TP6685

User and maintenance manual for generating sets

20REOZT-60Hz 33501945101NE_0_1

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of

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.

1. Preface ..................................................................................................................................................................................................3 1.1. General recommendations .......................................................................................................................................................3 1.2. Pictograms and their meanings ................................................................................................................................................4 1.3. Instructions and safety regulations ...........................................................................................................................................7

1.3.1 General advice .........................................................................................................................................................................7 1.3.2 Risks related to exhaust gases and fuels.................................................................................................................................8 1.3.3 Risks related to toxic products .................................................................................................................................................8 1.3.4 Risk of fire, burns and explosion ..............................................................................................................................................9 1.3.5 Risks related to electrical networks ..........................................................................................................................................9 1.3.6 Dangers presented by electric currents (first aid)...................................................................................................................10 1.3.7 Risks related to moving the set ..............................................................................................................................................10

1.4. Identifying sets .......................................................................................................................................................................11 2. General description..............................................................................................................................................................................13

2.1. Description .............................................................................................................................................................................13 2.2. Technical specifications .........................................................................................................................................................18 2.3. Fuel and consumables ...........................................................................................................................................................20

2.3.1 Specifications .........................................................................................................................................................................20 2.3.1.1. Oil grades..................................................................................................................................................................20 2.3.1.2. Specifications of coolants..........................................................................................................................................21

3. Installation............................................................................................................................................................................................23 3.1. Unloading ...............................................................................................................................................................................23

3.1.1 Safety during unloading .........................................................................................................................................................23 3.1.2 Instructions for unloading .......................................................................................................................................................23

3.1.2.1. Slings ........................................................................................................................................................................23 3.1.2.2. Fork lift truck..............................................................................................................................................................23

3.2. Fluid retention.........................................................................................................................................................................24 3.3. Choice of location...................................................................................................................................................................25 3.4. Electricity ................................................................................................................................................................................26 3.5. Special arrangements ............................................................................................................................................................27

4. Trailer...................................................................................................................................................................................................28 4.1. Trailer linkage.........................................................................................................................................................................28 4.2. Check before towing...............................................................................................................................................................28 4.3. Operation ...............................................................................................................................................................................29 4.4. Unhitching the trailer ..............................................................................................................................................................29 4.5. Implementation for installation................................................................................................................................................29

5. Preparation before operating the set ...................................................................................................................................................30 5.1. Installation checks ..................................................................................................................................................................30 5.2. Checks after starting the generating set .................................................................................................................................30

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6. Using the generating set ......................................................................................................................................................................30 6.1. Pre-Start Inspection................................................................................................................................................................30 6.2. Generating set with DEC 1000 control panel..........................................................................................................................32

6.2.1 Control panel presentation .....................................................................................................................................................32 6.2.1.1. Introduction to pictograms .........................................................................................................................................33

6.2.2 Manual starting.......................................................................................................................................................................34 6.2.3 Switching off ...........................................................................................................................................................................35 6.2.4 Alarms and faults....................................................................................................................................................................35 6.2.5 Faults and alarms - Details.....................................................................................................................................................35

6.3. Generating set with DEC 4000 control panel..........................................................................................................................38 6.3.1 Control panel presentation .....................................................................................................................................................38

6.3.1.1. View of the front panel...............................................................................................................................................38 6.3.1.2. Description of the screen...........................................................................................................................................40 6.3.1.3. Description of the pictograms in zone 1.....................................................................................................................41 6.3.1.4. Description of the pictograms in zone 2.....................................................................................................................42 6.3.1.5. Description of the pictograms in zone 3.....................................................................................................................43 6.3.1.6. Display of messages in zone 4..................................................................................................................................45

6.3.2 Starting...................................................................................................................................................................................49 6.3.3 Switching off ...........................................................................................................................................................................50 6.3.4 Alarms and faults....................................................................................................................................................................50

6.3.4.1. Viewing alarms and faults..........................................................................................................................................50 6.3.4.2. Activation of an alarm or fault ....................................................................................................................................51 6.3.4.3. Activation of an alarm and a fault ..............................................................................................................................52 6.3.4.4. Engine fault codes display.........................................................................................................................................53 6.3.4.5. Horn reset..................................................................................................................................................................54

7. Maintenance schedule .........................................................................................................................................................................55 7.1. Reminder of use .....................................................................................................................................................................55 7.2. Engine ....................................................................................................................................................................................55 7.3. Alternator ................................................................................................................................................................................55

8. Battery..................................................................................................................................................................................................56 8.1. Storage and transport .............................................................................................................................................................56 8.2. Battery setting into service......................................................................................................................................................57 8.3. Check .....................................................................................................................................................................................57 8.4. Load preconization .................................................................................................................................................................58 8.5. Faults and remedies ...............................................................................................................................................................59

9. Appendix ..............................................................................................................................................................................................60 9.1. Appendix A – Engine user and maintenance manual .............................................................................................................61 9.2. Appendix B - Alternator user and maintenance manual .......................................................................................................105

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1. Preface 1.1. General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In the intention of permanently improving the quality of our products, this information may be amended without warning. Read the safety instructions carefully in order to prevent any accident, incident or damage. These instructions must always be followed. You are likely to encounter several warning symbols in this manual.

Danger

This symbol indicates a definite risk to the health and life of people. Not following this instruction may seriously affect the health of people or prove fatal.

Warning

This symbol draws attention to the potential risk to the health and life of people. Not following this instruction may seriously affect the health of people or prove fatal.

Important

This symbol indicates a dangerous situation if the warning is not heeded. Not following this instruction could result in non-serious injury or damage.

In order to obtain optimum efficiency and the longest possible life for the electrical generating sets, maintenance operations must be carried out according to the periods indicated in the attached 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 adjustments and repairs are carried out by personnel who have received the appropriate training. The dealers are suitably qualified and can answer all of your questions. They can also supply you with spare parts and other services. The left and right sides can be seen from the back of the electrical generating set (the radiator is at the front). Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum. For all parts replacement, contact your nearest dealer representing our company who will have the necessary equipment and properly trained and informed staff to carry out maintenance, parts replacement and even total reconditioning of generating sets. Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance.

Important

Some user manuals and maintenance manuals that come with the generating sets have instrument units and show the starting and stopping procedures for the engines. For the generating sets fitted with command and control boxes that are specific to the sets, only the information that appears in the documentation for the sets' boxes should be taken into consideration. Based on this and depending on the manufacture criteria for the generating sets, some engines may be fitted with specific electric cables different from those described in the engine's documentation.

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1.2. Pictograms and their meanings

Warning danger

Publications delivered with the generating set must be referred to

Warning, risk of explosion

Warning, risk of electric shock

Protective clothing must be worn

Entry prohibited to non-authorised persons

Warning, toxic materials

Your eyes and ears must be protected

Earth

Warning, pressurised liquids

Periodic maintenance must be carried out

Naked flames and unprotected lights prohibited. No smoking

Warning, high temperature, risk of burns

Battery level must be checked

Extinction by water prohibited

Warning, rotating or moving parts (risk of getting caught in the machinery)

Lifting point required

When on a trailer, earth the set before starting it

Warning, corrosive product

Stacking point required

Emergency cut-out

Diagram 1.1 : Pictograms and their meanings

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Diagram 1.2 : Pictograms and their meanings

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1.3. Instructions and safety regulations

THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction.

KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries. 1.3.1 General advice Use

The operating and safety instructions must be made known to operating personnel. They will be regularly updated. Read and understand the manuals provided with the generating set, pump unit or lighting column properly. The manufacturer's

instructions must remain at the disposal of technicians, if possible in situ. The installation must be operated under the direct or indirect monitoring of a person appointed by the operator, who is familiar with

the operation of the installation, and the dangers and drawbacks of the products used or stored in the installation. Do not wear loose clothing, or approach machines in operation. Note that the fans are not clearly visible when the engine is

running. Warn personnel present to keep their distance during operation. Do not run the generating set, pump unit or lighting column without refitting the protective covers and closing all the access doors. Never let a child touch the generating set, pump unit or lighting column, even when shut down. Avoid running the generating set, pump unit or lighting column in the presence of animals (disturbance, scares, etc.). Apply the parking brake when the generating set or lighting column on its trailer is installed on the operating site. When chocking

the trailer on a slope, ensure that there is nobody behind it. Never start the engine without an air filter or exhaust. Engine with turbocharger: never start 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, causing injury. Do not touch the lighting column lights when they are switched on.

Maintenance

Follow the maintenance table and its prescriptions. Always use tools in good condition and suited to the work to be done. Ensure you have understood the instructions before

beginning any operation. Goggles should be worn when carrying out maintenance operations and watches, bracelets etc. should be removed. Fit only original parts. To prevent the motor from starting accidentally, disconnect the battery and pneumatic starter (if fitted) before beginning any

repairs. Fit a panel over the controls to prevent any attempt to start. Use only the correct crankshaft turning techniques, to turn the crankshaft manually. Do not try to turn the crankshaft by pulling it or

levering the fan. This method may cause serious bodily or material damage, or damage the fan vane(s), leading to premature fan failure.

Clean off any trace of oil or coolant using a clean cloth. Never use petrol or other inflammable substances to clean the parts. Use only approved cleaning solvents. Do not use a high pressure cleaner for cleaning the engine and equipment. The radiator, hoses, electrical components, etc. may

be damaged. Avoid accidental contact with parts at high temperatures (exhaust manifold, exhaust). Before any maintenance operation on a lighting column light, cut the electrical power supply and wait for the bulbs to cool down.

Consumables

Observe regulations in force concerning use of the fuel before using your generating set, pump unit or lighting column. Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.

Environment

The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be maintained in a good state of cleanliness.

The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products and dust.

The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to operating requirements.

The facilities must be operated under the constant monitoring of a qualified person, who must regularly check that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply.

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Apart from the combustion devices, it is prohibited to use fire in any form. This ban must be displayed in clear terms. Spreading of waste water, sludge and waste is prohibited. The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the

combustion device manufacturer. The fuel is considered to be in the physical state it is in upon introduction into the combustion chamber. Burning of waste in the open air is prohibited. Always protect your hands when checking for leaks. Pressurised liquids may penetrate body tissue and cause 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 have access to it under certain conditions. Check these for each site. 1.3.2 Risks related to exhaust gases and fuels

Danger

Generating sets, pump units and lighting columns must not run in an unventilated place

Observe the local regulations in force for generating sets, pump units or lighting columns, as well as local regulations for the use of

fuel (petrol, diesel and gas), before using your generating set, pump unit or lighting column The fuel must be topped up with the engine shut down (except for generating sets with an automatic filling system). Engine exhaust gases are toxic: do not run the generating set, pump unit or lighting column in unventilated premises. If installed in

a ventilated room, additional requirements for fire and explosion protection must be observed. A leaking burnt gas exhaust may increase the sound level of the generating set, pump unit or lighting column. To check its

efficiency, regularly examine the burnt gas exhaust. The pipes must be replaced as soon as their condition demands it.

1.3.3 Risks related to toxic products

Warning

The corrosion inhibitor contains alkali. Do not swallow it. This substance should not come into contact with the eyes. In the event of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Avoid prolonged or repeated contact with the skin. In the event of contact with the skin, wash thoroughly with water and soap. CONSULT A DOCTOR IMMEDIATELY. KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN. The anti-rust product is toxic and dangerous if absorbed. Avoid all contact with the skin and eyes. Read the instructions on the packaging.

Glycol is a toxic product and dangerous if absorbed. Avoid all contact with the skin and eyes. Read the instructions on the packaging.

Never expose the equipment to liquid splashes or rainfall, and do not place it on wet ground. Always use the recommended fuels. Using low quality fuels risks damaging the engine and altering performance. The battery electrolyte is harmful to skin and especially eyes. If splashes get into eyes, rinse immediately with running water and/or

a 10% diluted boric acid solution. Wear protective eyewear and strong base resistant gloves for handling the electrolyte

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1.3.4 Risk of fire, burns and explosion

Danger

The engine should not be operated in areas containing explosive products. As not all of the electrical and mechanical components are shielded, there is a risk of sparks forming.

Make sure not to create sparks or flames, and not to smoke near the batteries, as the electrolyte gases are highly flammable

(especially if the battery is charging). Their acid also poses a risk to the skin, and in particular to the eyes. Never cover the generating set, pump unit or lighting column 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 generating set, pump unit or lighting column to work properly. Without this ventilation, the

engine would very quickly rise to too high a temperature, causing accidents or damage to the equipment and to surrounding property.

Do not remove the radiator cap if the engine is hot and the coolant is pressurised, due to risks of burns. Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.

Watch out for the possible presence of pressure when disconnecting a device from a pressurised system. Do not try to find pressure leaks by hand. Oil at high pressure can cause bodily damage.

Some preservative oils are flammable. Also, some are dangerous to inhale. Ensure proper ventilation. Use a protective mask. Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before carrying out any

procedures. Never start or run the engine with the oil filler cap off (oil may splash out). Never coat the generating set, pump unit or lighting column with a thin layer of oil to protect it from rust. Never top up the oil or coolant if the generating set, pump unit or lighting column is running, or if the engine is hot.

1.3.5 Risks related to electrical networks

The electrical equipment supplied with the generator set complies with standard NF C15.100 or the standards of the relevant countries.

The earth connection must be made in accordance with the standards in force in each country concerned and at the neutral speed sold.

Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that these values match the supply use.

Never accidentally touch naked wires or disconnected connections. Never handle a generating set with wet hands or feet. Maintain electrical wires and connections in good condition. Using equipment in poor condition can lead to electrocution and

damage to equipment.

Always disconnect the equipment or installation (generator voltage, battery voltage and network voltage) before any operations. Electrical connections must be made in accordance with the standards and regulations in force in the country of use. Do not use faulty, poorly insulated or provisionally connected wires. Never invert the positive and negative battery terminals when connecting them. This could cause severe damage to the electrical

equipment. Follow the wiring diagram supplied by the manufacturer. The generator set should not be connected to any other power sources, such as the public distribution network. In specific cases

where there is provision for a reserve connection to existing electrical networks, this must only be carried out by a qualified electrician, who should take the operating differences of the equipment into account, according to whether the public distribution network or generating set is being used.

Protection against electric shocks is ensured by an assembly of specific equipment. If this needs to be replaced, it should be by components with identical nominal values and specifications

If the protective plates (blanking covers) need to be removed to pass cables, the protection (blanking cover) must be replaced when the operations are finished.

Due to strict mechanical specifications you should only use flexible resistant rubber sleeved wires, in compliance with CEI 245-4 or equivalent wires.

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1.3.6 Dangers presented by electric currents (first aid) First aid

In the event of an electric shock, shut off the power immediately 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. Take extreme care to avoid the electric arc that will be generated by this.

Begin emergency procedures Resuscitation If breathing has stopped, begin artificial respiration at once in the same place the accident took place unless the victim or operator's life could be endangered by this. In the event of cardiac arrest, carry out cardiac massage. 1.3.7 Risks related to moving the set To unload the generating sets, pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions, you must ensure that the following points are observed:

Lifting machinery or equipment suited to the work required, in good condition and with sufficient lifting capacity. Slings positioned in the rings provided for this operation, or forklift arms resting fully underneath all of the base frame cross-beams,

or lifting bars inserted in the apertures provided for this purpose in the base to lift the entire generating set (according to models). For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set, pump unit or

lighting column, the generating set, pump unit or lighting column must be lifted up with an adjustable boom. All the chains and cables must be parallel with each other, and as perpendicular as possible with the upper edge of the generating set, pump unit or lighting column.

