electrolyte is spilled on your skin flush immediately with plenty of water If battery electrolyte enters the eyes flush them immediately with lots of fresh water and seek medical attention at once Do not u...

Page 175: ... of Mit subishi Heavy Industries Ltd Fig 8 31 Starter Inspect Alternator Inspect Visually check the alternator for damage If the alternator is dusty blow foreign material using compressed air Remove the belt and check that the movement is smooth when rotating the pulley by hand Note If the alternator is defective consult a dealer of Mitsubishi Heavy Industries Ltd Fig 8 32 Alternator Inspect Start...

Page 176: ... breather and other openings with an adhesive cloth tape 8 Cover the entire engine Note a Store the engine in a well ventilated indoor area b It is not necessary to drain coolant since it contains LLC Add LLC to increase the concentration to between 30 to 60 c Post a sign at an easily noticeable place to warn that the rust preventive oil in the engine must be replaced with engine oil and the fuel ...

Page 177: ...ute then repeat the operation two or three times 11 Make sure the engine oil pressure rises 12 Conduct a warm up operation for a sufficient duration Note For starting the engine refer to Starting 3 4 13 Apply load and increase the engine speed to the rated speed Storing the engine in an operable condition for 3 months or more When the engine is not operated during storage of 3 months or more inter...

Page 178: ...ne s center of gravity Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident Attach wire ropes to the hangers after removing the pipe cover and the insulator near the hangers To prevent wire ropes from contacting the engine use a cloth or other s...

Page 179: ...177 242 ...

Page 180: ...isassembly sequence so that you can reassemble the component in reverse order of disas sembly Cautions against contamination Dust and foreign materials are the most common cause of rapid wear of parts When disassembling a component take measures to prevent dust and foreign materials from entering the component being disassembled Cautions regarding parts han dling Handle parts carefully When replac...

Page 181: ...he starter cranks but the engine does not start Cause Remedies Fuel system Run out of fuel blocked pipe Inspect fuel tank supply fuel bleed air Refer to P8 2 Check fuel pipes valves Improper fuel property Use appropriate fuel Refer to P4 1 Remove dust water impurities Refer to P8 2 Fuel leakage in fuel pipes and injection pipes Check faults and retighten fuel pipes and injection pipes Consult a de...

Page 182: ... fan and radiator Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Refer to P8 16 Check intake air pressure and leakage of intake air Check intake air temperature and ventilation device Cons...

Page 183: ...ke temperature Consult a dealer of Mitsubishi Heavy Industries Ltd Incorrect fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Lubricating system Combustion of engine oil Check amount of engine oil and lubrication system Refer to P3 2 Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overcooled Check radiator Refer to P8 13 Check control system Thermostat I...

Page 184: ...ems Insufficient amount of air Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Refer to P8 16 Check intake air pressure and leakage of intake air Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Increase resistance of exhaust air Check turbocharger Refer to P8...

Page 185: ... dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Refer to P8 16 Check intake air pressure and leakage of intake air Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd ...

Page 186: ...on system Refer to P3 2 Check oil cooler and oil thermostat Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overheating Check radiator Refer to P8 13 Check control system Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Spread oil to intake part Check oil leakage to the turbocharger Consult a dealer of Mitsubishi Heavy Industries L...

Page 187: ...cating system Insufficient amount of engine oil Check amount of engine oil and lubrication system Refer to P3 2 Faulty engine oil property viscos ity Analyze oil property Use appropriate engine oil Refer to P5 1 Oil temperature too high Check coolant system Consult a dealer of Mitsubishi Heavy Industries Ltd Oil filter clogged Inspect and replace oil filter Refer to P8 8 Faulty oil pump operation ...

Page 188: ... switch to the OFF position 2 Add fuel to the fuel tank For filling fuel tank refer to Fuel tank oil level Check 3 2 3 Bleed air from the fuel system For bleeding fuel system refer to Fuel system in line type fuel injection pump Bleed air 8 4 or Fuel system distributor type fuel injection pump Bleed air 8 5 4 Restart the engine For starting the engine refer to Starting 3 4 186 242 ...

