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Maintenance

This chapter describes the most common maintenance items, see

Service program

for service intervals.

NOTICE!

Service points which are not described here must be performed by authorized Volvo Penta workshop.

CAUTION!

Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance
and service operations in a safe and correct manner.

WARNING!

Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the engine
before opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the start
key and cutting the system voltage with the main switches.

Read about security measures for maintenance and service in the chapter

Safety Information page 3

before you

begin.

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Summary of Contents for R570U

Page 1: ...User and maintenance manual for generating sets R570U 33504081501NE_1_1 ...

Page 2: ...California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine WARNING The engine from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The state of California requires the above two warnings ...

Page 3: ...6 4 Trailer 27 4 1 Trailer linkage 27 4 2 Check before towing 27 4 3 Operation 28 4 4 Unhitching the trailer 28 4 5 Implementation for installation 29 4 6 Break transmission adjustment 29 4 7 Faults and repairs 31 4 8 Electrical connection diagram 32 4 9 Complete wheels technical information 32 5 Preparation before operating the set 33 5 1 Installation checks 33 5 2 Checks after starting the gener...

Page 4: ...79 6 3 5 4 Facility power outlet 83 6 3 5 5 Connecting cable between the generating sets power plant 84 6 3 5 6 Power 85 6 3 5 7 Client terminal block 85 6 3 6 Operation and setting menus 86 6 3 6 1 Layout of the menus 86 6 3 6 2 Setting of regional parameters 87 6 3 6 3 Information on the KERYS 89 6 3 6 4 Operating menus 91 6 3 7 Rental configurations 93 6 3 7 1 Choice of application configuratio...

Page 5: ...tached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training Dealers have this qualification and can answer all of your questions They can also supply you with spare parts and other services The l...

Page 6: ...othing must be worn Naked flames and unprotected lights prohibited No smoking Caution toxic materials Eyes and ears must be protected Entry prohibited to non authorised persons Caution pressurised fluids Periodic maintenance must be carried out Jet washing prohibited Caution high temperature risk of burns Battery level must be checked Earth Caution rotating or moving parts risk of getting caught i...

Page 7: ...ance operations DANGER Use diesel fuel only The fuel is highly flammable handle with care Do not smoke near the generating set or expose it to a naked flame or sparks Shut down the generating set engine before filling the fuel tank Fill with fuel outside To prevent fire risks clean the generating set regularly Wipe away any dirt and traces of grease or fuel WARNING DANGER The exhaust gases from th...

Page 8: ...osures Shut down the generating set before any maintenance or servicing operation DANGER Avoid any contact with the exhaust pipes turbochargers and silencers Keep flammable materials away from hot parts Wait for the machine to cool down completely before touching it WARNING DANGER The gas from the battery electrolyte is explosive Keep the batteries away from any flames The battery electrolyte sulp...

Page 9: ...ing set to an external earth terminal WARNING Voltage selector This function should be used by qualified persons only WARNING Adjust the output voltage correctly before connecting a load WARNING The voltage selector must not be used when the generating set is operating Figure 1 2 continued Pictograms and their meanings 7 297 ...

Page 10: ...rt the engine without fitting the air filter The compressor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube cau...

Page 11: ... serious damage Risk of blood contamination Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil Except by special agreement once closed the gas supply main unit must only be re opened by the gas distributor However the user may access it under certain conditions Check these for each site 1 3 2 Risks related to exhaust gases and fuels The ca...

Page 12: ...rticular to the eyes Never cover the generating set pump unit or lighting tower with any material during operation or just after shutdown wait for the engine to cool Do not touch hot parts such as the exhaust pipe or put combustible materials on it Keep all flammable or explosive materials e g petrol oil cloth etc out of the way when the set is running Proper ventilation is required for your gener...

Page 13: ...ately and activate the emergency stop on the generating set or lighting column If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire may be cut with an axe ...

Page 14: ...s of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documents contained in this manual Examples of identification plates Generating set Engines Figure 1 2 Examples of identification plates 12 297 ...

Page 15: ...Alternator Cabinet Figure 1 3 Examples of identification plates 13 297 ...

Page 16: ...cription 2 1 Description Overview 1 Control unit 4 Protective grilles 2 External emergency stop 5 Chassis 3 Expansion bottle 6 Circuit breakers Figure 2 1 General description of the generating set 3 4 2 1 5 6 14 297 ...

Page 17: ...nection termination box Figure 2 1 continued General description of the generating set 11 Filling with fuel 13 External fuel supply combined tap optional 12 Oil filters 14 Circuit breaker Figure 2 1 continued General description of the generating set 7 8 10 9 11 12 13 14 15 297 ...

Page 18: ...Sockets voltage 208 120V 16 297 ...

Page 19: ...r 2 kW kVA 480 277 V 60 3 0 8 758 504 630 458 2 572 7 Available 380 220 V 220 127 V 208 120 V 1 ESP Stand by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528 1 no overload available under these service conditions 2 PRP Main output available continuously under variable load for an unlimited time period per year as per ISO 8528 1 an overload of 10 one ho...

Page 20: ...e AREP Voltage regulator R450 Short circuit current 3 IN Number of bearings 1 Coupling Direct Control unit s TELYS Standard specifications Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage K...

Page 21: ... with the most demanding applications Depolluted engines complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel especially ecological diesel with low sulphur content PERFORMANCE ACEA E3 API CH 4 Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition ADVANTAGES Less frequent oil services this product has been put to ...

Page 22: ...against high temperature corrosion by oxidisation of ethylene cylinder head protection Protects against high temperature cavitation top of cylinder and coolant pump protection Non corrosive for seals and hoses Improves the efficiency and longevity of the cooling system GenCOOL PC 26 is especially recommended for engines fitted with aluminium or light alloy radiators HIGH TEMPERATURE SUITABILITY Pr...

Page 23: ...e observed Lifting machinery or equipment appropriate to the work required Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members Ground able to take the load of the set and the lifting machinery without stress otherwise lay down beams of sufficient strength and stability Set put down as close as possible to its point of use or ...

Page 24: ...tion Figure 3 1 Transporting a generating set using a forklift truck 3 2 Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container if the generating set is fitted with this option The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this...

Page 25: ... a high level indicator in the retention container 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 either via the drain port or by using the drain pump for containers fitted with this pump Note Never allow these fluids to drain onto the ground ensure they are collecte...

Page 26: ...rnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered Incorrect exhaust and ventilation Ground too uneven or soft Set incorrectly positioned Reduced access Fuel filling impossible Opening cover doors impossible Figure 3 5 Example...

Page 27: ... 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 phase Calculation hypothesis Fitting method wiring in cable runs...

Page 28: ...Nature of ground Length of rod in metres Thick arable land moist compact ballast 1 Lean arable land Gravel coarse ballast 1 Bare stony soils dry sand impermeable rock 3 6 To obtain an equivalent length you can use several earthing rods connected in parallel and set apart by at least their length Example 4 interconnected 1 metre rods separated by 1 metre Note For the United States National Electric...

Page 29: ... the locks on each side of the wheels then lift up the front wheel fully using its handle Connect the electrical circuit of the trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook on the tow vehicle Figure 4 1 Coupling a trailer 4 2 Check before towing Before towing check the following Tightness of the generating set enclosure bolts Wheel tightness Hitching hook locked ...

Page 30: ...les driving heating of the brake hubs and drums will actually reduce the wheel tightness It is therefore essential to check the tightness every 6 miles 10 kilometres until no further loosening is noted Nonetheless the tightness must be checked whenever you are about to tow the trailer Warning Lights signalling only for on road trailers Warning lights are obligatory for on road driving Signalling m...

Page 31: ...using the tensioner 6 until a gap J1 of 1 mm max is obtained between the linkage 9 and slide 2 Adjust the compensating spring 4 at one end pressing it against the anchorage plate and at the other end leaving a 2 mm gap J2 max between the spring and nuts 5 Tighten all the lock nuts Checking the setting trailer on axle stands Pull the parking lever 2 notches the wheels cannot turn in a FORWARD direc...

Page 32: ...Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 30 297 ...

Page 33: ...lide guide rings Replace the rings and possibly the slide and grease Faulty shock absorber Replace the shock absorber Trailer tending to swerve upon braking Cross bar s not balanced Adjust the cross bar s Different brake setting on the two sides Adjust the brake settings Cables damaged or incorrectly fitted Replace the damaged parts Refit the cables Poor load distribution Check the load distributi...

Page 34: ... 550 134 265 335 2 4 145 R 13 75 T 566 145 272 387 2 4 155 R 13 79 T 578 150 277 437 2 4 145 70 R 13 71 T 534 150 259 345 2 5 155 70 R 13 75 T 548 147 263 387 2 5 185 70 R 13 86 T 594 185 285 530 2 5 165 R 14 C 98 N 622 172 284 650 3 8 155 70 R12 100 N 525 155 244 650 1 800 2 6 25 185 R 14 C 102 P 650 188 316 675 1 850 2 4 5 195 R 14 C 106 P 666 198 32 950 4 5 195 50 x 10 98 N 450 190 750 6 0 1 Wh...

Page 35: ...set Carry out the mechanical checks oil pressure water temperature absence of noise etc Carry out the electrical checks voltage and frequency Carry out the safety checks emergency stop oil pressure water temperature etc 6 Using the generator set 6 1 Pre Start Inspection Engine and engine compartment general check Visually check the engine and engine compartment before starting the engine and after...

Page 36: ...oil to drain into the sump Never fill oil past the maximum level Only use oil of the recommended grade Important Coolant level check Do not open the filler cap when the engine is hot except in an emergency Boiling liquid or vapour may be ejected Warning The system must be filled up with liquid which has identical proportions to that already contained in the cooling system Only open the filler cap ...

Page 37: ...eel 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 fo...

Page 38: ...shing red 3 Module on green on continuously Figure 6 6 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 2 3 1 1 2 3 36 297 ...

Page 39: ...ams 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 we...

Page 40: ...NU mode AUTO Mode Fixed TELYS in automatic mode AUTO Flashing For 5 seconds when switching from MANU mode to AUTO mode Flashing Generating set in start up phase Fixed Generating set started Fixed Generating set stabilised voltage and frequency Flashing appearance of constant movement from left to right The generating set is powering the installation Fixed The installation is supplied Not used Not ...

Page 41: ...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 42: ...ature coolant HT units according to settings menu Indication of Battery Voltage Indication of Oil Temperature units according to settings menu Generating set start up or generating set started or generating set switching off in progress Screen no Pictograms Data displayed P2 Engine Speed Indication Indication of Temperature of High Temperature coolant units according to settings menu Indication of...

Page 43: ...U31 Alternator composite Voltage Indicator Alternator Frequency Indicator P5 V1 Alternator single Voltage Indicator V2 Alternator single Voltage Indicator V3 Alternator single Voltage Indicator Alternator Frequency Indicator P6 U12 Alternator composite Voltage Indicator V2 Alternator single Voltage Indicator V1 Alternator single Voltage Indicator Alternator Frequency Indicator P7 V1 Alternator sin...

Page 44: ...el Level Indicator Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on Type of network Order of appearance 3P N 3P 2P N 1P N 1 P3 P3 P3 P3 2 P4 P4 P6 P7 3 P5 P8 P8 P9 4 P8 P9 P9 P2 5 P9 P2 P2 P10 6 P2 P10 P10 7 P10 Change screens by using the scrolling and selection wheel When the wheel is rotated clockwise the sc...