If other equipment fitted on the generating set, pump unit or lighting column alters its centre of gravity, special lifting devices may be necessary to maintain correct balance and completely safe working conditions.

Ground that can withstand the load of the generating set, pump unit or lighting column and its lifting machinery without stress (otherwise, put down beams of sufficient strength in a stable configuration).

Position the generating set, pump unit or lighting column as close as possible to its place of use or transport, in a clear space with free access.

Never perform work on a generating set, pump unit or lighting column just hanging from a lifting device.

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1.4. Identifying sets Generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documentation contained in the appendices of this manual.

1 - Generating set 2 - Manufacturer name 3 - Model 4 - Serial number 5 - Year of manufacture 6 - Rated output (kVA and kW) according to the ISO

8528-1 standard PRP: main power ESP: emergency power

7 - Rated power factor 8 - Maximum altitude of the site above sea level (m)

for the rated power

9 - Maximum ambient temperature for the rated power (°C)

10 - Rated frequency (Hz) 11 - Generating set rotation speed (RPM) 12- Rated voltage (V) 13 - Rated current (A) 14 - Weight (kg) 15 - CE marking 16 - Non CE standard marking e.g.: GOSSTANDART) 17 - Sound pressure 18 - Sound power

Diagram 1.3: Example of generating set identification plate

Diagram 1.4: Examples of engine identification plates

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Diagram 1.5: Examples of alternator identification plates

Control box

Diagram 1.6: Example of control box identification plate

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2. General description 2.1. Description Overview

1 External emergency stop 4 Circuit breakers 2 Electric sockets 5 Control unit 3 Connection termination box 6 Generating set identification plate

Diagram 2.1: General description of the generating set

1

2

3

6

4 5

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7 Protective grilles 10 Starter battery 8 Galvanised 11 Battery charge alternator 9 External fuel supply combined tap (optional) 12 Filling with fuel

Diagram 2.1 (continued): General description of the generating set

11

12

7

7

9

8

10

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Fittings Socket control panels and terminals by enclosure type:

TYPE 0 - 16/125A

OPTION

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M127 60Hz US

OPTION

1

2

1 : WIRING CAPACITY MAX 185mm²

2 : HOLE Ø M10 + SCREW M10

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M127 60Hz

1 2 3 4 5 6

Q06 - 20A MODULAR CIRCUIT BREAKER X03 - 50A 125/250V SOCKET X06 - 20A US 125V 2P+T SOCKET Q03-Q04 - 2x50A COMPACT CIRCUIT BREAKER X04 - 50A 125/250V SOCKET X07 - 20A US 125V 2P+T SOCKET

1 2 3

4 5 6

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2.2. Technical specifications Range / Generating set type TOWABLE / 20REOZT Weights and Dimensions Dimensions with high autonomy tank

Dimensions l x w x h: 2160mm x 966mm x 1582mm Weight: 1000kg dry weight 1210kg in operating configuration Hood: M127C-DW Noise level: 65.4 dB @ 7 m

Output

Voltage Hz Phase Load factor Max current (A) Emergency/Prime

Emergency power 1

kW / kVA Prime power 2

kW / kVA 480/277 60 3 0.8 33 / 30 23 / 29 21 / 25 208/120 60 3 0.8 75 / 69 23 / 29 21 / 25

240 MONO 60 3 1 72/ 65 14 / 18 13 / 16 (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 hour every 12 hours is available, as per ISO 3046-1. Engine data Manufacturer / model MITSUBISHI S4Q2-Y362SD Type 4 Cycles Naturally aspirated Cylinder configuration 4 XL Cubic capacity 2.5 L Rotation speed 1800 Rpm Max emergency/prime power at nominal speed 24.3 / 22.8 kW Adjustment type Mechanical Fuel consumption 110 % (emergency power) 7.6 L/h 100 % main power 7.2 L/h 75 % main power 5.4 L/h 50 % main power 4.1 L/h Fuel Fuel type Diesel High autonomy fuel tank 230 L Lubrication Oil capacity with filter 6.5 L Min. Oil pressure 1.9 bar Nominal oil pressure 3.9 bar Oil consumption (100 % load) 0.072 L/h Oil sump capacity 5.5 L Type of lubricant Genlub

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Cooling Engine capacity with radiator 6 L Max coolant temperature 110 °C Fan power 0.7 kW Ventilator air flow 1 m3/s Refrigerant type Gencool Thermostat 76.5 – 90 °C Emissions NoX + HC ≤ 7.5 g/KW.h CO ≤ 5.5 g/KW.h PM ≤ 0.3 g/KW.h Alternator data Compliant with NEMA MG21 standards, UTE NF C51.111, VDE 0530,

BS 4999, IEC 34.1, CSA The alternator is protected against short circuits Vacuum impregnation, epoxy winding, IP23 protection rating

Type LEROY SOMER LSA422S5 Number of phases 3 Power factor (cos Phi) 0.8 Number of poles 4 Excitation type AREP Voltage regulator R438 Short-circuit current 1.4 AC Number of bearings 1 Coupling Direct Control unit(s) DEC-1000

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

DEC-4000

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

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2.3. Fuel and consumables All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual. In addition, we recommend the consumables to be used in the "specifications" section. 2.3.1 Specifications 2.3.1.1. Oil grades

Engine Oil Make Type Make Type

John Deere John Deere PLUS-50 John Deere All GenPARTS GENLUB TDX 15W40 MITSUBISHI All GenPARTS GENLUB TDX 15W40

Volvo All GenPARTS GENLUB TDX 15W40 GENLUB TDX 15W-40 Top-of-the-range lubricant recommended for diesel engines: for generating sets used under severe conditions. USES:

Particularly suited to more modern engines with or without turbochargers, intercoolers, or sophisticated injection systems (e.g. HEUI, injector-pumps).

All types of use: can cope 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 the test during thousands of hours of use on worksites under varying conditions, demonstrating its high quality.

Conformity with new environmental legislation: adherence to new anti-pollution standards required for new EURO 2 and EURO 3 engines.

SPECIFICATIONS:

SAE Grade 15W-40

Density at 15°C 0.883 Cinematic viscosity at 40 °C Cinematic viscosity at 100 °C

105 14.1

mm2/s (cSt) mm2/s (cSt)

Viscosity index 140 Dynamic viscosity at -15 °C 3000 mPa.s(cP) Pour point - 30 °C Flash point 220 °C Sulphated ash content 1.4 % weight (Values given as examples only)

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2.3.1.2. Specifications of coolants Engine Coolants

Make Type Make Type John Deere All GenPARTS GENCOOL PC -26°C

Mitsubishi LLC MITSUBISHI All GenPARTS GENCOOL PC -26°C Volvo All GenPARTS GENCOOL PC -26°C

GenCOOL PC -26 High-protection coolant, approved by manufacturers. GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers. It is made from antifreeze and G 48 inhibitors. It protects up to -26°C. It is free from nitrates, amines and phosphates. It is a clear, fluorescent orange liquid.

REFERENCES/APPROVALS (for the antifreeze):

HEAVY GOODS VEHICLE LIGHTER VEHICLES Approved by MTU, MERCEDES BENZ, MAN, KHD, GENERAL MOTORS Conforms with VOLVO, IVECO, VAN HOOL and STAYR TRUCK specifications

Approved by BMW, VOLKSWAGEN, MERCEDES, PORSCHE Conforms with VOLVO, OPEL, SEAT and SKODA specifications

Conforms with the NF R 15.601 standard REINFORCED ANTI-CORROSION FEATURES:

Protects 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:

Provides good conditions for thermal exchange. Perfect stability at high temperatures. GenCOOL PC -26 is specially adapted for engines with high power densities.