Page 189: ...28 23 in 781 567 815 mm 30 75 x 22 32 x 32 09 in Dry weight 245 kg 540 lbs 250 kg 551 lbs Fuel Diesel fuel equivalent for JIS K 2204 Fuel injection pump In line type or distributor type VE type Fuel filter Cartridge type pape element with water separator Fuel injection nozzle Throttle type Hole type Initial fuel injection pressure 11 77 MPa 120 kgf cm2 1707 psi 17 65 MPa 180 kgf cm2 2560 psi Lubri...

Page 190: ... in 1038 567 842 mm 40 87 x 22 32 x 33 15 in Dry weight 345 kg 761 lbs 355 kg 783 lbs Fuel Diesel fuel equivalent for JIS K 2204 Fuel injection pump In line or distributor type VE type Fuel filter Cartridge type pape element with water separator Fuel injection nozzle Throttle type Hole type Initial fuel injection pressure 11 77 MPa 120 kgf cm2 1707 psi 17 65 MPa 180 kgf cm2 2560 psi Lubrication me...

Page 191: ...July 2009 Pub No 99610 29120 OPERATION MAINTENANCE MANUAL 189 242 ...

Page 192: ...Printed in Japan Pub No 99610 29120 190 242 ...

Page 193: ...10 2 Appendix B Alternator user and maintenance manual 191 242 ...

Page 194: ...192 242 ...

Page 195: ...nual L LE ER RO OY Y S SO OM ME ER R A Al lt te er rn na at to or r L LS SA A4 42 2 2 2 S S4 4 L LS SA A4 42 2 2 2 S S5 5 L LS SA A4 42 2 2 2 L L9 9 4 42 2 2 2 S SH HU UN NT T A AR RE EP P 3433 g 01 10 2010 33522019901_6_1 193 242 ...

Page 196: ...194 242 ...

Page 197: ...This manual must be supplied to the end user LSA 42 2 2 4 POLE ALTERNATORS Installation and maintenance 3433 en 2010 10 g 344 343 347 1 124 120 198 100 132 37 4 15 30 33 323 324 322 49 28 195 242 ...

Page 198: ... general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristicsofitsproductsatanytimeinordertoincorporate the latest technological developments The information contained in this document may therefore be changed without notice WARNING SYMBOLS We would like to draw your attention to the following two safety measures th...

Page 199: ... INSTALLATION COMMISSIONING 3 1 Assembly 6 3 2 Inspection prior to first use 6 3 3 Electrical diagram 7 3 4 Commissioning 9 3 5 Setting up 9 4 SERVICING MAINTENANCE 4 1 Safety measures 10 4 2 Regular maintenance 10 4 3 Fault detection 10 4 4 Mechanical defects 11 4 5 Electrical faults 11 4 6 Dismantling reassembly 13 4 7 Characteristics table 15 5 SPARE PARTS 5 1 First maintenance parts 16 5 2 Des...

Page 200: ...nditions of relative humidity of more than 90 the alternator insulation can drop very rapidly to just above zero at around 100 monitor the state of the anti rust protection on unpainted parts For storage over an extended period the alternator can be placed in a sealed enclosure heatshrunk plastic for example with dehydrating sachets inside away from significant and frequent variations in temperatu...

Page 201: ...ge and standard cylindrical shaft extension Drip proof machine self cooled 2 2 1 Options Protection against harsh environmentsh Air input filter air output labyrinth cowling Alternators fitted with air inlet filters should be derated by 5 power To prevent excessive temperature rise caused by clogged filters it is advisable to fit the stator winding with thermal sensors PTC or PT100 Varistor Field ...