Page 45: ...displayed G 1 Initialisation of TELYS when the power is switched on and or when loading a configuration G 2 SERIAL No 08030010000 SOFTWARE 6 1 0 NOMINAL VOLTAGE 400V FREQUENCY 50Hz NOMINAL KW 320kW EARTH SYSTEM TNS Generating set serial no Software version of TELYS Alternator Nominal Voltage Alternator Nominal Frequency Nominal Active Output Neutral Point Bar graph indicating the display delay of ...

Page 46: ...UTOMATIC Start 19 min 30 sec 24 08 2005 13 12 Operating mode generating set in Auto Mode with programmed start Countdown to micro disconnection delay or EJP notice delay for France only Date and time depending on settings Generating set start up Screen no Screen Data displayed G 6 START UP IN PROGRESS 24 08 2005 13 12 Operating phase generating set in starting phase Date and time depending on sett...

Page 47: ... changeover switch controlled by TELYS Countdown for the mains return delay OR the load test delay Date and time depending on settings G 10 AUTOMATIC STOP IN PROGRESS COOLING DOWN 1 min 30 sec 24 08 2005 13 14 Operating mode operation in Auto Mode Generation set cooling in progress Countdown for Engine Stop delay cooling OR Gradual Stop delay Coolant temperature OR Overload Gradual Stop delay OR O...

Page 48: ...perating mode operation in Manual Mode AUTOMATIC start demand Generating set stop request due to fault or by pressing STOP in Auto Mode Screen no Screen Data displayed G 13 Manual Mode activated Do you wish to change to AUTO mode OK Esc Operating mode operation in Auto Mode generating set in operation Warning message for switching to Manual Mode after the STOP button has been pressed or a fault ha...

Page 49: ... 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 eng...

Page 50: ...6 2 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 message on graphic display example FAULT ALARM Low Fuel Level 25 12 05 15 30 OK HELP ...

Page 51: ...f 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 available example below HELP Check the level fuel Esc EXIT If the alarm is no longer...

Page 52: ... 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 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 reset ...

Page 53: ...articularly 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 Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combin...

Page 54: ...ult are included in the user and maintenance manuals of the engines supplied with the generating set documentation For JOHN DEERE JD PERKINS PE and VOLVO VO engines the codes displayed are SPN and FMI codes 6 2 4 5 Horn reset Depending on the settings made menu 363 HORN the activation of an alarm and or a fault leads to the horn sounding and the following screen appearing HORN STOP PRESS OK 25 12 ...

Page 55: ...ce module also called MMI module base module heart of the system regulation module protection module logic input output module analogue input output module temperature input module For the operation of a generating set in the smallest possible architecture at least the following elements will be found a man machine interface module a base module a regulation module 6 3 1 1 Operating conditions Ope...

Page 56: ...ency range 57Hz 150Hz Continuous 0 5 g constant acceleration Occasional 1 g constant acceleration Complies with standard IEC 68 2 6 test Fc Shock resistance Occasional shocks 15g 11ms semi sinus Complies with standard IEC 68 2 27 test Fa Emissions Complies with standard EN55022 class A Variation in supply voltage EN61131 2 6 3 7 3 Immunity Complies with standard IEC 61000 4 2 Electrostatic dischar...

Page 57: ...batch number 1800 the 1800th module manufactured since the start BATCH No 08 06 08 year of manufacture year 2008 06 week of manufacture week 6 Base module Base module P N 31613390901 Module item reference D338000 B8 D338000 manufacturer product reference B8 Module hardware upgrade index S N 3491 3491 serial number not related with a batch number 3491 the 3491st module manufactured since the start ...

Page 58: ... in week 04 of the year 2008 i e a maximum of 999 modules that can be related with a batch number Protection module Protection module 31613391601 Module item reference A44Z2 E A44Z2 manufacturer product reference E main module hardware upgrade index 4307A035 43 week of manufacture week 43 07 year of manufacture year 2007 A secondary module hardware upgrade index 035 serial number related with a ba...

Page 59: ...P N 31613391301 Module item reference D343000 B1 D343000 Manufacturer product reference B1 module hardware upgrade index S N 0200 0200 serial number not related with a batch number 0200 the 200th module manufactured since the start BATCH No 06 49 06 year of manufacture year 2006 49 week of manufacture week 49 Temperature inputs module Temperature inputs module ETEMP P N 31613391401 Module item ref...

Page 60: ...ific projects 2007_02_12 Date of software version in English year month day For a modification of a software version during the life of one of the products developments corrections etc the new software version implemented will be entered by hand in a space reserved for this The old software version will then be deleted factory soft version V1 05c 2007 02 12 Location of the version labels MMI Base ...

Page 61: ...cifications 7 inch colour TFT display 16 9 65536 colours dimensions 154 mm x 86 mm neon backlighting 480 x 234 resolution touch panel 8 columns x 8 rows Signalling control keys Operating buttons of the generating set Backlit display with touch sensitive keypad Alphanumeric keypad Navigation keys M M I operation LED flashing 59 297 ...

Page 62: ... breaker is open 8 Grid circuit breaker opening control 9 Led indicating that grid circuit breaker is open 10 Grid circuit breaker closing control 11 Led indicating that grid circuit breaker is closed 12 Led indicating the presence of grid voltage 13 Led indicating that grid circuit breaker is closed 14 Closing control for generating set circuit breaker 15 Led indicating the presence of generating...

Page 63: ...e numerical key corresponding to its name The alphanumeric keys They allow alphanumeric input by successive pressing of the keys The characters entered appear in the order they were typed on the keypad Move to the right Move up Move down Confirm function of selected key Return to upper level or escape for the dialogue boxes Move to the left 61 297 ...

Page 64: ...ance Navigation screens These screens enable the various sub menus to be accessed 15 07 09 19 10 00 GS 1 System Auto Faults Alarms 0 Welcome 1 Operation 2 Function keys 7 User adjustments 3 Synchro column 6 Alarms Faults 4 Central measurements summary 5 Measurements When a key is selected the lower level sub menu appears if available or the allocated operation screen A sub menu can also be accesse...

Page 65: ...ent archive Auto Faults Alarms 1 Electrical archive 2 Mechanical archive 3 Event metering Upper band Indications 15 07 09 19 10 00 GS 1 Welcome Auto Faults Alarms Upper band Central section Lower band Date of the system Time of the system Reference of the GS with which the M M I dialogues Indication of the presence of a fault on the GS concerned flashing red Indication of the presence of an alarm ...

Page 66: ... key Valid saves the modification the escape key Esc cancels the modification Access to the regional parameters screen Access to the regional parameters screen Access to the Drive or TOR variables screen Access to the Alarms and Faults screen Access to the Alarms and Faults screen When configured in power plant with switches displays a dialogue box enabling you to select the generating set to whic...

Page 67: ...concerned These indications are linked to the type of modified parameter Time in 1 10 second 6000 0 0000 9999 Valid Esc Saves the changes and closes the dialogue box Deletes the entire text Deletes the letter shown by the cursor Closes the menu without saving the changes Name of the modified function Text to be modified or created Inserts a space to the left of the cursor Saves the modifications a...

Page 68: ... Sauvegarde à faire Save indicator light flashes at the top left of the screen Pressing this indicator light brings up one of the following dialogue boxes Save in flash Valid Esc Save in flash Customer Factory Valid Esc Always select Client Pressing Valid confirms the operation pressing Esc cancels it During saving the following screen indicates that the operation in is progress Saving in flash Li...

Page 69: ...anical interlocking With coupling the switch is not equipped with an electrical and mechanical interlock 6 3 4 2 Legends M Electrically controlled circuit breaker Exchange of information from A to B and from B to A Transmission of information from A to B only 3 PH Current information 3 PH 3 phases 3 PH N Voltage information 3 PH N 3 Phases Neutral 67 297 ...

Page 70: ...and set to standby FORCED OPERATION Kerys in AUTO mode Start of FORCED OPERATION Generating set start request dry contact switch clock etc The speed and voltage of the generating set increase Generating set power unit switched off after voltage and frequency stabilisation The installation is supplied by the generating set End of FORCED OPERATION Dry contact switch clock etc switched on Generating ...

Page 71: ...id loss acquisition delay controlled by the Kerys or by a mains detection module Generating set start request The speed and voltage of the generating set increase Power unit switched on grid side Generating set power unit switched off after voltage and frequency stabilisation Return of grid voltage Adjustable grid return acquisition delay controlled by the Kerys or by a mains detection module Sync...

Page 72: ...The installation is supplied by the generating set End of FORCED OPERATION Opening of the forced operation order Synchronisation of the generating set to the grid Grid power unit switched off Transfer of the generating set s active and reactive power to the grid Generating set power unit switched on Cooling delay Generating set stopped and set to standby The Kerys remains in AUTO mode The installa...

Page 73: ...tion generating set voltage the generating sets are static Note 2 In an installation of the power station type several generating sets in parallel two modes of coupling between generating sets are possible Coupling when stopped Coupling in normal operation Principle of coupling when stopped all the generating set power units are switched off starting of all the generating sets when the speed reach...

Page 74: ...ircuit breaker 1 is closed the voltage is present on the busbar Kerys 2 analyses the differences between U2 and U of the busbar before coupling Kerys 3 analyses the differences between U3 and U of the busbar before coupling Each Kerys independently of its neighbour will close its discharge on the central busbar Wattmetric control The wattmetric control is used when two generating sets are coupled ...

Page 75: ...for each generating set at nominal speed the voltage is then quickly established on the busbar Start of distribution of active power Resumption of use at the rated power and frequency Wattmetric control This wattmetric control will be activated after a global operation delay This global operation enables the application to be resumed after power is restored to the different outputs and ensures sta...

Page 76: ...l buses connected between all the regulation modules Regulation module Base module CAN bus Ethernet 3PH N 3PH M 3PH 3PH Regulation module Base module CAN bus Ethernet 3PH N M 3PH Genset 1 Genset 2 Genset x Digital Bus Digital Bus the EJP system is specific to the French power grid Note 1 In this operating mode active and reactive power is distributed by a digital bus between the regulation modules...

Page 77: ... and U of the busbar before coupling Kerys 3 analyses the differences between U3 and U of the busbar before coupling Each Kerys independently of its neighbour will close its discharge on the central busbar Wattmetric control The wattmetric control is used when two generating sets are coupled It provides optimum management of the number of generating sets operating by constantly analysing the power...

Page 78: ...t The generating sets increase in speed Speed stabilisation delay Order of excitation for each generating set at nominal speed the voltage is then quickly established on the busbar Start of active power distribution Resumption of application at rated voltage and frequency Wattmetric control This wattmetric control will be activated after a global operation delay This global operation enables the a...

Page 79: ...ng set power units switched on Cooling delay Generating sets stopped and set to standby The Kerys PLCs remain in AUTO mode The installation is supplied by the grid Manual power plant operation This mode of operation is selected with the MANU key This enables the operator to start and stop the generating sets one by one via the MMI keypad The generating set power unit is switched off manually with ...

Page 80: ...ommon part and without inverter A633 Ground connection X X Ground connection box X X Facility power outlet O O O O Connecting cables between the generating sets CAN BUS X Connecting cables between the generating sets Parallel line X Power cables X X X X Customer terminal Remote operation External emergency stop EJP Switch grid detection 1 Grid detection by regulation card 1 X Emergency N E switch ...

Page 81: ...pact hard core 1 Poor arable land 1 Poor arable land gravel coarse hard core 1 Stony bare soils dry sand impermeable rocks 3 6 To obtain an equivalent length several ground rods can be used connected in parallel and separated by at least their length Example Four 1 metre rods interconnected and separated by 1 metre respectively Check the earthing connection before switching on the generating set C...