LONG LASTING PROTECTION:

High alkaline reserve/stability and longevity of corrosion inhibitors. Maintains its technical properties during prolonged use at high temperatures (neutralisation of acids). Ensures maximum heat transfer without the build up of deposits in the cooling system. GenCOOL PC -26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use.

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PACKAGING/STORAGE:

GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings. It can be stored for 2 years in its original container and packaging. Avoid zinc coated containers.

RECOMMENDATIONS FOR USE:

Compatible with the original fluid. It is recommended that the cooling system is completely drained when replacing the fluid.

SPECIFICATIONS UNITS SPECIFIED VALUES TRIAL METHODS

Density at 20°C kg/m3 1,059 +/- 3 R 15-602-1

pH pH 7.5 to 8.5 NF T 78-103

Alkalinity reserve ml >=10 NF T 78-101

Boiling point °C 105 +/- 2 R 15-602-4

Freezing point: °C -26 +/- 2 NF T 78-102 Glassware corrosion : (test with antifreeze) mg/test piece R 15-602-7

- Copper +/- 2.6

- Weld +/- 0.5

- Brass +/- 2.3

- Steel +/- 1.6

- Cast iron +/- 0.8

- Cast aluminium +/- 1.0 Corrosion on warm plate (test with antifreeze) mg/(cm²week) +/- 0.17 R 15-602-8

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3. Installation 3.1. Unloading 3.1.1 Safety during unloading - To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions, you need to ensure

that the following points are 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 transportation, in a clear area with free access. Example of equipment to be used:

Crane, slings, cross bar, safety catch, shackles. Fork lift truck.

3.1.2 Instructions for unloading 3.1.2.1. Slings

Attach the lifting vehicle slings to the rings on the generating set designed for this procedure. Hang the slings carefully. Check that the slings are correctly attached and the equipment is solid. Lift the generating set carefully. Direct and stabilise the set towards the chosen position. Carefully set down the equipment while continuing to position it. Release the slings, then detach and remove the lifting rings.

3.1.2.2. Fork lift truck

Position the arms of the fork lift under the frame, making sure that only the cross beams are resting on the arms. Lift and handle the equipment carefully. Set down the generating set in its unloading position.

Diagram 3.1: Transporting a generating set on a fork-lift truck

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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 option to be collected. Three different fittings are available.

Diagram 3.2: Fluid retention container integrated into the tank chassis.

Diagram 3.3: Offset fluid retention container underneath the generating set chassis.

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Diagram 3.4: Offset fluid retention container integrated into the chassis and tank.

Generating sets fitted with the offset tank option (DW) above also have 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 collected in a designated container. 3.3. Choice of location It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt 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

Diagram 3.5: Examples of problems that may be encountered

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3.4. Electricity a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country. b) Power cables These can be unipolar or multipolar according to the power of the generating set. Power cables should preferably be installed in ducts or on a cable tray for this purpose. The cable cross-section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52.

Three phase - Calculation hypothesis Fitting method = wiring in cable runs or non perforated trays. Permissible voltage drop = 5% Multiconductors or single conductor joined when precision 4X…(1) Cable type PVC 70°C (e.g. H07RNF). Ambient temperature = 30°C.

Cable sizes 0 - 50m 51 - 100m 101 - 150m

Circuit breaker calibre

(A) mm²/AWG mm²/AWG mm²/AWG 10 1.5 / 14 2.5 / 12 4 / 10 16 2.5 / 12 4 / 10 6 / 9 20 2.5 / 12 4 / 10 6 / 9 25 4 / 10 6 / 9 10 / 7 32 6 / 9 6 / 9 10 / 7 40 10 / 7 10 / 7 16 / 5 50 10 / 7 10 / 7 16 / 5 63 16 / 5 16 / 5 25 / 3 80 25 / 3 25 / 3 35 / 2

100 35 / 2 35 / 2 4X(1X50) / 0 125 (1) 4X(1X50) / 0 4X(1X50) / 0 4X(1X70) / 2/0 160 (1) 4X(1X70) / 2/0 4X(1X70) / 2/0 4X(1X95) / 4/0 250 (1) 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X150) / 2350MCM 400 (1) 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 630 (1) 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM

Single phase - Calculation hypothesis Fitting method = wiring in cable runs or non perforated trays. Permissible voltage drop = 5% Multiconductors. Cable type PVC 70°C (e.g. H07RNF). Ambient temperature = 30°C.

Cable sizes 0 - 50m 51 - 100m 101 - 150m Circuit breaker

rating (A) mm²/AWG mm²/AWG mm²/AWG

10 4 / 10 10 / 7 10 / 7 16 6 / 9 10 / 7 16 / 5 20 10 / 7 16 / 5 25 / 3 25 10 / 7 16 / 5 25 / 3 32 10 / 7 25 / 3 35 / 2 40 16 / 5 35 / 2 50 / 0 50 16 / 5 35 / 2 50 / 0 63 25 / 3 50 / 0 70 / 2/0 80 35 / 2 50 / 0 95 / 4/0

100 35 / 2 70 / 2/0 95 / 4/0 125 50 / 0 95 / 4/0 120 / 2250MCM

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c) Battery cables Install the battery or batteries in close proximity to the electric starter motor. The cables will be connected directly from the battery terminals to the starter motor terminals. The first instruction to follow is to check that the polarities of the battery and starter motor correspond. Never swap the positive and negative battery terminals when connecting them. This could cause severe damage to the electrical equipment. The minimum cross-section of the cables is 70 mm2. It varies according to the power of the starter motor but also the distance between the batteries and the set (voltage drops on the line). d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54 The generating set must be earthed. To do this, use a copper wire, with a minimum cross-section of 25 mm2 for a stripped cable and 16 mm2 for an insulated cable, connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground. For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below

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 Electrical Code reference NFPA-70). The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most) connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically and fully into the ground. This earthing rod embedded fully in the ground must have a minimum length of 2.5m. 3.5. Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring. The company does not accept any responsibility regarding damage caused by these occurrences. However, lightning conductors can be installed, on the understanding that this does not give total protection.

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4. Trailer 4.1. Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly.

Danger

Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents. Also check:

- no incipient fractures or excessive wear on the hitching system. - locking system is operating properly.

To hitch the trailer, proceed as follows:

Lock the wheels to stop the trailer from moving. Lift up the rear trailer supports and lock them. Release the parking brake. Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook. Hitch the trailer, remove 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.

Diagram 4.1 : Coupling a trailer 4.2. Check before towing Before towing, check the following:

tightness of the generating set enclosure bolts torquing of the wheels locking of the trailer hook pressure of the tyres operation of the light signals enclosure doors closed parking brake released front wheels and rear supports lifted. tightening and fixing of the draw bar arms locking levers brake test for "road" type trailers brake safety cable fitted.

Tow vehicle

Trailer

CORRECT

Tow vehicle

Trailer

CORRECT

Tow vehicle

Trailer

INCORRECT

Tow vehicle

Trailer

INCORRECT

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4.3. Operation "On-site" type trailer These trailers are not fitted with a main brake and so cannot brake when operating; the tyres are designed for a speed of 17 mph (27 Km/h). Therefore, it is absolutely forbidden to exceed this speed "Road" type trailer The driving speed should be adapted to road conditions and the trailer handling. Driving at sustained speed causes tyres to heat up; therefore it is important to stop from time to time to check them. Excessive heating can lead to a blow out and hence a serious accident. When reversing, do not forget to lock the overrun brake.

Warning

Particular attention must be paid to wheel torquing on new vehicles. Indeed, during the first few miles, heat build-ups on the wheel hubs and brake drums lead to reduced wheel torquing. It is therefore essential to check the torquing every 6 miles (10 kilometres) until no further loosening is noted. The torque test should nevertheless be carried out before towing.

4.4. Unhitching the trailer This operation should be carried out on horizontal, flat, stable ground.

Lock the wheels. Lower the front wheel. Disconnect the road signals wire. Refit the hitch using the wheel to release the hook ring from the tow vehicle. Engage the handbrake. Release the tow vehicle.