Page 202: ...This alternator has been balanced with a 1 2 key 3 1 3 Location Ensure that the ambient temperature in the room where the alternator is placed cannot exceed 40 C for standard power ratings for temperatures above 40 C apply a derating coefficient Fresh air free from damp and dust must be able to circulate freely around the air input louvres on the opposite side from the coupling It is essential to ...

Page 203: ...0 T4 T9 T3 T6 T11 T5 T2 T8 L2 V A 3 phase 3 phase Winding 60 Hz 50 Hz 190 208 190 240 220 230 190 208 6 7 8 N T1 T7 T12 T10 T4 T9 T3 T6 T11 T5 T2 T8 L1 U L3 W L2 V D F L1 U M L3 W T1 T7 T12 T10 T4 T9 T3 T6 T11 T5 T2 T8 L2 V Voltage LM 1 2 voltage LL R 250 voltage detection 0 T8 110 V T11 R 438 voltage detection 0 T3 220 V T2 N L1 U L2 V L3 W NDE T9 T8 T7 T12 T10 T11 T4 T3 T2 T1 T5 T6 Winding 60 Hz...

Page 204: ...detection 0 T3 220 V T2 M L L NDE T9 T8 T7 T12 T10 T11 T4 T3 T2 T1 T5 T6 1 phase or 3 phase L1 U L2 V L3 W L L Winding 60 Hz 50 Hz 110 120 120 110 120 120 130 6 7 8 R 250 voltage detection 0 T8 110 V T11 R 438 voltage detection 0 T3 110 V T2 NDE T9 T8 T7 T12 T10 T11 T4 T3 T2 T1 T5 T6 L L L3 W T1 T7 T10 T9 T3 T6 T11 T5 T2 T8 L2 V B T12 T4 L1 V R 791 T interference suppression kit standard for CE ma...

Page 205: ...l lugs on top of one another as shown in the terminal connection diagrams theequipotentialearth links have been implemented correctly cross section and continuity of the earths 3 4 Commissioning The alternator can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The alternator is tested and set at the factory When first u...

Page 206: ...defined pure volatile degreasing products can be used such as Normal petrol without additives inflammable Toluene slightly toxic inflammable Benzene or benzine toxic inflammable Ciclohexare non toxic inflammable The insulating components and the impregnation system are not at risk of damage from solvents see the list of authorised products Avoid letting the cleaning product run into the slots Appl...

Page 207: ...ge does not reach the rated value when the battery is removed Check the connection of the voltage reference to the AVR Faulty diode Armature short circuit The alternator builds up but its voltage disappears when the battery is removed Faulty AVR Field windings open circuit check winding Main field winding open circuit check the resistance Voltage too low Check the drive speed Correct speed Check t...

Page 208: ...pply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the alternator field excitation power see the nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 L2 L3 checking the excitation voltage and current at...

Page 209: ... M 5 4 N m Assembly rod M 8 20 N m Earth screw M 6 5 N m Balancing bolt M 5 4 N m Discs shaft screw M 10 66 N m Lifting screw M 8 4 N m Grille screw M 6 5 N m Cover screw M 6 5 N m 4 6 3 Access to connections and the regulation system The terminals are accessed by removing the terminal box lid 48 To access the adjustment potentiometers on theAVR the side plate should be removed 367 4 6 4 Accessing...

Page 210: ...and tighten the 8 fixing screws Check that the whole alternator is correctly assembled and that all screws are fully tightened 4 6 7 Accessing the main field and stator 4 6 7 1 Dismantling Follow the procedure for dismantling bearings see sections 4 6 5 1 and 4 6 5 1 Remove the coupling discs single bearing alternator or the DE flange two bearing alternator and insert a tube of the corresponding d...

Page 211: ...9 0 9 0 91 0 9 0 92 4 7 3 3 phase 4 pole with SHUNT excitation Resistances at 20 C W LSA 42 2 VS0 VS2 S3 S4 S5 M6 M7 L9 L N stator 1 54 0 7 0 53 0 32 0 32 0 2 0 2 0 19 Rotor 1 71 2 1 2 3 2 7 2 7 3 3 3 3 3 7 Field 25 6 25 6 25 6 25 6 25 6 25 6 25 6 25 6 Armature 0 51 0 51 0 51 0 51 0 51 0 51 0 51 0 51 Field excitation current i exc A 400 V 50 Hz Symbols i exc excitation current of the exciter field...

