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Installation Instructions

29.12.04

Panda AGT-DC 4000 PVMV-N s00670 - Chapter E: Installation Instructions Page 59

E. Installation Instructions

E.1 Generator Connections

ATTENTION! Before working on the System read the “Safety Instructions” on Page iv

E.1.1 General Instructions

• It is important to pay attention to the fresh air intake.

• It must be guaranteed that the cooling air supply is sufficient.

• The radiator may not be covered.

• Untrained personnel should never open the generator.

E.1.2 Connections

01. Passage for battery cable (+)
02. Passage for battery cable (-)
03. Cable for DC/DC converter
04. Socket for remote control panel
05. Socket for vcs cable

06. Connection fuel OUT
07. Connection fuel IN
08. Air suction intake
09. Cooling water OUT
10. Exhaust output

Содержание AGT 4000 PVMV-N

Страница 1: ...Panda_AGT4000_PVMV N_Book_Vossloh_s00670 29 12 04 Generator type Panda AGT 4000 PVMV N 24V 140A 4kW Icemaster Fischer Panda...

Страница 2: ...n efficiency also ensures a fuel saving to the same extent The 100 water cooled Panda Aggregate are currently manufactured in the performance range from 2 to 100 kW in various versions Fast running mo...

Страница 3: ...o which the generator is to be installed in also corresponds to the regulations of the machine gui deline 98 37 EG This concerns among other things the exhaust system cooling system and the electrical...

Страница 4: ...ccessible a power relay must be used instead of the main switch which can be served manually which can be served then if necessary from different places The switches for the power relay are to mark ac...

Страница 5: ...or A battery must always be connected to the inverter as a capacity Recommended capacity at 12V 240Ah at 24V 120Ah The screws at the electric rectifier may be pulled tight only with a torque wrench To...

Страница 6: ...it imme diate a doctor Don t smoke in the near of the batteries Avoid naked flames or open fires In the area of batteries exists danger of explosions Pay attention that no tools fall on the battery po...

Страница 7: ...minary remarks 32 B 2 3 Overloading of engine during longer operation 33 B 2 4 Starting the Generator 33 B 2 5 Stopping the Generator 34 B 2 6 Operating control system on the Panda Generator 34 C Main...

Страница 8: ...the starter battery 62 E 1 5 Installation electronic components 63 E 2 Voltage Control System 64 E 3 The battery monitor 65 E 3 1 Adjustments 65 E 3 2 Installation of the remote control panel 67 E 3...

Страница 9: ...crew on the pre silencer 03 Air suction socket 04 Air suction housing with air filter insert 05 Protection resistor for thermo switch 75 C 70 C 06 Starter motor 07 Adjusting nut 08 Oil pressure switch...

Страница 10: ...de block 03 Generator housing with coil 04 Generator front cover 05 Bracket for silencer 06 Cooling water hose 07 Compensator under heat isolation 08 Water cooled pre silencer 09 Cable for DC DC conve...

Страница 11: ...witch at exhaust manifold 98 C 83 C 07 Ventilation vlave on the exhaust manifold 08 Generator front cover 09 Generator housing with coil 10 Cooling waterpump 11 Thermo switch 75 C 70 C 12 Thermo switc...

Страница 12: ...Right side View 01 02 03 06 08 07 09 04 05 01 Terminal block 02 Schottky diode under protection cover 03 Cooling water pump 04 Earth switch relay 05 Engine Kubota EA 300 06 Connection cooling water f...

Страница 13: ...r 29 12 04 Panda AGT DC 4000 PVMV N s00670 Chapter A The Panda Generator Page 7 A 1 5 Left side View 02 01 03 04 01 Water cooled pre silencer 02 Starter motor 03 Ventilation screw on the pre silencer...

Страница 14: ...70 Chapter A The Panda Generator 29 12 04 A 1 6 Radiator View 03 02 01 04 05 06 01 Connection for cooling water overflow 02 Fan 03 Connection cooling water in flow cold side 04 Cooling water filler 05...