4.5. Implementation for installation Operations to be carried out:

Ensure that the ground is strong enough for the assembly not to sink into it. Release the handbrake. Using the front wheel, position the generating set as horizontally as possible. Apply the handbrake. Lower the rear trailer supports and lock them.

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5. Preparation before operating the set

Danger

The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents.

5.1. Installation checks

• Check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.) are observed. • Carry out the level checks (oil, water, diesel fuel, battery). • Check the generating set earth connection is earthed. • Check that the electrical connections are in order.

5.2. Checks after starting the generating 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 generating set 6.1. Pre-Start Inspection Inspection round Check that the following are not present:

deposits of debris, oil, fuel or refrigerant leaks, damage to or wearing of the component parts.

Checking the engine oil level

Important

The engine must be in the horizontal position for the oil level check. Pull out the dipstick, clean it, put it back in the tube for 2 seconds and pull it out again to read the oil level.

The engine oil level must be between the MAX and MIN marks on the dipstick. Top up the oil if necessary.

Checking the fuel level

Fuel level information, expressed as a percentage of the fuel tank filling level is displayed on the control unit screens. If necessary, top up the level before using the generating set.

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Checking the fuel pre-filter

Danger

The fuel is highly flammable and its vapours are combustible. The fuel pre-filter must only be bled when the engine is stopped and cold.

Check that there is no water or sediment at the bottom of the pre-filter. If necessary, drain the pre-filter using the following procedure:

Undo the drain plug (A) at the bottom of the pre-filter by two or three turns. Collect the water and/or sediment in a suitable container. When fuel starts to flow out, tighten the drain plug. Check that there are no leaks. If necessary, reprime the fuel circuit.

Checking the refrigerant level

Important

If topping up, be sure to maintain the Long Lasting Refrigerant concentration level. Do not use water as it will dilute the Long Lasting Refrigerant and compromise the anti-freeze protection. The refrigerant level should be checked when the engine is cold.

The refrigerant level should be below the filling port. Top up, if necessary, with recommended refrigerant (see “fuels and consumables”).

A

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6.2. Generating set with DEC 1000 control panel 6.2.1 Control panel presentation

Diagram 6.1: View of the front side

Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for starting up/shutting down the module and RESET function

Electronic card protection fuse

Screen-scroll button, press successively to access the various screens which are available

STOP button, press to switch off the generating set START button, press to switch on the generating set

Normal operation LEDs and alarm and fault warning LEDs

Slot reserved for panel fascia options

Mounting bolt

LCD for displaying alarms and faults, operating states, electrical and mechanical quantities

2

1

3

9 9 7

8 5 64

9

10

9

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Diagram 6.2 – Description of the LEDs

A lit LED indicates:

Module being supplied (green, lights up and remains lit)

Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit)

Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to generate (green, lights up and remains lit)

General alarm (orange, flashing)

General fault (red, flashing) 6.2.1.1. Introduction to pictograms The pictograms are as follows:

Operating temperature Fuel

Overspeed

Non-starting fault Starting on external command

Preheating

Air intake

Oil pressure

Battery Delay

Diagram 6.3: View of pictograms

The "fuel level" pictogram is used to display the fault, the alarm and the fuel level. The "operating temperature" and "oil pressure" pictograms are used to display the fault and analog value. The "overspeed" and "non-starting fault" pictograms are used to display the fault. The "battery" pictogram is used to display the "alternator charge" fault and to indicate the battery voltage.

Symbols for electric and mechanical sizes

1 2 3 4 5

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6.2.2 Manual starting

Danger

Check that the generating set circuit breaker has triggered.

Connect the generating set battery.

Turn the key switch to the ON position (without forcing it) All of the LEDs light up for 2 seconds, to confirm that they are operating correctly. If the LEDs do not light up, check the protection fuse and replace it if necessary. All the items on the screen are displayed for 2 seconds. Only the "ON" LED remains lit to indicate that the module is powered up. The following screen appears.

The first line displays the motor speed in RPM. The second line displays the battery voltage in volts (V).

Check the battery voltage (min. 12 V)

Press (once briefly) the green "START" button. If the motor is equipped with an air preheating system, there is a 10-second delay before the motor starts (preheating

activation period). The following screen appears.

The third line displays the air preheating time remaining (with pictograms representing a resistor and an hourglass).

If the motor is not fitted with an air preheating system or once the preheating delay has elapsed, the engine starts up

(start of a cycle comprising 3 attempts to start up the engine). The following screen appears.

Warning

The number of successive and automatic starting attempts is limited to 3.

Note: the LED flashes as soon as the START button is pressed and continues to flash until the frequency stabilises if a "measurements" card has not been inserted and until the frequency and voltage stabilise if a "measurements" card has been inserted.

Following stabilisation, the LED light comes on continuously.

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6.2.3 Switching off Trigger the circuit breaker located at the base of the centre console.

Let the motor run under no load for 1 to 2 minutes to allow it to cool.

Press the "STOP" button to stop the generating set.

Switch off the DEC 1000 module by switching the key to "OFF" (without forcing it). 6.2.4 Alarms and faults The appearance of a fault or an alarm causes the following screen to be displayed (one or more pictograms or a fault code along with the SOS message are displayed).

The user can access the following screens by pressing the key The fault or alarm screen will disappear once the fault or alarm has been removed. Only one fault is displayed on this screen (the fault which caused the generating set to stop). If one or more faults have appeared after the first fault, they can only be displayed after the first fault has been reset (press "Reset" as many times as the number of faults present). Note: an alarm can appear at the same time as a fault. 6.2.5 Faults and alarms - Details List of faults which will cause the generating set to stop and generate a pictogram

Low coolant level fault: indicates that the level of coolant is low in the radiator (linked to a two second time delay). Or Overload or short-circuit fault (optional): with the circuit breaker SD contact closing (overload or short-circuit), the generating set switches off immediately also causing the main circuit breaker to be triggered.

Associated message

Additional fault linked to message opposite: is displayed in the following two cases:

Differential fault (1) insulation fault (2)

(1) Differential fault (optional): with a differential fault causing the activation of the differential relay, the generating set stops immediately also causing the main circuit breaker to be tripped.

(2) Insulation fault (optional): with an insulation fault causing the activation of the control unit performing insulation, the generating set stops immediately.

Associated message

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Underspeed fault: indicates an incorrect rotation speed (below 1000 rpm).

Associated message

Emergency stop or external emergency stop fault.

Associated message

"STOP" fault activated if the "STOP" button is pressed whilst the "AUT" LED is flashing to indicate that the generating set is operating in automatic mode.

Associated message

List of faults which will cause the generating set to stop and generate a fault code

Oil pressure fault: Indicates that the oil pressure is incorrect.

Associated pictogram

Engine temperature fault: Indicates that the engine temperature is too high.


Non-starting fault: Indicates that there have been three consecutive unsuccessful starting attempts.


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Overspeed fault: Indicates an excessive generating set running speed.


Low fuel level fault: Indicates the need to top up the fuel.


List of alarms associated with a pictogram

Low fuel level alarm: Indicates the need to fill up with fuel.


"Alternator charging fault" alarm indicates a problem affecting the alternator charging rate.