Page 212: ...arts without delay To ensure correct operation and the safety of our alternators we recommend the use of original manufacture spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage WARNING No Description Qty LSA 42 2 SHUNT 2 4 P Coding 198 Voltage regulator AVR 1 R 250 AEM 110 RE 019 343 Diode bridge assembly 1 LSA 411 1 59 60 ESC ...

Page 213: ... 30 1 DE flange 132 1 Terminal box 33 1 Air outlet grille 198 1 Regulator AVR 36 1 N D E bracket 322 1 Coupling disc 37 4 Tie rod 323 6 Fixing screw 48 1 Terminal box lid 324 1 Clamping washer 49 20 Terminal box fixing screw 343 1 Direct diode assembly 51 1 Air intake grille 344 1 Reverse diode assembly 70 1 NDE bearing 347 1 Surge suppressor 79 1 Preloading wavy washer 367 2 Inspection door 90 1 ...

Page 214: ... Terminal plate support AREP 33 1 Air outlet grille 124 1 Terminal plate 36 1 N D E bracket 132 1 Terminal box 37 4 Tie rod 198 6 Regulator AVR 48 1 Terminal box lid 343 1 Direct diode assembly 49 20 Terminal box fixing screw 344 1 Reverse diode assembly 51 1 Air intake grille 347 1 Surge suppressor 60 1 DE bearing 367 2 Inspection door 70 1 NDE bearing 349 1 O ring seal 79 1 Preloading wavy washe...

Page 215: ...cating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets The Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with the Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the following International Standa...

Page 216: ...MOTEURSLEROY SOMER16015ANGOULÊMECEDEX FRANCE RCS ANGOULÊME N B 671 820 223 S A au capital de 62 779 000 http www leroy somer com 214 242 ...

Page 217: ...T11 STATOR 12 wires marking T1 to T12 MAIN FIELD R 250 VOLT FREQ L A M CONFIG STAB F1 Slow fuse 250V 8 A P1 Voltage P2 Stability 110 E E 0V 0 9 8 7 6 5 4 3 2 1 o 1 2 3 5 6 7 9 8 4 60Hz 65Hz 57Hz 47 5Hz 50Hz KNEE SPECIAL LAM OFF OFF 13 13 25 25 LAM KNEE KNEE LAM OFF LAM OFF LAM OFF External potentiometrer for voltage adjusting ST4 Option Frequency selector 50 H 60 Hz for U F fonction and LAM adjust...

Page 218: ...e following warning symbols Warningsymbolforanoperationcapable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The information conta...

Page 219: ...reakdown operations on the A V R are to be done by personnel trained on commisioning servicing and maintenance for the electrical and mechanical elements The R250 is an IP00 product It must be installed inside a unit so that this unit s cover can provide IP20 minimum total protection it must only be installed on LS alternators in the appropriate location so that when viewed externally it has a hig...

Page 220: ...a short circuit capacity 4 x holes Ø 5 8 x 50 x 115 mm 140 mm 75 mm SHUNT SYSTEM Field Induced T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11 T12 STATOR 12 wires marking T1 to T12 MAIN FIELD R 250 VOLT FREQ L A M CONFIG STAB F1 Slow fuse 250V 8 A P1 Voltage P2 Stability 110 E E 0V 0 9 8 7 6 5 4 3 2 1 o 1 2 3 5 6 7 9 8 4 60Hz 65Hz 57Hz 47 5Hz 50Hz KNEE SPECIAL LAM OFF OFF 13 13 25 25 LAM KNEE KNEE...