Страница 15: ...ig A 1 Remote control panel Automatic Start Option An automatic start option is available as an accessory This includes a separate control board which is connected to the main remote control board pan...

Страница 16: ...oling water filler neck Fig A 2 Cooling water filler neck Output of radiator The cooling water cold side flows from here to the generator Fig A 3 Output of radiator Cooling water in flow This connecti...

Страница 17: ...g water is conducted by the waterpumpe into the diode block Fig A 5 Cooling water pump Cooling water pipe into diode block The diode block is cooled with cooling water Fig A 6 Cooling water pipe Cooli...

Страница 18: ...Engine input Ventilation screw engine The ventilation screw on the engine may not be opened while the generator runs If this happens inadvertently by the opening air is sucked in A very complex ventil...

Страница 19: ...Chapter A The Panda Generator Page 13 Preheat pump Fig A 11 Preheat pump Inlet into engine Fig A 12 Inlet into engine Water cooled exhaust manifold The exhaust manifold is cooled by the water withdra...

Страница 20: ...pened while the generator runs If this happens inadvertently by the opening air is sucked in A very complex ventilation of the entire system is necessary thereafter Fig A 14 Ventilation valve exhaust...

Страница 21: ...Die Entl ftungsschraube am wasserge k hlten Vorschalld mpfer wird bei Erstbe f llung oder nach Reperaturarbeiten benutzt Fig A 17 Ventilation screw pre silencer R cklauf externer K hler From here the...

Страница 22: ...he Panda Generator Page 16 Panda AGT DC 4000 PVMV N s00670 Chapter A The Panda Generator 29 12 04 Input into radiator Fig A 20 Input into radiator Cooling water overflow Fig A 21 Cooling water overflo...

Страница 23: ...Fuel solenoid valve The fuel solenoid valve opens automati cally if START is pressed on the remote control panel The solenoid closes if the generator is switched to OFF position It takes a few seconds...

Страница 24: ...V N s00670 Chapter A The Panda Generator 29 12 04 Injection nozzle Fig A 25 Injection nozzle Glow plug The glow plug heats up the pre chamber Fig A 26 Glow plug Additionnal glow plugs Glow plugs for c...

Страница 25: ...be consistently paid attention that the generator is installed in such a way that from no water can arrive into the pro ximity of these air openings Fig A 28 Combustion air intake Air suction housing...

Страница 26: ...s led through the engine it occurs into the water cooled exhaust manifold Fig A 31 Water cooled exhaust manifold Compensator under heat isolation This part is because of the internal con struction ela...

Страница 27: ...e electrical system Main connection 1 Pasage for battery plus cable 2 Pasage for battery minus cable Fig A 34 Main connections Electrical connection for control 1 Remote control panel 2 VCS Fig A 35 E...

Страница 28: ...Starter motor and 2 Solenoid switch The Diesel engine is electrically started On the top of the engine is accordingly the electrical starter with the solenoid switch Fig A 38 Starter motor Actuator fo...

Страница 29: ...enerator Page 23 Diode block 1 Schottky diode 2 Schottky diode 3 Schottky diode 4 Main connection plus 5 Main connection minus 6 Shunt for VCS regulation Fig A 40 Diode block DC DC converter 24V 12V F...

Страница 30: ...e is used for monitoring the engine temperature 98 C 83 C Fig A 43 Thermo switch at engine Thermo switch at exhaust manifold 98 C 83 C Fig A 44 Thermo switch at exhaust manifold Thermo switch at pre s...

Страница 31: ...s with the thermo switch 75 C 70 C Fig A 46 Protection resistor Thermo switch coil 01 Thermo switch 125 C 02 Generator housing 03 Thermo sensor NTC 981S for measuring Fig A 47 Thermo switch coil Oil p...

Страница 32: ...r Fig A 49 Thermo switch of the bar Thermo switch on the bar Fig A 50 Thermo switch on the bar Terminal block for remote control panel fuses and relays Ks relay for starter motor Kp relay for plw plug...

Страница 33: ...Terminal block fuses A 2 7 Components of the lubircation system Oil filler neck with cap Please pay attention tht the filler necks are always well locked after filling in engine oil Consider also the...