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6.3. Generating set with DEC 4000 control panel 6.3.1 Control panel presentation 6.3.1.1. View of the front panel

Diagram 6.4: View of the front side 1 Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage equipment 2 Key switch for starting up/shutting down the module 3 Electronic board protection fuse 4 Scrolling and selection wheel for scrolling through screens and selecting items simply by pressing the wheel 5 STOP button, press to switch the generating set off 6 START button, press to switch the generating set on 7 Power ON LEDs and fault warning LEDs 8 Location of USB ports 9 Mounting bolt 10 LCD for displaying alarms and faults, operating status, electrical and mechanical quantities 11 ESC button: return to the previous selection and fault RESET function 12 MENU button to access the menus 13 Lighting for emergency stop button

2

1

3

5

967

8 49 10 9 11

12

13 9

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Diagram 6.5: Description of the LEDs A lit LED indicates: 1 Alarm activated (flashing yellow) 2 Fault found (flashing red) 3 Module on (green, on continuously)

Diagram 6.6: Close-up of USB ports

1 USB key connection (HOST): file transfer between US key and DEC 4000 and vice-versa 2 Connection for microcomputer (DEVICE):

file transfer between PC and DEC 4000 and vice-versa main module power supply.

3 Protective cover

1 2 3

2

3

1

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6.3.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.

SERIAL No.: 08030010000 SOFTWARE: 5.3.5 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS

Diagram 6.7: Description of the screen (example)

Zone 1: in this zone, the status of the generating set is displayed

Zone 2: in this zone, pictograms 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 well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set. Certain screens may therefore not be present.

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6.3.1.3. Description of the pictograms in zone 1 Pictograms in zone 1

Pictograms Display Activation conditions Fixed DEC 4000 in manual mode (MANU)

"MANU" Mode

Flashing For 5 seconds when switching from AUTO mode to MANU mode

Fixed DEC 4000 in automatic mode (AUTO)

"AUTO" Mode

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 used

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6.3.1.4. Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when DEC 4000 is initialised.

Data displayed Fuel level indicator

Alarm / Fault low fuel level

Alarm / Fault high fuel level

Coolant level / temperature indicator

Alarm Low level

fault

High 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 breaker following an overload or short circuit

Engine speed

Underspeed fault

Overspeed fault

Non-starting fault

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6.3.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when DEC 4000 is initialised. The pictograms below are given as examples. Generating set stopped

Screen no. Pictograms Data displayed

Fuel Level Indicator

Indication of Temperature of High Temperature coolant (HT) (units according to settings menu)

Indication of Battery Voltage P1

Indication of Oil Temperature (units according to settings menu)

Generating set start-up or generating set started or generating set switching off in progress


Engine Speed Indication

Indication of Temperature of High Temperature coolant (units according to settings menu)

Indication of Oil Pressure (units according to settings) P2

Indication of Oil Temperature (units according to settings menu)

Generating set started



Alternator composite Voltage Indicator

Total Active Power Indicator

P3 Default

screen in operation

Alternator Frequency Indicator

U12 Alternator composite Voltage Indicator



P4


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V1 Alternator single Voltage Indicator



P5





P6



Single phase Alternator current indicator P7


Single phase Alternator current indicator

Two phase Alternator current indicator

Three phase Alternator current indicator

P8

Neutral Alternator current indicator

Total Active Power Indicator

Total Reactive Power Indicator

Total Effective Power Indicator

P9

Total Power Factor Indicator (lagging or leading)


Indication of Battery Voltage P10

Indication of Battery Amps

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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 screens scroll upwards and vice-versa. The screens scroll in a loop. E.g.: On three-phase + neutral network, then screen 7, then screen 1 and vice-versa. 6.3.1.6. Display of messages in zone 4 The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows: Initialisation of DEC 4000

Screen no. Screen Data displayed

G 1

Initialisation of DEC 4000 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 DEC 4000 Alternator Nominal Voltage Alternator Nominal Frequency Nominal Active Output Neutral Point Bar graph indicating the display delay of the screen

Generating set stopped


G 3

OPERATION MANUAL

Press START

to start 24/08/2005 13:12

Operating mode - generating set in Manual Mode ready to start Date and time (depending on settings)

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G 4

OPERATION AUTO

WARNING

START-UP POSSIBLE IMMEDIATELY

24/08/2005 13:12

Operating mode - generating set in Auto Mode ready to start Date and time (depending on settings)

G 5

WARNING

AUTOMATIC 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


G 6

START-UP IN PROGRESS

24/08/2005 13:12

Operating phase - generating set in starting phase Date and time (depending on settings)

G 7

AIR PREHEATING

10 seconds

24/08/2005 13:12

Operating phase - air preheating prior to starting generating set Countdown for air preheating delay Date and time (depending on settings)

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Generating set started


G 8 Default screen

AVAILABLE POWER

75%

24/08/2005 13:12

Operating phase – generating set in operation – stable voltage and frequency Available power Date and time (depending on settings)

G 9

AUTOMATIC STOP

IN PROGRESS

LOAD SUPPRESSION 1 min 30 sec

24/08/2005 13:12

Operating mode - operation in Auto Mode Opening of power supply device (motorised circuit breaker or source changeover switch controlled by DEC 4000) 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 OFF load test delay Date and time (depending on settings)

Generating setstop

Screen no.

Screen Data displayed

G 11

OFF IN PROGRESS

24/08/2005 13:16

Generating set stop in progress Date and time (depending on settings)

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Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand)

Screen no.


G 12

Start Demand AUTO

Do you wish to change to Auto Mode?

WARNING Immediate start

OK Esc

Operating mode - operation in Manual Mode AUTOMATIC start demand

Generating set stop request due to fault or by pressing STOP in Auto Mode

Screen no.


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 has appeared

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6.3.2 Starting

Danger

Check that the generating set circuit breaker has triggered.

Connect the generating set battery

Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not light up, check and replace the fuse if necessary)

Test the Alarm and Fault LEDs (menu 15 – TEST LAMPS)

1 ACTIONS 1/5

11 MANUAL <> AUTO 12 CONTROL LOAD

13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS

OK Esc

Press "Esc" several times to return to the following home menu

OPERATION MANUAL

Press START

to start 24/08/2005 13:12

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 engine).

START-UP IN PROGRESS

24/08/2005 13:12

Warning: the number of successive and automatic starting attempts is limited to 3. The following pictogram will flash

AVAILABLE POWER

100.0%

24/08/2005 13:12

The following pictogram is displayed

The following information is displayed

Speed of rotation

Coolant temperature

Oil pressure

Oil Temperature

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6.3.3 Switching off Open the circuit breaker manually OR by selecting menu 12 "CONTROL LOAD"

The following display will disappear (supply stopped)

Press the STOP button

The following screen is displayed and the generating set will stop

OFF IN PROGRESS

24/08/2005 13:12

Switch DEC 4000 off by turning the key to "OFF" (without forcing it to the "OFF" position).

6.3.4 Alarms and faults 6.3.4.1. Viewing alarms and faults Alarms and faults are displayed as follows:

Alarms All alarms will cause:

the yellow LED to flash "General alarm".

In conjunction with this LED:

a flashing pictogram appears on the LCD screen representing the circuit affected by the alarm and the associated indicator, if present

(example)

message on graphic display (example) FAULT

ALARM Low Fuel Level

25/12/05 15:30

OK=HELP

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Faults All faults will cause:

the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit)

the red LED to flash "General fault".

In conjunction with this LED:

a flashing pictogram appears on the LCD screen representing the circuit affected by the fault and the associated indicator, if present

(example)

message on graphic display (example) FAULT

FAULT Oil Pressure

25/12/05 15:30

OK=HELP

Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the oldest). 6.3.4.2. Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below)

FAULT

ALARM Low coolant Level 06/10/06 10:30

OK=HELP

FAULT

FAULT Emergency Stop 06/10/06 15:30

Esc=RESET OK=HELP

Press OK (on the scrolling and selection wheel) to access the help message if it is available (example below)

HELP

Check the level fuel

Esc=EXIT

If the alarm is no longer active, it is reset automatically (cause disappears). Press Esc to reset a fault:

- reset acknowledged if the cause of the fault has been removed - reset not performed if the cause of the fault is still present.

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6.3.4.3. Activation of an alarm and a fault The appearance of an alarm and a fault causes:

The yellow and red LEDs to flash the related screen to be displayed (example below)

FAULTS 1/2

FAULT Emergency Stop 25/12/05 15:30

Esc=RESET OK=LIST

If several faults are present, the number of faults is displayed at the top of the screen.