Page 221: ...houtLAMforimpacts between 30 and 40 of the rated load 1 threshold at 48 Hz with LAM 13 for impacts between 40 and 70 of the rated load 2 threshold at 48 Hz with LAM 25 for impacts 70 of the rated load Operating at 60 Hz U F gradient 3 thresholdat58HzwithoutLAMforimpacts between 30 and 40 of the rated load 4 threshold at 58Hz with LAM 13 for impacts 40 and 70 of the rated load 5 threshold at 58Hz w...

Page 222: ... speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engines To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the lowest frequency in steady state It is advised t...

Page 223: ...a diesel engine or without a LAM U F only 2 5 1 Voltage 2 5 2 Frequency 2 5 3 Power UN 0 0 9 0 8 U f with LAM Time without LAM 1 s 2 s 3 s Transient voltage drop 0 9 0 8 fN Max speed drop 0 with LAM Time without LAM 1 s 2 s 3 s 0 1 s 2 s 3 s Time LAM Load variation Load on shaft kW Shedding due to LAM 221 242 ...

Page 224: ...er positions voltage setting potentiometer P1 for the A V R full left remote voltage setting potentiometer in the middle Operate the alternator at its rated speed if the voltage does not rise it is necessary to re magnatise the magnetic circuit slowly adjust the voltage potentiometer of theA V R P1untiltheoutputvoltagereaches its rated value Stability setting with P2 3 2 2 Special type of use Exci...

Page 225: ...urnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the A V R pot P1 before returning to the correct speed Voltage too high Adjust A V R potentiometer Adjustment ineffective Faulty A V R 1 faulty diode Voltage oscillations Adjust A V R stability potentiometer Check the speed possibility of cyclic irregularity Loose terminals Faulty A...

Page 226: ... For replacement part orders it is necessary to indicate the type and the code number of the A V R Please contact your usual correspondant An extensive network of service centres is available to rapidly supply any necessary parts In order to ensure the correct operation and safety of our machines we strongly recommend that original manufacturer s spare parts are used Failure to do so will discharg...

Page 227: ...Installation and maintenance R250 A V R 4067 en 2009 05 b LEROY SOMER 11 225 242 ...

Page 228: ...MOTEURS LEROY SOMER 16015 ANGOULÊME CEDEX FRANCE 338 567 258 RCS ANGOULÊME S A au capital de 62 779 000 www leroy somer com 226 242 ...

Page 229: ...3 T4 T5 T6 5 6 T7 T8 T9 T10 T11 T12 R 438 F1 ST5 P5 ST11 ST2 ST1 P3 P2 ST4 ST9 AREP PMG PMG T I S1 P1 Ph 1 P2 S2 R731 50Hz 60Hz ST10 13 LAM 25 P1 2010 11 f 3971 en This manual is to be given to the end user R438 A V R Installation and maintenance 227 242 ...

Page 230: ...s This A V R can be incorporated in a ma chine marked C E Warning symbol for an operation ca pable of damaging or destroying the ma chine or surround ing equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at anytimeinordertoincorporatethelatesttech nological dev...

Page 231: ...PARE PARTS 12 4 1 Designation 12 4 2 Technical support service 12 All such operations performed on the A V R should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components The R438 is an IP00 product It must be installed inside a unit so that this unit s cover can provide IP20 minimum total protection it must only be installed on LS...

Page 232: ...nsistor This principle ensures that regulation is not affected by distortions ge nerated by the load 4 x holes Ø 5 8 x 175 x 115 mm 200 mm 140 mm X2 X1 Z2 E E 0V 110 220 380 Z1 T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11 T12 R 438 F1 ST5 P5 ST11 ST2 ST1 P3 P2 P1 ST4 ST9 Option AREP PMG PMG T I Option S1 P1 Ph 1 P2 S2 R731 Option AREP SYSTEM Field Armature 10 Yellow 11 Red 9 Green 12 Black MAIN...