Page 82: ...R N R S T Neutral Ground Current transformer Ground rod DISJONCTEUR N R S T Neutral Ground Ground rod DISJONCTEUR N R S T Ground Ground rod Interconnection bar between genset grounds Interconnection bar between genset grounds Interconnection bar between genset grounds CIRCUIT BREAKER Neutral connected to grounds Current transformer Current transformer CIRCUIT BREAKER CIRCUIT BREAKER 80 297 ...

Page 83: ...nd rod for one generating set power plant Important Genset 1 Genset 2 Ground rod Neutral Earth junction box GS1 current transformer link GS2 current transformer link GSX current transformer link 1 current transformer per GS Genset x Genset 2 Genset 1 Genset x 81 297 ...

Page 84: ...ral Ground Ground rod Junction box DISJONCTEUR N R S T Neutral connected to grounds Ground Ground rod DISJONCTEUR N R S T Ground Ground rod If equipped CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER Current transformer Current transformer Isolated neutral Current transformer 82 297 ...

Page 85: ...ility power outlet if fitted provides the emergency supply to the generating set from an external electrical source It enables the different units preheating desk etc to be powered without using their batteries 7 44 45 42 43 40 41 38 39 36 37 34 35 32 33 30 31 28 29 46 47 48 Xcbc3 7 44 45 42 43 40 41 38 39 36 37 34 35 32 33 30 31 28 29 46 47 48 Xcbc3 Junction box Remove the shunts at terminals 45 ...

Page 86: ...t Important The generating set power cables the generating set connecting cable and the connections must be in perfect condition Replace them if necessary Important Generating set 1 019x04 019x12 Generating set 2 019x04 019x12 2 generating sets Generating set 1 019x04 019x12 Generating set 2 019x04 019x12 Generating set 3 019x04 019x12 Generating set x 019x04 019x12 3 or more generating sets Conne...

Page 87: ...k that the direction of rotation of the phases between the generating set and the application is the same Important Type of cables Use H074NF type cables according to the standards in force in the country of use of the generating set In France refer to the standard C15 100 6 3 5 7 Client terminal block Refer to the wiring diagrams according to the configuration selected and the requirements GENERA...

Page 88: ...es 3 1 Events archives 3 2 Electrical archives 3 3 Mechanical archives 3 4 Events metering 3 5 Mechanical metering 3 6 Electrical metering 1 1 Operation 4 1 Provider 4 2 Emails 4 3 Service intervals 4 4 Consumables 4 5 Progress reports 5 1 Equipment 5 2 Applications 5 3 Regulations 5 4 Safety features 6 1 Regional parameters 6 2 Application identification 6 3 Software versions 6 4 Printing 6 5 Acc...

Page 89: ...ers Stop Faults Alarms Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Inhibit the keys 1 Identification application 2 Software versions 3 Printing To clean the touch screen dust hydrocarbons etc the key inhibition function prevents keys on the screen from being pressed for some twenty seconds A special screen shows the time elapsin...

Page 90: ...inutes Seconds 22 10 07 17 10 00 Inhibit the keys SDMO welcome logo KOHLER welcome logo 1 Identification application 2 Software versions 3 Printing In this case the transmission of a signal to the bus enabling the different real time clocks to be reset is defined by the synchronisation time Pressing the KOHLER home logo key alters the appearance of the home screen by replacing the KOHLER logo with...

Page 91: ...eference 6 2 This screen enables SDMO to identify the project This information is required for queries sent to SDMO s customer service so that the associated file can be consulted 15 07 09 19 10 00 GS 1 Identification application Stop Faults Alarms Site name Dealership number 000000 OM number 000000 Connection number 000000 1 Software versions 2 Printing 3 Access management Project number referenc...

Page 92: ...menu Only the lines corresponding to the installed equipment appear 15 07 09 19 10 00 GS 1 Software versions Stop Faults Alarms Module Software versions Software version dates IHM 0 00 00 00 00 Base 0 00 00 00 00 Resident logic 0 00 00 00 00 Regulation 0 00 Protection 0 00 Engine 0 00 1 Identification application 2 Printing 3 Access management 90 297 ...

Page 93: ...tor Navigation reference 1 1 15 07 09 19 10 00 GS 1 Operation Manu Faults Alarms I1 A 2701 P F 0 9 L Status messages Q kVAr Speed rpm 1505 765 Operating time 10 05 F F U U 1 Function keys 2 Synchro column 3 Central unit measure summary In the needle dials the nominal values are in blue The speed and voltage adjustment keys are only displayed for coupled applications in manual mode Important The di...

Page 94: ...atus Title 26 11 03 11 11 12 55 1 6131 HT LOW COOLANT LEVEL FAULT 26 11 03 10 35 16 28 0 6017 INSULATION 1 ALARM 26 11 03 10 10 10 10 0 60C3 CIRCUIT BREAKER FAULT ON GENERATING SET OUTPUT 1 Function keys 2 Synchro column 3 Central unit measure summary To clear a fault it is necessary to check that the fault has disappeared status 0 and whether it is necessary to eliminate its causes select the lin...

Page 95: ...THOUT GRID COUPLING APPLICATION A612 2 PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION A632 A633 3 NOT APPLICABLE 4 SOLO GENERATING SET WITH GRID COUPLING APPLICATION A651 If the switch is already set to 1 turn the switch and return to position 1 After changeover the screen below appears 15 07 09 19 10 00 GS 1 Rental application Stop Faults Alarms A612 Single Genset without N E Validation...

Page 96: ...ng by means of an external switch you must select the configuration Mains supply detection using an external contact and connect the external switch to the terminals Xcbc3 32 33 For solo starting in the absence of a mains connection you must select the configuration Mains supply detection using an external contact No connection is necessary N B selecting detection depends on the connection made ac...

Page 97: ...card Mains supply detection using an external contact 7 The KERYS saves your new configuration 8 After return to the KERYS home screen The configuration will only be taken into account if the following operations are carried out Turn on the battery isolator switch Wait 5 seconds Turn off the battery isolator switch Important Saving in flash 95 297 ...

Page 98: ... If the switch is already set to 4 turn the switch and return to position 4 After changeover the screen below appears 15 07 09 19 10 00 GS 1 Rental application Stop Faults Alarms A651 Temporary power grid single Genset coupling Validation Grid CT ratio 20 0 5 To enter the value of the grid current transformer ratio press the GRID CT RATIO button on the touch screen Using the alphanumeric keys of t...

Page 99: ...nset coupling Validation Grid CT ratio 20 0 7 Press the Validation button on the touch screen 15 07 09 19 10 00 GS 1 Rental application Stop Faults Alarms A651 Temporary power grid single Genset coupling Validation Grid CT ratio 20 0 8 The KERYS saves your new configuration Saving in flash 97 297 ...

Page 100: ...OLO GENERATING SET WITH GRID COUPLING APPLICATION A651 If the switch is already set to 2 turn the switch and return to position 2 After changeover the screen below appears Choix configuration centrale loueur A632 Power plant without shared switching unit without Normal Emergency parallel line A633 Power plant without shared switching unit without Normal Emergency Digital Bus 5 Select the configura...

Page 101: ...ental application Stop Faults Alarms A633 Power plant without shared switching unit without Normal Emergency Digital Bus Validation Number of gen sets in power plant 2 Genset number 1 7 Enter the number of generating sets in the power plant using the numeric keypad Start with 0 if the number is less than 10 generating sets E g 2 generating sets enter 0 then 2 10 generating sets enter 1 then 0 8 Pr...

Page 102: ...n Back up to perform GS 1 Rental application Stop Faults Alarms A633 Power plant without shared switching unit without Normal Emergency Digital Bus Validation Number of gen sets in power plant 2 Genset number 1 10 Select the number of the generating set with the arrows The number of the generating set determines its type of connection see the section Electrical connections Important 11 Press Valid...

Page 103: ...er of gen sets in power plant 2 Genset number 1 12 Press Validation on the touch screen Back up to perform GS 1 Rental application Stop Faults Alarms A633 Power plant without shared switching unit without Normal Emergency Digital Bus Validation Number of gen sets in power plant 2 Genset number 1 13 The Kerys saves your new configuration Saving in flash 101 297 ...

Page 104: ...Important Operations to be carried out on each generating set of the power plant Important 6 3 8 Use 6 3 8 1 Choice of priority generating set in power plant if equipped Mnemonic aid info for menus 1 7 4 3 GS selection Priority selection Valid 15 07 09 19 10 00 GS 1 Welcome Stop Faults Alarms 1 Operation 6 System 2 Fault finding 5 Configuration 3 Archiving Metering 4 Maintenance 1 Press Operation ...

Page 105: ...hro column 6 Alarms Faults 4 Central unit measure summary 5 Measurements 2 Press User settings on the touch screen 15 07 09 19 10 00 GS 1 User adjustments Stop Faults Alarms 0 Operation 1 Set point 2 Output threshold 3 Wattmetric Control 4 User parameters 1 2 3 Press User parameters 1 2 on the touch screen 103 297 ...

Page 106: ... coupl In normal mode 1 Set point 2 Wattmetric COntrol 3 Generating set priority 4 Press Generating set priority on the touch screen 15 07 09 19 10 00 GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 5 Press the selection arrows on the touch screen to selec...

Page 107: ...eral parameters 2 Thresholds 6 Press the selection arrows on the touch screen to select the priority of the generating set selected 15 07 09 19 10 00 GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 7 Press Valid on the touch screen 105 297 ...

Page 108: ... GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 8 Press Save on the touch screen Back up to perform GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 9 Press Valid on the touch screen Save in flash Valid Esc 106 297 ...

Page 109: ...0 00 GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 11 Press Generating set priority on the touch screen to return to the home screen The configuration will only be considered valid if the following operations are carried out Open the battery cutout Wait ...

Page 110: ... screen can be accessed by pressing Reset Refer to the section Alarms and Faults in the Operating menus to eliminate the faults If no faults are present manual mode can be activated by pressing Manu Check there are no faults grey no fault red fault present grey no alarm orange alarm present 108 297 ...

Page 111: ...tances be used to turn the engine over manually During the start up phase and until the alternator voltage and speed of the generating set stabilise the green LED under the generating set symbol flashes and then lights up permanently once the phase is complete Tests If no faults are present automatic mode can be activated by pressing Auto The test starting phase is then initiated after pressing 1 ...

Page 112: ...e orange LED on the test keypad lights up steady During the start up phase and until the alternator voltage and generating set speed stabilise the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase The installation is then controlled via the programmable controller in accordance with the configuration of the application normal emergency sourc...

Page 113: ...t Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped Switching off The generating set may be stopped at any time by pressing Stop or 0 on the test keypad The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped Pressing Stop stops the generating set immediately Pressing 0 does not ...

Page 114: ...In AUTO mode except for the test functions the generating set starts as a result of an external command which may be triggered by various sources power loss EJP command France only client command The installation is then controlled via the automatic systems in accordance with the configuration of the application inversion of normal emergency source grid coupling etc Check there are no faults grey ...

Page 115: ...anu Faults Alarms I1 A 2701 F P 0 9 L Q kVAr Speed rpm 1505 765 Operating time 10 05 Speed Speed U U 1 Function keys 2 Synchronisation column 3 Power plant measurements summary Using the KERYS Tactil Man Machine Interface the under load test is started by pressing the corresponding key Using the KERYS Tactil Man Machine Interface the off load test is started by pressing the corresponding key Test ...

Page 116: ...g etc The Normal Emergency switchover with grid coupling is only possible by carrying out a load test The purpose of the off load test is to start a single GS or to couple a power plant x generating sets to the emergency busbar Important At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad Pressing Stop may interrupt the power supply depending on its s...