The faults list can be accessed by pressing OK (of the scrolling 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 automatically (cause disappears). Press Esc to reset a fault:

- reset acknowledged if the cause of the fault has been removed - reset not performed if the cause of the fault is still present.

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6.3.4.4. Engine fault codes display Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable). Terminology used by the SAE CAN J1939 standard

SPN: Suspect Parameter Number

This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor.

FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault.

Terminology used by VOLVO

SID: System Identifier This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). However, this term corresponds, more particularly, to an assembly of components, for example, the injection system.

PID: Parameter Identifier This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). However, this term corresponds, more particularly, to a specific component, for example, a sensor.

PPID: Parameter Identifier This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). PPID corresponds to PID, but is only used by VOLVO.

FMI: 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 combination.

Terminology used by PERKINS

CID: Component parameter This term used by PERKINS has an equivalent in the J1939 standard (SPN).


Terminology used by JOHN DEERE

SPN: Suspect Parameter Number

This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor.


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Terminology used by MTU

Displaying faults The MDEC general system faults are indicated on the equipment in the following way: fault code numbers (generated by the ECU - Engine control unit).

In the event of a fault, the screen will display the following message:

FAULT

ALARM ENGINE GENERAL 110 18

25/12/2005 15:30

OK=HELP

Engine fault code. Pressing OK will display fault finding information. In addition, appendix A and B indicate the meaning of the code. The checking and maintenance operations to carry out in order to solve the fault 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. 6.3.4.5. 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

25/12/2005 15:30

This screen will display first any messages relating to the alarms and faults that appear as soon as OK is pressed.

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7. Maintenance schedule 7.1. Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline. N.B. the environment in which the generating set is operating determines this schedule. If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given in this manual.

7.2. Engine Position 10 hrs /

1 day 50 hrs 250 hrs / every year 500 hrs 1000 hrs Every

2 years As

required Inspection round Check the engine oil/fuel/refrigerant levels

Check the fuel pre-filter Check the battery electrolyte level and its density

Change the engine oil (First 50 hours)

Replace the oil filter (First 50 hours)

Retighten the nuts and bolts * (First 50 hours)

Clean the fuel filter element Clean the radiator strips Replace the fuel filter element Check and adjust the fan belt tension

Check and adjust the injection pressures *

Check and adjust the valve clearance *

Check the spark plugs * Check the starter Check the alternator Check the turbochargers * Replace the coolant Reprime the fuel circuit Clean the air filter element Replace the air filter element

* This procedure should only be carried out by one of our agents. 7.3. 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.

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8. Battery

Danger

Fit the battery so that it is properly ventilated. Maintenance should only be carried out by a qualified person. If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire. Only use insulated tools (the operator should not be wearing a watch, bracelet or any metal object) Never use sulphuric acid or acid water to top up the electrolyte level. Use an approved battery fluid. Batteries release oxygen and hydrogen gas, which are flammable. Never bring flames or sparks near the battery (risk of explosion). Discharge any static electricity before handling the batteries by first touching an earthed metal surface. Do not use the battery when the fluid level is below the minimum required levelUsing a battery with a low electrolyte level could result in an explosion. Do not short the battery terminals with a tool or other metal object. When disconnecting battery cables, remove the cable from the negative (-) terminal first. When reconnecting the battery, connect the positive lead (+) first. Charge the battery in a well-ventilated area, with all filler caps removed. Ensure that the battery terminals are correctly tightened. A loose cable clamp can cause sparks that could result in an explosion. Before servicing electrical components or performing electric welding, set the battery switch 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 or clothes, wash it off immediately with plenty of water, then carefully wash the area with soap. If electrolyte comes into contact with your eyes, rinse immediately with plenty of water and consult a doctor as soon as possible. If electrolyte is accidentally swallowed, gargle with plenty of water and drink large quantities of water. Consult a doctor immediately. Large quantities of electrolyte should be rinsed off using a neutralising agent. A common method is to use a solution of 500g of bicarbonate of soda diluted in 4 litres of water. The bicarbonate of soda solution should be added until the reaction has finished (lather). The remaining liquid should be rinsed off with water and left to dry.

8.1. Storage and transport

Dry batteries do not need any maintenance. Batteries ready to use must be stored in a cool dry place (frost free) protected from the sun (self-discharge). Batteries ready for use must be recharged at the latest when the acid density drops below 1.20g/ml. Batteries must be transported and stored in the vertical position (risk of acid escaping). Leave the terminal cover on the positive terminal.

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8.2. Battery setting into service Batteries filled with acid have a density of 1.28 g/ml and are charged. In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the

battery 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 1.13 20% Under 11.88 V Unusable

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8.4. Load preconization Very discharged or sulphated batteries can no longer regenerate or charge in a generating set.

Note: Sulphation is the formation of whitish lead sulphate deposit on the plates which becomes hard and insoluble in acid. This deposit reduces the active surface of the plates and increases their internal resistance.

Important

A discharged battery may become irreparably damaged. Recharge it immediately

Battery charge

When several batteries are connected together, the following points should be checked:

Are the batteries connected in series? Is the voltage chosen exact? 1 x 12 V battery, 3 x 36V batteries Adjust 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 should be recharged to 30Ah Charge factor: 1.2 Ah x 1.2 = 36 Ah to be charged Charging current: 6A approximately 6 hours charging required.

Recharging is complete when the battery voltage and the acid density stop increasing. → The charging current must always be 1/10th of the nominal capacity of the battery. The power of the charger must be suitable for the battery to be charged and the charging time available. You need to use an automatic charger able to provide a sufficient voltage and charging current, as well as a compensation voltage to handle spontaneous battery discharge.

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8.5. Faults and remedies Fault observed Probable origin Measures or observations

The acid heats up when a new battery is filled

- Incorrect composition - Incorrect storage - Prolonged storage in a damp place

- Cool - Load - Check the acid density

The acid escapes through the filler holes - Overfilled battery - Reduce the battery fluid level

Acid level too low - Battery tray not leaktight - Excessive charge voltage leading to a

significant accumulation of gas.

- Replace the battery - Check the charger and repair if

necessary.

Acid level too low Incorrect operation from start-up

- Insufficient charge - Short circuit in the power circuit - Consumption fault

- Recharge - Check the electrical installation

Acid density too high - The battery has been filled with acid instead of battery fluid

- Reduce the acid level by filling with distilled water. Repeat the operation if necessary.

Starting problems Starting test incorrect

- Battery empty - Battery exhausted or faulty - Capacity too low - Battery sulphated

- Recharge the battery - Fit a new battery

Battery terminals melted - Incorrect electrical connection - Battery cabling incorrect

- 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 - High self-discharge (through electrolyte

contamination etc.) - Sulphation (storage of discharged

battery)

- Check the load - Replace the battery

Short service life - Incorrect battery part no. - Repeated deep discharging - Battery stored too long without charge

- Define the correct battery part no. for the recommended use

- It is recommended to charge the battery using a regulator

High water consumption - Overload - Charging voltage too high - Check the charger (voltage regulator)

The battery explodes

- Spark after battery charging - Short circuit - Connection or disconnection during

charging - Internal fault and low electrolyte level

- Replace the battery - Ventilate well

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9. Appendix 9.1. Appendix A – Engine user and maintenance manual 9.2. Appendix B - Alternator user and maintenance manual

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Mitsubishi

SQ series

Version 08/2004 33522050201_2_1

Users guide and and maintenance manual

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INTRODUCTION

INTRODUCTIONThis publication covers the standard specification model for the Mitsubishi SQ-Series diesel engines. The information, specifications, and illustrations in this publication are based on the information that was current at the time this issue was written.

This manual contains operation instructions, lubrication and maintenance information.