Page 233: ... 5 8 x 175 x 115 mm 200 mm 140 mm X2 X1 Z2 E E 0V 110 220 380 Z1 T1 T2 T3 T4 T5 T6 V a r i s t o r 5 6 T7 T8 T9 T10 T11 T12 R 438 F1 ST5 P5 ST11 ST2 ST1 P3 P2 P1 ST4 ST9 Option AREP PMG 14 15 16 PMG T I Option S1 P1 Ph 1 P2 S2 R731 Option PMG SYSTEM Field Armature MAIN FIELD Slow fuse 250V 8 A with LAM without LAM Excitation ceiling knee point 65 Hz open Response time normal fast Stability Voltage...

Page 234: ...ection ST4 External potentio meter Without Potentiometer ST5 Without With LAM ST9 Others PMG AREP Supply ST10 13 or 25 LAM voltage drop amplitude ST11 65 Hz 48 or 58 Hz U f function bend position 2 1 2 Setting potentiometers function Delivrery position Pot Function 0 P1 Quadrature droop operation with C T 400V P2 Voltage Centre P3 Stability Maxi P5 Excitation current ceiling 2 2 Frequency compared...

Page 235: ... Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only 2 4 1 Voltage 2 4 2 Frequency 2 4 3 Power LAM UN 0 48 or 57 5 Hz 0 85 UN Voltage U f 50 or 60 Hz fC fN Voltage ST5 disconnected ST3 P2 Underspeed and LAM 0 Time Drop N 46 Hz U Drop N 46 Hz UN 0 0 9 0 8 U f w...

Page 236: ...l as the potentiometer terminals wires at the same voltage as the power R731externalmodule sensingof3 phase voltage 200 to 500 V compatible with parallel operation Disconnect ST1 to connect the module set the voltage via the module po tentiometer R734module detectionof3 phasecurrent and voltage for parallel operation on unba lanced installations imbalance 15 R 726 module 3 functions mounted exter ...

Page 237: ...tial potentiometer settings see table below Remote voltage adjustment potentiometer centre ST4 jumper removed Stability adjustments in standalone operation b Install a D C analogue voltmeter needle dial cal 50V on terminals E E and an A C voltmeter cal 300 500 or 1000V on the alternator output terminals c Make sure that the ST3 jumper is positio ned on the desired frequency 50 or 60 Hz d Voltage p...

Page 238: ...rrect if a reactive load is available By altering the speed match the kW or di videtheratedpoweroftheunitsproportionally Byalteringthequadraturedrooppotentiome ter P1 match or divide the currents 3 2 2 Max excitation setting excitation ceiling Static adjustment of the current limit potentiometer P5 factory setting 7 5 A fuse rating 8 A 10 seconds The maximum factory setting corresponds to that of ...

Page 239: ... field weakening SHUNT The exciter is switched off by disconnecting the AVR power supply 1 wire X1 or X2 Contact rating 16 A 250V A C 3 2 3 2 R438 field weakening AREP PMG The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxi liary winding contact rating 16 A 250V A C Connection is identical for resetting theAVR internal protection In case of using the de excitation...

Page 240: ... Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Voltage oscillations Adjust AVR stability potentiometer If no effect try normal fast recovery modes ST2 Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F bend set too high Voltage correct at no load and too low when on load Run at no load and check th...

Page 241: ...lete machine type its serial number and the information indicated on the nameplate Part numbers should be identified from the exploded views and their description in the parts list Our extensive network of service stations can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacture spare parts In the event o...

Page 242: ...14 LEROY SOMER 2010 11 f Installation and maintenance R438 NOTES 3971 en 240 242 ...

Page 243: ...LEROY SOMER 15 2010 11 f Installation and maintenance R438 NOTES 3971 en 241 242 ...

Page 244: ...MOTEURSLEROY SOMER16015ANGOULÊMECEDEX FRANCE 338 567 258 RCS ANGOULÊME S A au capital de 62 779 000 www leroy somer com 242 242 ...

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