Page 117: ... generating set will stop after the cooling delay 180 seconds by default Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped 6 3 8 3 Rental options Damper valve Optional If the generating set stops when the valve damper is closed repair the fault Display the fault according Press Reset to clear the fault after it has been repaired I...

Page 118: ...r plant Important Bi frequency Optional Turn the switch to the desired frequency and voltage FREQUENCY Earthing system Turn the switch to the desired earthing system EARTHING SYSTEM 1 IT 2 TN TNS 3 TT TT or EDF APPLICATION The EDF earthing system is only used in the so called rental configurations The switch must necessarily correspond to the wiring described in the section on Connection of the ge...

Page 119: ...akage I Inspection with VODIA diagnostic tool I Engine and transmission abnormal noises I Stop engine Engine oil and oil filters by pass filter R Restart engine Oil pressuer oil leakage I Every 50 600 hours At least every month 12 24 48 Engine oil and oil filters by pass filter R After the first 1 000 hours Valve clearance I Every 500 hours At least every month 12 24 48 Fuel tank sludge trap drain...

Page 120: ...Alternator After 20 hours in operation check the tightness of all the mounting bolts the general condition of the machine and the various electrical connections of the installation The bearings fitted on the machine are greased for life to around the service life of the grease depending on use 20 000 hours or 3 years Regularly clean the inlet and outlet grid 118 297 ...

Page 121: ...itch to the OFF position or disconnect the battery negative cable to cut off the electrical current Electrolyte contains dilute sulphuric acid Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns Wear safety goggles and rubber gloves when working with the battery topping up fluid charging etc If electrolyte comes into contact with your skin...

Page 122: ...ttery rest for 20 minutes Before fitting the battery stop the engine and any power consumer clean the terminals and give them a light coating of grease When connecting connect the positive terminal first and then the negative terminal 8 3 Check Acid density Charge status Voltage when idle 1 27 100 Above 12 60 V 1 25 80 12 54 V 1 20 60 12 36 V From 50 recharge 1 19 40 12 18 V Risk of sulphation 1 1...

Page 123: ...the charge current to the lowest battery The power difference between the batteries must be as low as possible Example of charge 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery is short 30 Ah and this must be recharged Charge factor 1 2 Ah x 1 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required Recharging ...

Page 124: ...city too low Battery sulphated Recharge the battery Fit a new battery Battery terminals melted Incorrect electrical connection Incorrect battery wiring Tighten the ends of the battery cables or replace them if necessary One or two cells release a lot of gas at high charge Cell s faulty Fit a new battery The battery discharges very quickly Charge status too low Short circuit in the current circuit ...

Page 125: ...9 Appendix 9 1 Appendix A Engine user and maintenance manual 123 297 ...

Page 126: ...124 297 ...

Page 127: ...OL LV VO O E En ng gi in ne e T TA AD D1 16 64 40 0G GE E T TA AD D1 16 64 41 1G GE E T TA AD D1 16 64 42 2G GE E T TA AD D1 16 65 50 0G GE E T TA AD D1 16 65 51 1G GE E T TW WD D1 16 64 43 3G GE E 7748681 01 12 2011 33522064501_3_1 125 297 ...

Page 128: ...126 297 ...

Page 129: ...OPERATOR S MANUAL Generating set and industrial engines 16 liter EMS 2 127 297 ...

Page 130: ...e om du inte har till gång till internet Dit instructieboek kan gratis via internet in een a dere taal worden besteld tot 12 maanden na aflevering http vppneuapps volvo com manual coupon Als toegang tot het internet niet mogelijk is neem dan contact op met uw Volvo Penta dealer Denne instruktionsbog kan bestilles gratis på et an det sprog via Internettet i op til 12 måneder efter leveringen http v...

Page 131: ...Introduction 7 Presentation 9 Instruments and Controls 11 Starting 22 Operation 26 Engine Shutdown 27 Fault Handling 30 Fault Code Register 36 Maintenance Schedule 49 Maintenance 51 Storage 78 Technical Data 80 Alphabetical index 89 1 129 297 ...

Page 132: ...r s manual thoroughly and consider the advice we give on running and maintenance Please pay attention to the safety instructions contained in the manual As owner of a Volvo Penta engine we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice service requirements and replacement parts Please con tact your nearest authorized Volvo...

Page 133: ...our attention to the fact that this is safety information Always read such information very carefully Safety texts in the Operators Manual have the following order of priority DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicat...

Page 134: ...can still be hot and cause scald ing Fuel filling There is always a risk of fire and explosion during fuel filling Smoking is forbidden and the engine should be stopped Never overfill the tank Shut the tank cap securely Only use the fuel recommended in the instruction book The wrong grade of fuel can cause serious mal functions power loss or stop the engine Fuel and lubrication oils Always protect...

Page 135: ...hey have the correct capacity for the lift engine weight together with auxiliaries if fitted The engine should be lifted with an adjustable lifting boom for safe handling All chains or cables should be parallel to each other and should be as square as possible to the top of the engine Please note that auxiliary equipment installed on the engine could change its center of gravity Special lifting de...

Page 136: ...t once with soap and a lot of water If you get battery acid in your eyes flush at once with a lot of cold water and get medical assistance at once Electric welding Remove the positive and negative cables from the batteries Then disconnect all cables connected to the alterna tor Disconnect both connectors from the engine con trol module Always connect the welder earth clamp to the com ponent to be ...

Page 137: ... reli ability and long life They are not only built to withstand a demanding environment but also to have the small est possible environmental impact These qualities will be maintained through regular servicing and the use of genuine Volvo Penta replacement parts or replacement parts approved by Volvo Penta Volvo Penta has a world wide network of authorized dealers They are Volvo Penta product spe...

Page 138: ...n an emission certified engine used in an area where exhaust emissions are regulated by law it is important to be aware of the following Certification means that an engine type has been checked and approved by the relevant authority The engine manufacturer guarantees that all engines of the same type conforms to the certified engine This places special demands on the care and main tenance you prov...

Page 139: ...50VE TAD1650GE and TAD1651GE have internal EGR Exhaust Gas Recirculation TWD1643GE TAD1650VE These are in line directly injected 6 cylinder industrial diesel engines All engines are equipped with elec tronically controlled fuel management EMS turbo charger charge air cooler thermostatically controlled cooling systems and electronic speed control 7748681 12 2011 9 137 297 ...

Page 140: ...ulate the correct fuel injection volume and timing check engine status etc Diagnostic function The task of the diagnostic function is to discover and localize any malfunctions in the EMS system to pro tect the engine and to ensure operation in the event of serious malfunction If a malfunction is discovered this is announced by warning lamps a flashing diagnostic lamp or in plain language on the in...

Page 141: ...e EMS system NOTICE Settings and what engine data that appears in the display may vary depending on installation and engine model NOTICE The menus and illustrations shown here are the English version The language can be changed however refer to the Setup menu 1 2 3 4 5 6 7 8 9 10 P0002062 Start When the DCU panel is started the Engine Data menu is displayed press ESC to come to the main menu 1 LED...

Page 142: ...ust be activated with temperatures below 0 C 32 F Governor mode activation of droop Diagnostics shows fault codes as text Trip reset resets trip data Setup parameter setting Information shows the currently applicable hard software data sets and engine identification for the engine and DCU data Engine data shows relevant engine data Engine speed can be controlled with the SPEED and SPEED buttons rp...

Page 143: ...ess SEL the text Preheat requested will be shown The display automatically returns to the Engine Data menu Governor mode activates shuts off droop To set the droop level refer to the Setup Governor gradient or Governor droop menu Select Isochronous mode or Droop mode with the SEL button Diagnostics shows the error list containing the 10 latest active and inactive faults The fault codes are shown a...

Page 144: ...op the engine Run The stop input must be connected to voltage to run the engine Customer parameter setting alarm limits Refer to Customer parameter Versatile and Customer parameter Gen set Throttle input setting setting of engine speed control and voltage limits Refer to Throttle input setting Display setting setting the display refer to Display setting Customer parameter Versatile Idle engine spe...

Page 145: ...e shut down with overspeed alarm Refer to Overspeed limit to activate the alarm limit for the excess rpm alarm Oil temp warning limit C setting alarm limit for oil temperature Coolant temp limit C setting alarm limit for coolant temperature Throttle input setting rpm control setting throttle operation Set throttle mode OFF engine rpm is controlled via the DCU panel ext throttle input engine speed ...

Page 146: ...brightness setting Information shows the data for the engine and DCU Engine hardware Id engine control unit part num ber Engine software Id engine control unit software part number Engine dataset1 Id engine data set 1 part number Engine dataset2 Id engine data set 2 part number Vehicle Id chassis number DCU hardware Id DCU part number DCU software Id DCU software part number DCU dataset1 Id DCU da...

Page 147: ...unction The display will work but may act in an unex pected way The DU is connected to the engine interface connector Display modes Press any of button 1 4 to view the function menu for the buttons apperaring in the lower part of the display To leave the menu wait a few seconds or press button 5 EXIT 1 Engine 2 Multi 3 Trip 4 Graph 5 Exit Contrast In the display modes Engine Trip and Graph it is p...

Page 148: ...ton 2 is pressed repeatedly By pressing button 5 the right arrow you choose what information to be shown in the different windows Press repeatedly on the button that correspond to the window until desired information is shown Trip To display the trip computer press button 3 Trip Trip Fuel since last reset Fuel Rate fuel consumption Trip hours since last reset Engine hours total amount of operating...

Page 149: ...oken there will be a straight line in the display Configuration menu Press button 5 for three seconds to enter the Config uration menu Navigate with the up and down arrows select with the right arrow Units PRESSURE kPa PSI VOLUME LITRE GAL Imperial GAL Fuel rate is adjusted according to volume unit L H GAL H IGAL H TEMPERATURE C F Instruments and Controls 7748681 12 2011 19 147 297 ...

Page 150: ...S 30MINS 60MINS 2HRS 4HRS 8HRS SYSTEM DEMO switches the DEMO mode ON OFF RESTORE DEAFAULTS reset all configuration to default values COM VIEWER displays latest message on com munication ports PROG TX transfers content of the application on Flash memory to other CAN units on the same CAN bus ABOUT displays ID NO display serial number EEPROM number of write on EEPROM VERS software version number CHK...

Page 151: ...onnectors and poten tiometers is controlled by this link The slow link manages diagnostic information for flash ing codes etc Easy Link Instruments The following Easy Link instruments are available Tachometer hours counter fault codes are also displayed on the tachometer display when the diag nostic button is pressed Coolant temperature Oil pressure Oil temperature Battery voltage Alarm panel Turb...

Page 152: ...Oil level checking and topping up Open the fuel valves Check the fuel pre filter refer to Draining conden sate fuel system page 65 Check that no leakage of oil fuel or coolant is pres ent Check the coolant level and that the radiator is not blocked externally Refer to Coolant Level Check ing and Topping Up page 68 and Charge Air Cooler External Cleaning page 70 WARNING Do not open the coolant fill...

Page 153: ...ng DCU Display Control Unit With pre heating 1 Depress the ON OFF button 6 2 Press the SEL button 8 to come to the main menu 3 Scroll down to Pre heater with scroll button 7 press SEL button 8 4 In the pre heater menu press the SEL button 8 to select pre heating 5 Press the START button 2 Without pre heating 1 Depress the ON OFF button 6 2 Press the START button 2 Leave the engine to idle for the ...

Page 154: ... the Main tenance lubrication system chapter Synthetic lubri cants are able to manage a wider temperature range than mineral based lubricants Pre heat the coolant with a separately installed ele tric engine heater In extreme cases a diesel burn ing engine heater may be needed Ask your Volvo Penta dealer for advice Make sure that the cooling system is filled with a glycol mixture Please refer to th...