Страница 34: ...A 55 Oil strainer Oil drain hose The Panda generator is equipped that the engine oil can be drained over an drain hose The generator should be always installed therefore that a collecting basin can be...

Страница 35: ...for the controlling of the aggregate and for the evaluation of the engine generator monitoring In the case of deviation of the operational data from the desired values the generator is switched off au...

Страница 36: ...The Panda Generator Page 30 Panda AGT DC 4000 PVMV N s00670 Chapter A The Panda Generator 29 12 04...

Страница 37: ...ches off automatically in the case of insufficient oil pressure Do not run the generator with the oil at the lowest level in the crankcase A smaller volume of oil will become contaminated considerably...

Страница 38: ...res up to minus 20 C as long as running conditions are suitable The fuel must be suitable for such conditions as conventional diesel fuel can produce a paraffin coating at temperatures lower than minu...

Страница 39: ...e fuel valve 2 If necessary close the main battery switch 3 Check if all the load have been switched off The load is switched off before the generator is switched off The generator is not to be starte...

Страница 40: ...e generator 4 Activate additonal switches Battery switch fuel stop valve etc B 2 6 Operating control system on the Panda Generator Panda generators are equipped with various sensors One of these senso...

Страница 41: ...ature 98 C 83 C Fig B 2 Thermo switch at engine Thermo switch at pre silencer The cooling water have here the hotest value The cooling water flows from here back to the radiator 1 98 C 83 C 2 82 C 77...

Страница 42: ...da AGT DC 4000 PVMV N s00670 Chapter B Generator Gebrauchsanweisung 29 12 04 Oil presuure switch engine In order to be able to monitore the lubrica ting oil system an oil pressure switch is built into...

Страница 43: ...ith dry air in which environment of muted oil and fuel steams and increased temperature The hoses must be checked regularly for elasticity There are operating situations at which the hoses must be ren...

Страница 44: ...hrough the sound cover Open the sound cover passage and pull out the drain hose Oil drain screw The oil can be drained by opening the oil drain screw For countering use a second wrench Oil drain pump...

Страница 45: ...peatiing hours Open the oil filler neck After opening the cap of the oil filler neck the new oil is refilled Please wait instant before measure the oil level the oil must set off in the sump Oil dipst...

Страница 46: ...be repeated several times ATTENTION Before opening the de aerating points the generator must be stagnant Open the ventilation screw on the engine Open the ventilation screw on the water cooled silence...

Страница 47: ...enset also get warm Please wait until the temperatures raise more and check if the fan will activate It makes sense to once again repeat the de aerating procedure after a few days in order ensure that...

Страница 48: ...anel ON 4 Press START button The fuel pump runs audible 5 Switch the panel OFF 6 Switch the panel ON 7 Press again the START button This procedure must be repeated several times until fuel nonporously...

Страница 49: ...in firmly C 6 Additional maintenance Furthermore in addition to the standards checks according to the manual following points of the generator have to be checked automatic shut down of the generator i...

Страница 50: ...tem peratures of the rectifier With the help of the infrared thermometer you can check all the temperatures on the rectifier Check all the cable connections of the DC wiring The easiest is to touch t...

Страница 51: ...he generator output cable Ensure that a battery switch is installed in the battery line Never leave the generator behind wit hout the cover mounted over the heat sink and capsule not closed Remind the...

Страница 52: ...Maintenance Instructions Page 46 Panda AGT DC 4000 PVMV N s00670 Chapter C Maintenance Instructions 29 12 04...

Страница 53: ...s In addition it is to be considered that the exhaust gas values in the full load enterprise become more unfavorable soot formation Effects of Short Circuiting and Overloading on the Generator The gen...

Страница 54: ...s at the quipments D 2 1 Lubrication of the spiral thread spindle The spiral thread spindle must be lubricated carefully and regularly Please only use a temperatur independence lubricant up to 100 C w...

Страница 55: ...that the spindle of the actuator doesn t run faultless first check if the aggregate was overloaded for a short time and if thereby the winding of the actuator was damaged Then the actuator has to be...