Page 155: ...red jumper cable to the auxili ary battery then to the flat battery Then connect the black jumper cable to the auxiliary battery and to a location that is somewhere away from the discharged battery e g the main switch negative terminal or the negative terminalon the starter motor 3 Start the engine WARNING Do not touch the connections during the start attempt Risk of arcing Do not bend over any of...

Page 156: ...d long term operation at idle or at low load since this can lead to increased oil consumption and even tually to oil leakage from the exhaust manifold since oil will seep past the turbocharger seals and accom pany the induction air into the inlet manifold at low turbo pressure One consequence of this is carbon build up on valves piston crowns exhaust ports and the exhaust turbine At low loads the ...

Page 157: ...clutch if possible Depress the STOP button 5 After Engine Shutdown 1 Check the engine and engine bay for leakage 2 Turn off the main switches before any long stop page 3 Carry out maintenance in accordance with the schedule For longer breaks in operation During longer breaks in operation the engine must be warmed up at least once every two weeks This pre vents corrosion attacks in the engine If yo...

Page 158: ...f the extra stop please refer to Location of Sensors page 55 WARNING Working with or going close to a running engine is a safety risk Watch out for rotating components and hot surfaces Engine Shutdown 28 7748681 12 2011 156 297 ...

Page 159: ...157 297 ...

Page 160: ...tion Engine can not be stopped 2 5 Starter motor does not rotate 1 2 3 4 5 6 7 24 Starter motor rotates slowly 1 2 Starter motor rotates normally but engine does not start 8 9 10 11 Engine starts but stops again 8 9 10 11 13 Engine does not reach correct operating speed at full throttle 9 10 11 12 13 21 25 26 Engine runs roughly 10 11 High fuel consumption 12 13 15 25 Black exhaust smoke 12 13 Blu...

Page 161: ... filter air leakage between the turbo and the engine s intake manifold dirty compressor part in the turbocharger faulty turbo compressor poor engine room ventilation 14 Coolant temperature too high 15 Coolant temperature too low 16 Oil level too low 17 Coolant level too low 18 Air in the coolant system 19 Faulty circulation pump 20 Defective thermostat 21 Blocked charge air cooler 22 Oil level too...

Page 162: ...er together with information about cause reaction and actions for further information see chapter Fault Code Register CIU Control Interface Unit When the system detects a malfunction the diagnos tics lamp flashes If the diagnostics button is pressed and then released a fault code is flashed out The fault code consists of two groups of flashes sep arated by a pause of two seconds A fault code is ob...

Page 163: ...ss the SEL button to get to the fault list The fault list shows fault messages and the number of hours of operation when the fault occurred 4 Press ACK to acknowledge the fault code The dis play background changes color and the buzzer stops The fault must be acknowledged before it can disappear from the fault list 5 Look up the fault code in the Fault Code Register and take the necessary actions 6...

Page 164: ...get to the fault list when no fault codes are set press the SEL button and select Diagnos tics from the menu Easy Link Instruments 1 When the system detects a fault the diagnostics lamp flashes 2 Press the diagnostics button The fault code is shown as text in the tachometer display 3 Look up the fault code in the Fault Code Register and take the necessary actions 4 When the fault has been rectifie...

Page 165: ...ult codes is registered NOTICE Power must be disconnected completely This means that fault that hasn t been corrected 1 are shown as active the active fault code can then be erased with the VODIA tool 2 must be acknowledge and read out every time the engine is switched on If the diagnostic button is depressed after the fault has been corrected and fault code deleted the code 1 1 No fault will show...

Page 166: ...r cable is not damaged Check that the fuel pressure sensor is correctly installed Check fuel pressure sensor function Fuel Pressure Code 3 8 PID SPN 94 Cause Reaction Remedy Low supply pressure None Check if it is possible to build up pressure with the hand pump Check the fuel filter Check the fuel pre filter Water in Fuel Code 2 1 PID SPN 97 Cause Reaction Remedy Water in fuel None Empty the prim...

Page 167: ... is not blocked Check system pressure valves and safety valves in the oil system Check oil pressure sensor function Boost Temperature Sensor Code 3 2 PID SPN 105 Cause Reaction Remedy Short circuit to positive or earth ground Open circuit None Check that the boost temper ature sensor connector is cor rectly installed Check that the boost temper ature sensor cable is not dam aged Check that the boo...

Page 168: ...gine stops Check that the charge air pressure sensor connector is correctly installed Check that the charge air pressure sensor cable is not damaged Check that the charge air pressure sensor is correctly installed Check charge air temperature sensor function Air Filter Pressure Code 5 5 PID SPN 107 Cause Reaction Remedy Too large pressure drop across filter Less good response from engine Check the...

Page 169: ...m Check the pressure cap on the expansion tank Check coolant temperature sensor function Check thermostat function Coolant Level Code 2 2 PID SPN 111 Cause Reaction Remedy Low coolant level Engine control module reduces engine power unless the protection has been shut off with the VODIA diagnostic tool Check the coolant level Check coolant level monitor function Coolant Level Sensor Code 2 3 PID S...

Page 170: ...Check the supply voltage from the control unit Battery Voltage CIU Code 6 9 PID SPN 158 Cause Reaction Remedy Short circuit to negative Faulty alternator Faulty battery battery cables Problems in engine starting Check the supply voltage from the control unit Check the batteries Check the alternator Check the 8 pin contact Air Temperature Sensor Inlet Code 7 9 PID SPN 172 Cause Reaction Remedy Shor...

Page 171: ... perature sensor connector is properly mounted Check that the wiring to the exhaust temperature sensor is not damaged Check that the exhaust tem perature sensor is correctly mounted Check the exhaust tempera ture sensor function Oil Temperature Sensor Code 3 7 PID SPN 175 Cause Reaction Remedy Shorted to plus or minus Break None Check that the cable harness to the oil temperature sensor has not be...

Page 172: ...his time When a fault code is active the engine can be started but not stopped Check that the starter switch connections are not damaged Check that the ignition switch cable is not damaged Stop Input EMS Code 4 8 PPID 6 SPN 970 Cause Reaction Remedy Short circuit to negative Open circuit Engine can only be stopped with the auxiliarystop Check that the starter switch connections are not damaged Sta...

Page 173: ...ction Remedy Control unit too hot incorrect assembly Electrical fault damaged sen sor None Check the control unit instal lation Recommended ambi ent temperature is 50 C 122 F Speed Potentiometer Connected to CIU Code 2 8 PPID 132 SPN 91 608 Cause Reaction Remedy Shorted to plus or minus Fault in sensor Engine goes to idle Speed feezes Check that the potentiometer has been connected correctly Check...

Page 174: ...pressure Check the valve clearance Do a compression test and check cylinder 3 Injector Cylinder 4 Code 7 4 SID 4 SPN 654 Cause Reaction Remedy Electrical fault Faulty compression or injec tor Engine runs on 5 cylinders Abnormal sound Reduced performance Check that the injector cables are not damaged Check that the injector con nections are not damaged Check fuel supply pressure Check the valve cle...

Page 175: ...ed in the upper timing gear cover Check engine speed sensor function Flywheel Speed Sensor Code 2 4 SID 22 SPN 637 Cause Reaction Remedy No signal Abnormal frequency Intermittent signal from the sensor Fault in sensor Engine is very difficult to start and runs roughly when it starts Check that the sensor con nector is correctly installed Check that the engine speed sensor cable is not damaged Chec...

Page 176: ... management unit are not damaged Check that sleeves 11 and 12 in the connector on the CIU are not damaged TWD1643GE Power Supply to Sensor Code 9 3 SID 211 232 SPN 1079 1080 Cause Reaction Remedy Shortcut Fault in sensor Faulty values in oil pressure and boost pressure sensors Fault code for oil pressure and boost pressure sensor Low engine output The instrument shows zero oil pressure and boost p...

Page 177: ...n the CIU DCU and the engine management unit are not damaged Data Set Memory EEPROM CIU Code 9 8 SID 253 SPN 630 Cause Reaction Remedy Internal fault in control mod ule Programming faulty Engine does not start Re program the control mod ule Data Set Memory EEPROM EMS Code 9 9 SID 253 SPN 630 Cause Reaction Remedy Internal fault in control mod ule Internal fault in control mod ule Engine does not s...

Page 178: ... fan actuator is correctly mounted Check the fan actuator EATS Fault codes for the EATS system is in the installation manual for this system Calibration memory EEPROM SID 232 SPN 628 Possible reason Reaction Action Control unit None Check cables and connec tions CAN1 J1939 time out PSID 201 SPN 2029 Possible reason Reaction Action Faulty harness Faulty sensor Faulty fuse None Fault only visible in...

Page 179: ...enance job at the interval which is reached first Service program FSI First Service Inspection C Clean S Special Service R Replace A F Type of service regular service L Lubrication I Inspection includes if necessary cleaning adjust ment lubrication and change FSI First Service Inspection After the first 100 200 Hours Fuel pre filter draining condensed water I Coolant Level I Drive Belts I Start an...

Page 180: ...r R Coolant filter if fitted Not at same time as coolant change R C Every 2000 Hours Valve clearance I D Every 2000 Hours At least every month 12 24 48 Turbo I Turbo Wastegate 1 I Engine with Respect to Leakage I Engine hoses cables and clamps I Engine cleaning and painting I Air Filter Tank Breather R Air Filter Compressor R 1 TWD1643GE E Every 4000 hours At least every month 12 24 48 Belt Tensio...

Page 181: ...how to carry out maintenance and service operations in a safe and correct manner WARNING Care and maintenance work should be done with the engine stopped unless otherwise specified Stop the engine before opening or removing the engine hatch hood Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches Read about security measures for ma...

Page 182: ...1650GE TAD1651GE 1 AC generator 2 Control unit EMS 2 3 Air Filter 4 Oil dipstick 5 Fuel filter with fuel pressure monitor 6 Fuel prefilter with water monitor 7 Expansion tank 8 Charge air cooler TAD 9 Starter motor 10 Oil Filter Maintenance 52 7748681 12 2011 180 297 ...

Page 183: ...il dipstick 5 Fuel filter with fuel pressure monitor 6 Fuel pre filter with water monitor 7 Air filter 8 HP turbo 9 LP turbo 10 Expansion tank 11 Starter motor located behind charge air cooler 12 Charge air cooler LP turbo 13 Oil filter Maintenance 7748681 12 2011 53 181 297 ...

Page 184: ...VE 1 Control unit EMS 2 Oil filler 3 Oil dipstick 4 Fuel filter to be installed separately 5 Fuel pre filter with water monitor to be installed separately 6 Starter motor Maintenance 54 7748681 12 2011 182 297 ...

Page 185: ...el sensor 2 Charge air pressure and temperature sensor 9 Oil level and temperature sensor 3 Air filter indicator 10 Fuel pressure sensor 4 Flywheel position and engine speed sensor 11 Crankhouse pressure sensor 5 Fuse 12 Coolant temperature sensor 6 Aux stop 13 Piston cooling pressure sensor not TAD1650 51GE 7 Oil pressure sensor 14 Camshaft position sensor Maintenance 7748681 12 2011 55 183 297 ...

Page 186: ...ouse pressure sensor 3 Oil pressure sensor 11 Coolant temperature sensor 4 Airfilter indicator 12 Exhaust temperature sensor 5 Aux stop 13 Piston cooling pressure sensor 6 Fuse 14 Flywheel position and engine speed sensor 7 Water in fuel sensor 15 Camshaft position sensor 8 Fuel pressure sensor 16 Solenoid valve drainage water trap optional not shown in illustration Maintenance 56 7748681 12 2011 ...

Page 187: ...rature sensor 2 Charge air pressure and temperature sensor 8 Water in fuel sensor 3 Flywheel position and engine speed sensor 9 Fuel pressure sensor 4 Fuse 10 Coolant temperature sensor 5 Aux stop 11 Piston cooling pressure sensor 6 Oil pressure sensor 12 Camshaft position sensor Maintenance 7748681 12 2011 57 185 297 ...

Page 188: ...ed WARNING If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine is started IMPORTANT Remember the following when washing with a power washer Never aim the water jet at radiators charge air cooler seals rubber hoses or electrical components Air Filter Check and Change The engine is equipped with electronic air filter indica tion The con...

Page 189: ...condition of the charge air hoses hose unions and clamp condition for cracks and other dam age Change as necessary IMPORTANT Clamps must be tightened using a torque wrench to 9 2 Nm 6 6 1 5 lbf ft P0002083 Maintenance 7748681 12 2011 59 187 297 ...

Page 190: ... voltage 2 Remove the fan guard and fan ring round the cool ing fan 3 Remove the belt guard 4 Insert a 1 2 square wrench in the belt tensioner 1 Lift the wrench up and lift the water pump drive belt off 5 Insert a 1 2 square wrench in the belt tensioner 2 Press the wrench down and remove the alternator belts 6 Check that the pulleys are clean and undamaged 7 Press the 1 2 wrench in the belt tensio...

Page 191: ...ve belt 5 Thread the drive belt round the fan and remove it 6 Check that the pulleys are clean and undamaged 7 Thread the new drive belt over the fan 8 Lift the 1 2 wrench and install the new drive belt 9 Install the belt guards 10 Install the fan guard and fan ring round the cooling fan 11 Start the engine and do a function check 1 P0002086 TAD1640GE TAD1641GE TAD1642GE TAD1650GE TAD1651GE TAD164...

Page 192: ... dipstick and with the engine running the OPERATING side of the dipstick Do not fill up above the maximum oil level Only use a recommended grade of oil please refer to Tech nical Data page 82 The oil level sensor only measures the oil level at the time when the ignition is turned on In other words not continually during operation TAD1650VE The oil level must be inside the marked area on the dipsti...

Page 193: ... Change WARNING Hot oil and hot surfaces can cause burns 1 Clean the oil filter bracket 2 2 Remove all oil filters with a suitable oil filter extrac tor 1 3 Clean the mating surface of the oil filter bracket Make sure that no pieces of old oil seal are left behind Carefully clean round the inside of the pro tective rim 2 on the oil filter bracket 4 Put a thin layer of engine oil on the seal rings ...

Page 194: ...fuel system make sure the engine is cold A fuel spill onto a hot surface or an electrical component can cause a fire Store fuel soaked rags so that they can not cause fire IMPORTANT Do not fill the new fuel filter with fuel before assembly There is a risk that contamination could get into the system and cause malfunctions or damage 1 Clean round the fuel filter 2 Remove the filter with a suitable ...

Page 195: ...ilter bracket by hand until the rubber seal just touches the mating surface Then tighten a fur ther half turn no more 7 Connect the cable to the water trap sensor 8 If necessary vent the fuel system please refer to Bleeding the Fuel System page 65 Draining condensate fuel system NOTICE Put a collection vessel under the fuel filter tocollect the condensate and fuel 1 Open the drain nipple 1 in the ...

Page 196: ...vo Penta Coolant VCS yellow both are available as concentrates and Ready Mixed Volvo Penta coolants have been prepared to work best with Volvo Penta engines and offer excellent protection against corrosion cavitation damage and bursts due to freezing Only coolants of this quality are adapted to and approved by Volvo Penta We recommend that the coolant supplied with the engine on delivery be used F...

Page 197: ...able IMPORTANT Different kinds of coolant must not be mixed with each other Mix 40 concentrated coolant and 60 water This mixture protects against internal corrosion cavi tation and bursts due to freezing down to 28 C 18 F A 60 glycol admix lowers the freezing point to 54 C 65 F Never mix more than 60 concentrate in the coolant A greater concentration provides reduced cooling effect with the risk ...

Page 198: ...recommended by Volvo Penta NOTICE Open only the filler cap 1 Do not open the pressure cap 2 NOTICE TWD1643GE The cap 2 is both filler cap and pressure cap Check the coolant level daily before starting 1 Check that the coolant level is above the MIN mark on the expansion tank 2 Top up with coolant as required so that the level is between the MIN and MAX marks TWD1643GE Fill the expansion tank to th...

Page 199: ... trapped air to escape If a heating unit is connected to the engine cooling system the heat control valve should be opened and the installation vented during filling 5 Stop the engine after about an hour and check the coolant level Top up as necessary TWD1643GE 1 Open the caps to both the expansion tank 1 and radiator 2 2 Fill coolant into the expansion tank until it is com pletely full 3 Fill the...

Page 200: ...he drain nipples are situated under the radiator on the right side of the engine block 4 Check that all coolant drains out Deposits may be found inside the drain plug tap and need to be cleared away There is otherwise a risk that coolant could remain and cause frost damage Check whether the installation has any further taps or plugs at the lowest points of the cooling water pipes 5 Shut any taps a...

Page 201: ...ng galleries The cooling system should be cleaned out when the coolant is changed IMPORTANT Cleaning must not be done if there is any risk of the cooling system freezing since the cleaning solution does not have any frost prevention ability IMPORTANT It is extremely important that the correct concentration and volume of coolant is put in the system Mix in a separate clean vessel before filling the...

Page 202: ...ns out is completely clean Make sure that any heater con trols are set to full heating during emptying 7 If contamination should still be left after a long period of flushing you can do a cleanout with Volvo Penta radiator cleaner followed by finishing off with Volvo Penta neutralizer Carefully follow the instructions on the package Otherwise continue as in item 8 below 8 When the cooling system i...

Page 203: ...und the fan cover guard as in fig 3b and 3c Removal and cleaning 1 Remove the cooling filter 2 Brush away any heavy dirt with a soft brush 3 Rinse the filter with water NOTICE If a cleaning agent is necessary an eco friendly degreaser e g coconut oil based must be used as a first choice Alternatively use a paraffin fraction as a second choice Spray on the degreaser or apply it using a sponge Allow...

Page 204: ...ng the alternator and electronics can be dam aged For the same reason the charging circuits must never be re connected with the engine running Fuses The engine is equipped with a 10 A circuit breaker which cuts the current if overloaded The circuit breaker is located on the left hand side of the engine Location of Sensors page 55 The engine stops if the fuse trips If the circuit breaker trips freq...

Page 205: ...ery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay Connecting and disconnecting the battery Connecting 1 Connect the cable red to the pole on the bat tery 2 Connect the cable black to the pole on the battery Disconnecting 1 Remove the cable black 2 Remove the cable red Cleaning Keep the batteries clean and dry Contamination an...

Page 206: ...teries Always use protective goggles and gloves If battery electrolyte comes into contact with unprotected skin whas off immediately using plenty of water and soap If battery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay WARNING Never confuse the positive and negative poles on the batteries Risk of arcing and explosion IMPORT...

Page 207: ... for a longer period of time the batteries should be fully charged then possibly trickle charged please refer to the battery manu facturer s recommendations Batteries are dam aged by being left discharged and can also freeze and burst easier in cold weather Special instructions apply to boost charging Boost charging can shorten battery life and should there fore be avoided P0002111 Maintenance 774...

Page 208: ...nth s stoppage Change the oil and oil filter on the engine then warm it up afterwards More than 8 month s stoppage Conserve the lubrication and fuel systems with con servation oil Please refer section Conservation of the lubrication and fuel systems for more than 8 months stoppage Check that the coolant offers sufficient frost protec tion Top up as necessary Alternatively you can drain the coolant...

Page 209: ...ine and warm it up at fast idle with no loading Check that no oil fuel or coolant leakage occurs Conservation of the lubrication and fuel systems for more than 8 months stoppage Drain the engine oil and fill up with conservation oil to just over the MIN marking on the dipstick Connect the fuel suction and return hoses to a 1 3 full jerrican containing conservation oil and 2 3 diesel fuel Vent the ...

Page 210: ...2 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Compression ratio 17 5 1 16 5 1 16 5 1 16 5 1 Low idle r min 900 900 900 900 High idle rpm 1500 1800 1500 1800 1500 1800 1500 1800 Type designation TAD1650GE TAD1651GE Power prime stand by Refer to the sales literature Torque Prime Standby Refer to the sales literature No of cylinders 6 6 Bore mm inch 144 5 67 144 5 67 Stroke mm inch 1...

Page 211: ...144 5 67 144 5 67 Stroke mm inch 165 6 50 165 6 50 165 6 50 Displacement liter inch3 16 12 983 9 16 12 983 9 16 12 983 9 Weight dry kg lb 1480 3263 1480 3263 1425 3142 Weight wet kg lb 1550 3417 1550 3417 1495 3296 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Compression ratio 17 5 1 17 5 1 18 0 1 Low idle r min 600 600 700 High idle rpm 1800 1800 1800 2000 Technical Data 7748681 12 2011 81 20...

Page 212: ...Mineral based oil as well as fully or semi synthetic can be used on condition that it complies with thequality requirements above 1 If sulfur content is 1 0 by weight use oil with TBN 15 2 The oil must also comply with at least one of the following specifications ACEA E7 ACEA E5 Global DHD 1 API CI 4 or API CH 4 VDS Volvo Drain Specification ACEA Association des Constructeurs Européenne d Automobi...

Page 213: ...ls Volvo Penta accepts the same FAME content as in major on road fuels EN 590 and ASTM D975 i e today up to 7 without any specific additional service requirements Please contact your Volvo Penta Dealer for futher information For engines produced after 1 Jan 2009 Volvo Penta accepts with specific service requirements max 30 FAME blend FAME component in accordance with EN 14214 and diesel fuel in ac...

Page 214: ...6 8 F TAD1650VE TWD1643GE 82 C 179 6 F Coolant Volvo Penta Coolant VCS and VCS Ready Mixed yel low colour are based on Organic Acid Technology OAT Volvo Penta Coolant and Coolant Ready Mixed green colour are silicate based Water Quality ASTM D4985 Total solid particles 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulfate 100 ppm pH value 5 5 9 Silica acc ASTM D859 20 mg SiO2 l Iron acc ASTM D1068...

Page 215: ...ent optional voltage max current 28V 110A power app 2800W Battery capacity 2 pcs series connected 12 V max 220 Ah Battery electrolyte density at 25 C fully charged battery 1 28 g cm3 1 24 g cm3 recharge battery at 1 20 g cm3 1 20 g cm3 Note Applies to batteries with tropical acid Technical Data 7748681 12 2011 85 213 297 ...

Page 216: ...A Engine designation B Engine power net without fan C Max engine speed D Main software E Dataset 1 F Dataset 2 G Product number 3 1 Engine designation 2 Serial number 3 Specification number A B C D E F G P0002052 Technical Data 86 7748681 12 2011 214 297 ...

Page 217: ...ignition engines The partially completed machinery also complies with the following relevant Directive 2004 108 EC Electromagnetic Compatibility EMC Directive Applied Standards EN 61000 6 1 EN 61000 6 2 EN 61000 6 3 EN 61000 6 4 EN 12895 EN ISO 14982 and EN 13309 Declaration for the installation of partially completed machinery in accordance with Machinery Directive 2006 42 EC Engine Manufacturer ...

Page 218: ...216 297 ...