Страница 56: ...e fingers the drive will be working faultless If there are nevertheless faults in the voltage control there is a fault in the control VCS If the actuator is not moving the following points are necessa...

Страница 57: ...Connect the load 8 Turn the actuator by hand gradually the insertable load up to the upper susoension point Charge current must not lay over 140A at U UNenn 9 If deviations are determined a new adjus...

Страница 58: ...s continuity between the individual windings connections If continuity is detected for any of the combinations the generator must be sent to the factory for inspection and repair If this is not possib...

Страница 59: ...ter together you should get a reading of 0 00Ohm When you isolate the probes the reading will be Overflow Please do this tests to check your meter Measure of the resistance within the individual windi...

Страница 60: ...ecial measuring instrument is necessary which mea sures the inductance of a coil Inductance is measured in the same way as the ohmic resistance i e the coils are compared The value is indicated in mH...

Страница 61: ...ng Problems D 4 1 VCS does not work For start problems one chief cause is that the VCS doen not work Check Is the voltage sense connecttion ok Check polatrity Is the shunt connection ok Check pola tri...

Страница 62: ...cally It is nevertheless essential to bleed the system as follows prior to the first operation as all hoses are empty 1 Put a container under the fuel return pipe to catch running out fuel to catch 2...

Страница 63: ...quires a few seconds before the motor comes to a full halt If the generator fails to start runs rough does not reach the proper RPM or does not stop pro perly the first item to suspect in most cases i...

Страница 64: ...Generator Failure Page 58 Panda AGT DC 4000 PVMV N s00670 Chapter D Generator Failure 29 12 04...

Страница 65: ...o pay attention to the fresh air intake It must be guaranteed that the cooling air supply is sufficient The radiator may not be covered Untrained personnel should never open the generator E 1 2 Connec...

Страница 66: ...ads to substantial initial problems after longer shut off the generator If the return pipe cannot put as immersion tube into the tank it should be absolutely ensured by a non return valve in the sucki...

Страница 67: ...in the Suction Pipe A non return valve must be fitted to the suction pipe which prevents the fuel flowing back after the generator has been switched off if it is not possible to use the return flow p...

Страница 68: ...gative cable of the battery is attached underneath the starter motor at the engine mount position 02 ATTENTION It must be guaranteed that first the cables are attached at the generator and then at the...

Страница 69: ...tions 29 12 04 Panda AGT DC 4000 PVMV N s00670 Chapter E Installation Instructions Page 63 E 1 5 Installation electronic components 01 04 03 02 01 Generator 02 Radiator 03 Remote control panel 04 VCS...

Страница 70: ...ng voltage must be attached directly at the battery and may not atta ched to the output of the electric rectifier By the voltage drop between generator and battery the accurate voltage can only reciev...

Страница 71: ...f the generator for example E 3 1 Adjustments Direction of turning the potentiometer The battery monitor has three adjustment potentiometer screws labeld OFF ON and td For all three clockwise turns in...

Страница 72: ...an be actuated by a small screwdriver You are able to simulate if the battery monitor will works correct even if the voltage differences have been reached This will be signaled by illumination of the...

Страница 73: ...ly Cores are numbered from 1 to 11 and the 12th core is coloured yellow green The con trol cables are securely connected to the genset On the back of the control panel there are terminals numbered fro...

Страница 74: ...panel switches to manual mode i e automatic cut off requirements are not carried out Switch pressure in manual mode If the generator starts automatically the generator continues to run and the panel...

Страница 75: ...tor voltage 1 7 Input generator voltage 2 8 Output pre glow 9 Output fuel pump 10 Output starter motor 11 Output VCS ON voltage control for VCS 12 Output operating voltage maximum permissible load 0 2...

Страница 76: ...attery voltage exceeds 60 Volts The panel must be mounted that the voltage carrying points can not touched This is also the case during testing 1 Operating and starting the Generator will works with t...

Страница 77: ...t the generator after a adjusted time of one minute if there is the voltage drops down in a adjustable level to reload the batteries On the panel at the terminal 15 and 16 is the allocation for extern...