Page 219: ... Alternator Belt Inspection 60 Drive Belt Change 61 DU Display Unit 17 E Easy Link Instruments 21 Electrical Connections 74 EMS Engine Management System 10 Engine Fuel Filter Replacement 64 Engine Oil Change 63 Engine General 58 Engines 9 Erasing fault codes 35 Extra Stop 28 F Fault Tracing 30 Fuel Pre filter Change 65 Fuel System 64 I Identification Numbers 86 L Location of Sensors 55 Lubrication...

Page 220: ...218 297 ...

Page 221: ... 2011 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper 219 297 ...

Page 222: ...7748681 English 12 2011 220 297 ...

Page 223: ...9 2 Appendix B Alternator user and maintenance manual 221 297 ...

Page 224: ...222 297 ...

Page 225: ...ER R A Al lt te er rn na at to or r L LS SA A4 47 7 2 2 L L9 9 L LS SA A4 47 7 2 2 M M7 7 M M8 8 L LS SA A4 47 7 2 2 S S4 4 S S5 5 L LS SA A4 47 7 2 2 V VS S2 2 V VS S3 3 4 47 7 2 2 S SH HU UN NT T A AR RE EP P P PM MG G 3742 g 01 03 2011 33522060501_10_1 223 297 ...

Page 226: ...224 297 ...

Page 227: ...2011 03 g 343 347 1 198 34 4 28 41 49 366 367 128 33 124 131 31 15 30 68 22 284 62 60 This manual is to be given to the end user 3742 en LSA 47 2 4 POLES ALTERNATORS Installation and maintenance 225 297 ...

Page 228: ...w anyone to stand in front of the air outlet guards in case anything is ejected from them b Do not allow children younger than 14 to go near the air outlet guards Aset of self adhesive stickers depicting the various warning symbols is included with this maintenance manual They should be positioned as shown in the drawing below once the machine has been fully installed WARNING The alternators must ...

Page 229: ...embly 6 3 2 Checks prior to first use 7 3 3 Terminal connection diagrams 7 3 4 Commissioning 10 3 5 Setting up 10 4 SERVICING MAINTENANCE 11 4 1 Safety measures 11 4 2 Routine maintenance 11 4 3 Fault detection 11 4 4 Mechanical defects 12 4 5 Electrical faults 12 4 6 Dismantling reassembly 14 4 7 Installation and maintenance of the PMG 16 4 8 Table of characteristics 17 5 SPARE PARTS 18 5 1 First...

Page 230: ...e quickly and accurately we suggest you write its specifications on the nameplate below 1 4 Storage Prior to commissioning machines should be stored Away from humidity 90 after a long period of storage check the machine insulation section 3 2 1 To prevent the bearings from becoming marked do not store in an environment with significant vibration 1 5 Application These alternators are mainly designe...

Page 231: ... bearings greased for life Mounting arrangements IM 1201 MD 35 foot and flange mounted single bearing with SAE coupling disc IM 1001 B 34 double bearing with SAE flange and standard cylindrical shaft extension Drip proof machine self cooled Degree of protection IP 23 2 1 1 Mechanical options Air inlet filter Regreasable ball bearings IP 44 protection T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11...

Page 232: ...e compatible by undertaking a torsional analysis of the transmission checking the dimensions of the flywheel and its housing the flange coupling discs and offset When coupling the alternator to the prime mover do not use the fan to turn the alternator or rotor The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Make sure the alternator is securely bedde...

Page 233: ...tection matching the defined environmental conditions 3 2 2 Mechanical checks Before starting the machine for the first time check that all fixing bolts and screws are tight the cooling air is drawn in freely the protective grilles and housing are cor rectly in place the standard direction of rotation is clock wise as seen from the shaft end phase rotation in order 1 2 3 For anti clockwise rotatio...

Page 234: ...380 480 440 600 380 416 R 250 voltage sensing 0 T8 110 V T11 NDE L1 U L2 V L3 W Single phase or 3 phase Winding 60 Hz 50 Hz 220 240 220 240 220 240 240 254 L L R 250 voltage sensing 0 T8 110 V T11 T11 T12 T10 T4 T6 T5 T7 T8 T9 T1 T2 T3 N In case of reconnection ensure that AVR voltage sensing is correct Winding 9 R 450 voltage sensing transformer Diagram on request NDE L1 U L2 V L3 W T11 T12 T10 T...

Page 235: ...nection ensure that AVR voltage sensing is correct The factory can supply a set of flexible shunts and special connection links as an option for making these connections R 450 voltage sensing 0 T3 380 V T2 Operating phases L2 V L3 W single phase 3 3 3 Option connection diagram R 791 T interference suppression kit standard for CE marking Remote voltage potentiometer Black Black Black Blue White Con...

Page 236: ...chine should be connected with the busbar separating the terminals as shown in the terminal connection diagram 3 4 Commissioning The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The machine is tested and set up at the factory When first used with no load make sure that the drive speed is correct and stable...

Page 237: ... h Lubrication intervals are given for grease type LITHIUM standard NLGI 3 In the factory the grease used for lubrication is ESSO Unirex N3 Before using another grease check for compatibility with the original one Monitor the temperature rise in the bearings see section 4 4 4 2 3 Electrical servicing Commercially available volatile degreasing agents can be used Do not use trichlorethylene perchlo ...

Page 238: ...still correct when the battery is removed Lack of residual magnetism The alternator builds up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to theAVR Faulty diodes Armature short circuit The alternator builds up but its voltage disappears when the battery is removed FaultyAVR Field windings open circuit check winding Revolv...

Page 239: ...Assembly A Connect a 12 V battery in series with a rheostat of approximately 50 ohms 300 W and a diode on both exciter field wires 5 and 6 6 5 Diode 1A 12V battery Rh 50Ω 300W ASSEMBLY A Exciter field Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation ...

Page 240: ...ts for mounting the diode bridges on the support Change the crescents respecting the polarity 4 6 4 Access to connections and the regulation system Access directly by removing the top of the cover 48 or the AVR access door 466 4 6 5 Replacing the NDE bearing Remove the air intake grille 51 Remove the lid of the protective cover 48 and the side panels 366 and 367 Remove the hook 21 and the cover re...

Page 241: ...section 4 6 5 Fit the new bearing after heating it by induction to approximately 80 C Screw a threaded rod into the thrust bearing 68 Refit the shield 30 on the machine Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Tighten the bottom thrust bearing screws 68 remove the threaded rod and fit the other screws Tighten the 6 shield screws 31 Refit the air o...

Page 242: ... new O ring seal 349 in the shield 36 Refit the shield 36 on the machine using a dowel and nut in the shaft extension see diagram Tighten the 5 shield screws 37 Reconnect exciter wires E E Finish reassembling the cover Screw a threaded rod into the thrust bearing 68 Refit the shield 30 on the machine Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Fit th...

Page 243: ...0 2 0 128 LSA 47 2 6 wires L9 0 0039 1 1 10 2 0 128 Resistance of AREP auxiliary windings at 20 C Ω LSA 47 2 Auxil wdg X1 X2 Auxil wdg Z1 Z2 VS2 0 2 0 38 VS3 0 2 0 38 S4 0 195 0 40 S5 0 195 0 40 M7 0 165 0 33 M8 0 17 0 35 L9 0 168 0 34 LSA 47 2 6 wires L9 0 168 0 34 Field excitation current i exc A Symbols i exc excitation current of the exciter field LSA 47 2 No load At rated load VS2 1 4 VS3 1 4...

Page 244: ...ce centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage 5 3 Accessories 5 3 1 Space heater for use when stopped The space heater must run as soon as the alternator stops I...

Page 245: ...LSA 47 2 4 POLES ALTERNATORS 3742 en 5 4 Exploded view parts list and tightening torque 5 4 1 LSA 47 2 single bearing 343 100 347 78 79 349 70 90 365 466 130 1 36 37 198 34 4 28 41 49 366 367 51 128 33 124 91 131 21 53 48 72 71 323 322 325 31 15 30 243 297 ...

Page 246: ...tallation and maintenance LSA 47 2 4 POLES ALTERNATORS 3742 en 5 4 2 LSA 47 2 double bearing 343 100 347 79 349 70 90 365 466 130 1 36 37 198 34 4 28 41 49 366 367 51 128 33 124 91 131 21 53 48 71 31 15 30 68 22 284 62 60 244 297 ...

Page 247: ...ng screws M12 69 128 3 Starting range 33 1 Protective grille 130 1 Neutral link 34 2 Fixing screws M6 5 131 9 Terminal block terminal screws 36 1 Exciter end shield 198 1 Voltage regulator AVR 37 4 Fixing screws M12 69 284 1 Circlips 41 1 Cover front panel 322 3 Coupling disc 48 1 Cover top panel 323 6 Fixing screw M16 170 49 Cover screws M6 5 325 Spacer shim 51 1 Air intake grille 343 1 Diode bri...

Page 248: ...34 1 and 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets 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...

Page 249: ...23 LEROY SOMER 2011 03 g Installation and maintenance LSA 47 2 4 POLES ALTERNATORS 3742 en 247 297 ...

Page 250: ...www leroy somer com 248 297 ...

Page 251: ...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 252: ...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 253: ...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 254: ...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 255: ...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 256: ... 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 257: ...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 255 297 ...

Page 258: ...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 259: ...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 260: ... 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 261: ...Installation and maintenance R250 A V R 4067 en 2009 05 b LEROY SOMER 11 259 297 ...

Page 262: ...MOTEURS LEROY SOMER 16015 ANGOULÊME CEDEX FRANCE 338 567 258 RCS ANGOULÊME S A au capital de 62 779 000 www leroy somer com 260 297 ...

Page 263: ...S LSA 49 1 50 2 7000 8000 SERIES LSA 49 1 50 2 7000 8000 SERIES LSA 46 2 47 2 5000 6000 SERIES LSA 46 2 47 2 5000 6000 1 PHASE SENSING 3 PAHASES SENSING 2 3 0 1 RAPIDE FAST RAPIDE FAST NORMAL NORMAL NORMAL NORMAL SHUNT AREP PMG 2 3 0 1 0 9 8 7 6 5 4 3 2 1 0 3 2 1 0 3 2 1 LEDS US C Installation maintenance manual www leroy somer com 380V 220 110 0V E E Z2 X1 Z1 X2 2012 03 e This manual is to be giv...

Page 264: ... take notice of the various warning symbols used 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 ...

Page 265: ...or without a LAM U F only 12 3 5 AVR options 13 4 INSTALLATION COMMISSIONING 14 4 1 Electrical checks on the AVR 14 4 2 Setting up 14 4 3 Electrical faults 17 5 SPARE PARTS 18 5 1 Designation 18 5 2 Technical support service 18 All servicing or repair operations performed on the AVR should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanica...

Page 266: ...OIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LAM ON ONLY FOR SPECIAL CONFIG KNEE LAM OFF 65Hz LAM OFF LAM MODE 2 LAM MODE 1 LAM OFF LAM MODE 2 LAM MODE 1 50Hz EXT FREQ SET 0 5 6 9 8 1 2 3 4 RAPIDE FAST RAPIDE FAST NORMAL NORMAL NORMAL NORMAL SHUNT AREP PMG 2 3 0 1 0 9 8 7 6 5 4 3 2 1 0 3 2 1 140 mm LEDS P1 Voltage P2 Stability P3 Exc...

Page 267: ...ould be in the AREP position see 3 2 3 AREP SYSTEM Field Armature T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11 T12 according to voltage Aux windings 10 Yellow 11 Red 9 Green 12 Black 10 Yellow 11 Red 9 Green 12 Black STATOR 6 wires T1 to T6 STATOR 12 wires T1 to T12 MAIN FIELD R 450 VOIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LA...

Page 268: ... T9 T10 T11 T12 according to voltage Field Armature STATOR 6 wires T1 to T6 STATOR 12 wires T1 to T12 MAIN FIELD R 450 VOIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LAM ON ONLY FOR SPECIAL CONFIG KNEE LAM OFF 65Hz LAM OFF LAM MODE 2 LAM MODE 1 LAM OFF LAM MODE 2 LAM MODE 1 50Hz EXT FREQ SET 60Hz 0 5 6 9 8 1 2 3 4 SERIES LSA 49 1 50 2...

Page 269: ... VOIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LAM ON ONLY FOR SPECIAL CONFIG KNEE LAM OFF 65Hz LAM OFF LAM MODE 2 LAM MODE 1 LAM OFF LAM MODE 2 LAM MODE 1 50Hz EXT FREQ SET 60Hz 0 5 6 9 8 1 2 3 4 SERIES LSA 49 1 50 2 7000 8000 SERIES LSA 49 1 50 2 7000 8000 SERIES LSA 46 2 47 2 5000 6000 SERIES LSA 46 2 47 2 5000 6000 2 3 0 1 RAPIDE...

Page 270: ...tentiometer P4 within a range from 0 to 8 with a PF 0 8 for 400V applications From 0 to 14 with a PF 0 8 for 240V applications From 0 to 8 for 110V applications with a step up transformer ratio of 4 placed on the voltage reference The potentiometer P4 has a non linear response Then when a 1Asecondary CT is connected the effective range starts from the the second 1 3 of P4 range and in the case of ...

Page 271: ...ation current must be limited to 9 A 0 5 A Overrun indications One green LED Lights up when the excitation current is below the continuous operation threshold It signals the AVR normal operation Turnsoffwhentheexcitationcurrentceiling used to obtain short circuit operation is reached and when the excitation current is reduced to the shutdown value Flashes when the over excitation counter is decrem...

Page 272: ...ys on flashes when the excitation current has reached the ceiling in 10s with PMG excitation ftays on if Iexc I Shutdown WARNING If the overload protection is activated a voltage drop possibly exceeding 10 of the reference voltage will be observed The AVR does not provide undervoltage protection The customer will need to make sure that their installation is correctly protected against under voltag...

Page 273: ...ecial not used Pos 8 Change in the voltage according to the U F ratio knee point position at 48 Hz or 58Hzaccordingtoselectionofthefrequency by an external contact Pos 9 Change in the voltage according to LAM 1 knee point position at 48 Hz or 58 Hz according to selection of the frequency by an external contact WARNING For Pavers and hydraulic applications select positions 0 50 Hz or 3 60 Hz 3 2 3 ...

Page 274: ...oad or to increase the applied load possible for one speed variation turbo charged engine To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the rated frequency LAM UN 0 48 or 58 Hz 0 85 UN Voltage Voltage U f 50 or 60 Hz fC fN ST3 3 3 2 2 Soft voltage recovery function During load impacts the function helps the genset to return to its rate...

Page 275: ...phase current and voltage sensing for parallel operation on unbalanced installations unbalance 15 R 726 module regulation system changed to 4 function see the maintenance manual and connection diagram PF regulation 2F Equalization of voltages before paralleling 3 F Possibility of coupling to the mains of alternators already running in parallel 4F R729 module same as R726 with additional functions ...

Page 276: ...3 P4 10 A maximum 400 V 50 Hz Not set centre position Not set fully anti clockwise Excitation ceiling Factory sealed Voltage quadrature droop operation with C T 0 quadrature droop fully anti clockwise Voltage minimum fully anti clockwise Stability Stability adjustments in standalone operation b Install a D C analogue voltmeter needle dial cal 100 V on terminals F F and an A C voltmeter cal 300 500...

Page 277: ...e speed match the kW or divide the rated power of the units proportionally By altering the quadrature droop potentiometer P4 match or divide the currents 4 2 2 Max excitation adjustment excitation ceiling In standard setting the potentiometer P3 is in maximum position However for applications requiring an overload protection see 3 2 1 4 the excitation ceiling must be adjusted by using the followin...

Page 278: ...ly 1 wire X1 or X2 Contact rating 16 A 250 V A C 4 2 3 2 R450 AREP PMG field weakening X2 Z1 X1 Z2 E E The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxiliary winding contact rating 16 A 250 V A C Connection is identical for resetting theAVR internal protection If field weakening is used provide field forcing 4 2 3 3 R450 field forcing Applications B Volt Time t ...

Page 279: ...h Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR 1 faulty diode Voltage oscillations Adjust AVR stability potentiometer If no effect try normal fast recovery modes Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F knee point set too high Voltage correct at no load and too low when on load Run at no load and check t...

Page 280: ...l information you may require When ordering spare parts you should indicate the AVR type and code number Address your enquiry to your usual contact Our extensive network of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this adv...

Page 281: ...2012 03 e LEROY SOMER 19 Installation and maintenance R 450 AVRs 4531 en 279 297 ...

Page 282: ...www leroy somer com 280 297 ...

Page 283: ...r 330050188 X 1 Pressure temperature sensor 330052072 X 1 Oil pressure oil temperature sensor 330052203 X 1 Level sensor 330052074 X 1 Pick up 330051934 X 1 Expansion bottle level detector 330051728 X 1 Cooling water temperature sensor 330052075 X 1 Sump pressure sensor 330051721 X 1 Starter motor brush holder 330051586 X 1 Radiator cap 330901552 X 1 Starter motor solenoid 330051509 X 1 Piston coo...

Page 284: ...0 330560243 x 1 330570120 330570119 X 1 330560617 330510015 330510015 x 1 330560551 x 2 330560634 x 1 LEROY SOMER LSA472M7 ALTERNATOR Direct diodes 330410032 X 3 Inverse diodes 330410033 X 3 Varistor 330410109 X 1 Note For all technical assistance or spare part requests contact your nearest SDMO agent 282 297 ...

Page 285: ... throttle abnormal pulse width 9 Throttle invalid CAN value 10 Throttle voltage out of range low 13 Throttle calibration aborted 14 Throttle voltage out of range 94 94 Fuel rail pressure sensor 1 Fuel supply pressure extremely low 3 Fuel rail pressure input voltage high Short to V 4 Fuel rail pressure input voltage low Short to V 5 Fuel rail pressure sensor open circuit 10 Fuel rail pressure lost ...

Page 286: ...urbo speed sensor 0 Turbo speed too high 5 Turbo speed sensor circuit open 6 Sensor shorted to earth Short to V 8 Speed signal invalid 31 Intermittent problem with speed information 105 105 Manifold air temperature sensor 0 Manifold air temperature extremely high 3 Manifold air temperature sensor input voltage high 4 Manifold air temperature sensor input voltage low 5 Manifold air temperature sens...

Page 287: ...re high 111 111 Coolant level sensor 0 Engine coolant level low 1 Engine coolant level low 3 Coolant level sensor input voltage high 4 Coolant level sensor input voltage low 153 153 Crankcase pressure sensor 0 Value above normal 3 Crankcase pressure sensor input voltage high 5 Crankcase pressure sensor open circuit 157 Fuel pressure sensor in the common rail 1 Fuel pressure too low 3 Input voltage...

Page 288: ...lty 175 175 Oil temperature sensor 0 Oil temperature extremely high 3 Oil temperature sensor input voltage high 4 Oil temperature sensor input voltage low 5 Oil temperature sensor open circuit 177 Transmission oil temperature sensor 9 Transmission oil temperature invalid Not possible with Genset application 189 Rated engine speed 0 Engine speed de rated 31 Engine speed de rated 190 190 190 Engine ...

Page 289: ...utput open circuit 412 Temperature sensor in the EGR valve 0 Temperature in the EGR extremely high 3 Input voltage of the temperature sensor high Short to V 4 Input voltage of the temperature sensor low Short to V 15 Temperature in the EGR high 16 Temperature in the EGR moderately high 443 443 ENGINE RUN output status 3 Engine run output open short to B 4 Engine run output short to B 523 Gear sele...

Page 290: ... injection pump communication error Possible only with 6068HF475 VP44 630 253 Data set memory EEPROM 632 Injection status 2 Fuel shutoff error 5 Fuel shutoff non functional 636 21 Pump position sensor Cam position sensor Speed sensor CAM Pump position or CAM position in function of the type of injection 2 Pump position sensor cam position sensor input noise 3 Permanent loss of signal 5 High impeda...

Page 291: ...ications Recalibration of the injectors required 1 Injector outside specifications Recalibration of the injectors required 2 Short circuit high side to B 3 Short circuit high side to low side or low side to B 4 Short circuit high or low side to ground 5 Cylinder 1 circuit open 6 Cylinder 1 circuit shorted 7 Cylinder 1 balancing error mechanical failure 11 Cylinder 1 unknown error mechanical failur...

Page 292: ...rs required 1 Injector outside the specifications Recalibration of the injectors required 2 Short circuit high side to B 3 Short circuit high side to low side or low side to B 4 Short circuit high or low side to ground 5 Cylinder 4 circuit open 6 Cylinder 4 circuit shorted 7 Cylinder 4 balancing error mechanical failure 11 Cylinder 4 unknown error mechanical failure 655 5 5 655 Cylinder 5 injector...

Page 293: ...trol open circuit 678 41 8 Volt power supply 3 ACM 8 Volt DC supply open short to B 4 ACM 8 Volt DC supply open short to ground 679 42 Regulation sensor of the injection pressure control 723 342 Secondary speed sensor 2 Secondary engine speed sensor data intermittent 11 Secondary engine speed sensor loss of signal 12 Loss of signal sensor failure 729 70 Inlet air heater signal Preheat detection 3 ...

Page 294: ...ent decay time invalid Injection DE10 1077 Fuel injection pump controller status 7 Attempting to fuel without command 11 Pump supply voltage out of range 12 Pump self test error 19 Pump detected communication error 31 Pump initiated engine protection 1078 ECU Pump timing status 7 ECU Pump timing moderately out of synchronisation 11 ECU Pump timing speed out of synchronisation 31 ECU Pump timing ex...

Page 295: ...ontrol error 10 Pump control valve fuel flow not detected 1348 Pump control valve 2 status Only for 6081HF070 5 Pump control valve 2 error mismatch 10 Pump control valve 2 fuel flow not detected 1485 1485 5 Pump power relay status ECU main relay of VOLVO EMS EDC 2 Pump power relay fault 3 ECU main relay short circuit high 1568 Torque curve selection 2 Torque curve selection invalid 4 Torque curve ...

Page 296: ...n of the EGR valve 2795 Position of TGV actuator 7 The actuator does not respond or is not in the expected position 3509 Common supply voltage of the sensors output 1 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3510 Common supply voltage of the sensors output 2 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of t...

Page 297: ...dcast of data value is substituted with the error indicator value FMI 5 CURRENT BELOW NORMAL OR OPEN CIRCUIT a A current signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose current remains off when the ECM...

Page 298: ...icated as a specific component and failure mode Possible reasons for using a System Diagnostic Code include 1 Cost of specific component fault isolation is not justified or 2 New concepts in Total Vehicle Diagnostics are being developed or 3 New diagnostic strategies that are not component specific are being developed Due to the fact that SPNs 611 615 are manufacturer defined and are not component...

Page 299: ... cases when the reported SPN name spells out the component and a non standard failure mode This type of fault may or may be directly associated with the value of general broadcast information This FMI will mean not available when the associated SPN is also not available as when the remainder of the packet is filled with binary ones after all data has been transmitted 297 297 ...

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