Страница 78: ...nstallation Instructions Page 72 Panda AGT DC 4000 PVMV N s00670 Chapter E Installation Instructions 29 12 04 E 4 Cooling system E 4 1 Connection of the external radiator 02 01 01 Generator 02 Radiato...

Страница 79: ...warm air is once again forced to rise to the area of the radiator Freely esca ping warm air cannot be guaranteed in this case Additional ventilators may be necessary should the warm air need to be ch...

Страница 80: ...ntifreeze solution supplied from the factory provides protection to 15 C If lower temperatures are occasio ned during transportation or storage then the coolant must be drained The cooling system is h...

Страница 81: ...for mounting below the vehicle 03 02 01 04 05 06 07 08 01 Exhaust oulet 02 Generator 03 Dachdurchf hrung mit Winkel 04 Vibration damper 05 External pre silencer 06 Exhaust pipe 07 External series sil...

Страница 82: ...Installation Instructions Page 76 Panda AGT DC 4000 PVMV N s00670 Chapter E Installation Instructions 29 12 04...

Страница 83: ...switches b exhaust thermo switch c oil pressure switch X X X X X X X X X X X Check all securing and fastening screws a all base mount screws b exhaust manifold screws c starter fixing d connection sc...

Страница 84: ...iquidly e g to 0W 10W 15W 20 30 40 The first number shows the liquid of cold wea ther the second number refers to the fluidity with heat Complete yearly oils have usually SAE 10W 40 SAE 15W 40 etc Qua...

Страница 85: ...ECT PLUS G 48 Engine coolant automotive industry Product description Product name GLYSANTIN PROTECT PLUS G48 Chemical nature Monoethylenglykol with inhibitors Physical form Liquid Chemical and physica...

Страница 86: ...n The engine is running at the wrong speed Check the speed of the motor with a rev or frequency counter set the correct speed VCS voltage controller defective or wrong adjusted Check resp renew Actuat...

Страница 87: ...VER AT THE NORMAL SPEED DURING THE STARTING PROCESS Cause Solution Starter battery voltage insufficient Check battery Damaged bearing s piston seized Repairs need to be carried out by Kubota Service r...

Страница 88: ...be sent to manufacturer for repair of damaged bearings or winding Damaged engine Repair of bearing damage etc by Kubota Service MOTOR SWITCHES ITSELF OFF Cause Solution Fuel solenoid valve or throttl...

Страница 89: ...by Kubota Low compression pressure See Kubota motor manual GENERATOR MUST BE SHUT OFF IMMEDIATELY IF Cause Solution motor rpm suddenly rises or drops unusual noise comes from genset exhaust colour sud...

Страница 90: ...Appendix Page VIII Panda AGT DC 4000 PVMV N s00670 Chapter F Appendix 29 12 04...

Страница 91: ...e govenor by VCS Valve clearance engine cold 0 16 0 20 mm Cylinder head nut torque 58 8 63 7 Nm Lubrication oil capacity 1 3 l Fuel consumption b b 0 35l kW electrical power the randomized values betw...

Страница 92: ...ominal charging current A AGT DC 4000 24V 4 3 2 24 110 140 Tabelle 2 Cable cross section Wiring for vehicle single phase not tin plated PVC isolated nominal wire cross section mm allowed conrinuous cu...

Страница 93: ...Measurements 29 12 04 Panda AGT DC 4000 PVMV N s00670 Chapter F Appendix Page XI F 6 Measurements...

Страница 94: ...Measurements Page XII Panda AGT DC 4000 PVMV N s00670 Chapter F Appendix 29 12 04...

Страница 95: ...ssible turn off the electrical power If you cannot turn off the electrical power pull push or lift the person to safety using a wooden pole rope or some nonconductive material After the injured person...

Страница 96: ...nd lift chin Shout Are you OK Look listen and feel for brea thing for 3 to 5 seconds 6 Give 2 Full Breaths Keep head tilted back Pinch nose shut Seal your lips tight around victim s mouth Give 2 full...

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