The OPERATION section is a reference for the new operator and a refresher for the experienced operator. Read — study — and keep it handy. Illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the engine. Operating techniques outlined in this manual are basic. Skills and techniques develop as the operator gains knowledge of the engine.

The MAINTENANCE section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service intervals. Items without specific intervals are listed under "When Required." Items in the Lubrication and Maintenance Chart are referred to in the detailed instructions which follow.

Notice that the technical information in this manual depends on the specification of the engine and the accessories. All specifications are subject to change without any prior notice.

For items other than those in this publication, please refer to the operation manual of the equipment in which this engine is installed.

Operation ManualMitsubishi SQ-Series diesel enginesVersion 08/2004Copyright © 2003 MHI Equipment Europe B.V.

1 / 42Operation Manual Mitsubishi SQ-Series diesel enginesVersion 08/2004

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WARNING SIGNS

WARNING SIGNSThe following safety related signs are used in this manual to emphasize important and critical instructions:

SymbolsIndicates a proper action or "DO".

Indicates a prohibited action or "DON’T".

Recommendation of daily operation recordsIt is obvious to every engine user and operator that an engine should not be run to destruction. Daily recording is a preventive maintenance program and will serve as a guide for:

• Effective troubleshooting (to help a serviceman from your Mitsubishi dealer to pin-point a problem).

• Quick service and less downtime (to help a serviceman from your Mitsubishi dealer save time (and costs for service))

• Grasp of operating conditions (to help you recognize conditions, signs or indications of approaching trouble)

Items to be recordedThe following items are recommended to be recorded:

1. Operating hours (service hour meter reading)2. The amount of oil, fuel, and coolant (soft water)

required for refilling3. Oil and coolant change intervals4. Engine oil pressure, exhaust temperature, coolant

temperature, and inlet air temperature5. Parts serviced, kinds of service (adjustment, repairs

or replacement), and the results of each service6. Changes in operating conditions (for example,

"Exhaust smoke turned black,” etc.)

DANGERIndicates the most serious specific potential hazard which could result in serious personal injury or death.

WARNINGIndicates a specific potential hazard which could result in personal injury.

CAUTIONIndicates operating procedures, practices, etc. which could result in personal injury or damage causing destruction to the engine. Some of the CAUTION signs also indicate a specific potential hazard which could result in serious personal injury or death.

NOTEIndicates procedures, conditions, etc. which are important to highlight.

2 / 42 Operation Manual Mitsubishi SQ-Series diesel enginesVersion 08/2004

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TABLE OF CONTENTS

TABLE OF CONTENTS1 SAFETY.......................................................................................................................................... 5

1.1 Preventing fire and explosions................................................................................................. 51.2 Prevent burns........................................................................................................................... 61.3 Lifting precautions.................................................................................................................... 71.4 Exhaust fumes ......................................................................................................................... 71.5 Prevention of cuts and other injuries........................................................................................ 71.6 Maintenance precautions......................................................................................................... 91.7 Operating precaution ............................................................................................................. 101.8 Maintenance precautions....................................................................................................... 121.9 If any trouble should occur..................................................................................................... 13

2 IMPORTANT INFORMATION ................................................................................................ 142.1 Operating the engine properly ............................................................................................... 142.2 Service the engine properly ................................................................................................... 142.3 If any trouble should occur..................................................................................................... 15

3 SPECIFICATIONS..................................................................................................................... 16

4 NOMENCLATURE .................................................................................................................... 174.1 Engine S4Q/S4Q2 ................................................................................................................. 17

5 OPERATION ............................................................................................................................... 185.1 Pre-start inspection ................................................................................................................ 185.2 Starting the engine................................................................................................................. 195.3 Warming up the engine.......................................................................................................... 205.4 Starting the load..................................................................................................................... 205.5 Stopping the engine ............................................................................................................... 20

6 MAINTENANCE ......................................................................................................................... 226.1 Every 50 service hours .......................................................................................................... 236.2 Every 250 service hours or once a year ................................................................................ 246.3 Every 500 service hours ........................................................................................................ 256.4 Every 1000 service hours ...................................................................................................... 276.5 Every 2 years ......................................................................................................................... 276.6 When required ....................................................................................................................... 29

7 FUEL SPECIFICATIONS ........................................................................................................ 317.1 Recommended types of fuels ................................................................................................ 317.2 Caring for the diesel fuel tank ................................................................................................ 317.3 Caring for the fuel supply ....................................................................................................... 31

8 LUBRICANT SPECIFICATIONS........................................................................................... 328.1 Recommended types of engine oils....................................................................................... 328.2 Recommended oil viscosities................................................................................................. 328.3 Limiting requirements for engine oils ..................................................................................... 33

9 COOLANT AND ANTIFREEZE SPECIFICATIONS ........................................................ 349.1 Coolant specifications ............................................................................................................ 349.2 Recommended types of LLC's (Long Life Coolant) ............................................................... 349.3 How to use non-amine type LLC............................................................................................ 359.4 Why LLC? .............................................................................................................................. 359.5 How LLC works...................................................................................................................... 359.6 Practical reported cases of circuit trouble for which additive is blamed................................. 36


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TABLE OF CONTENTS

10 STORAGE ................................................................................................................................... 3710.1 Storage of the engine in a non-operational condition ............................................................ 3710.2 Storage of the engine in an operational condition.................................................................. 37

11 TROUBLESHOOTING ............................................................................................................. 3811.1 General .................................................................................................................................. 3811.2 Problems................................................................................................................................ 39

12 ADDITIONAL INFORMATION ............................................................................................... 42


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SAFETY

1 SAFETY

1.1 Preventing fire and explosionsFire hazards!

Do not smoke while refueling, or when handling fuel containers. Do not use gasoline or diesel fuel for cleaning parts. Good quality commercial, non-flammable, and non-toxic solvents are recommended. Do not spill any fuel on hot surfaces. Clean up any spillage immediately.

Do not fill fuel tank while the engine is running!

Shut off the engine when fueling and use extra caution if the engine is hot.

Do not bring close to flammable materials!

Do not put flammable materials on hot parts of the exhaust pipe. Keep them away from the pipe. In addition, do not operate the engine in areas where flammable materials are present.

Connect the battery earth cable carefully!

Finally, connect the earth cable (negative terminal) to the engine block, when starting the engine using another battery. If it is accidentally connected to the negative terminal of the mounted battery, a spark may occur, igniting the explosive gas produced by the battery. After starting the engine, first disconnect the earth cable.

AIways be alert to any fuel or oil leaks!

If you discover any leaks, take counter-measures immediately. If there are fuel or oil spills on the hot engine, fire may occur, resulting in personal injury or damage to the equipment.

Engine block

Flat batteryService battery

Booster cable connection order


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SAFETY

Keep the engine and its compartment clean!

Remove all flammable materials such as fuel, oil, and other debris, before they accumulate on the engine.

1.2 Prevent burnsRemove the radiator filler cap carefully!

Under operating temperatures, the engine coolant is hot and under pressure. The steam can cause personal injury. Check the coolant level only after the engine has been turned off and the filler cap is cool enough to touch with your bare hands. If necessary grip the cap with a cloth and remove it slowly in order to gradually relieve the pressure.

Do not touch any hot components!

At operating temperature, the engine components become very hot. Avoid any contact during operation. Service the engine only after it has been stopped and the components are cool enough to touch with your bare hands.

Avoid burns!

Immediately after completing operations do not change the oil or the coolant. Hot oil or coolant may burn the skin. Allow the engine to cool down to room temperature before replacement.


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SAFETY

Turn off the battery switch before servicing!

Be sure to turn OFF the battery switch before servicing.

If electrical equipment, including the starter or alternator, is serviced with the battery switch turned ON, it may be shortcircuited by the current from the battery’s positive terminal, resulting in burns or in fire.

1.3 Lifting precautionsLift the engine carefully!

Never allow anyone to walk or stand underneath a suspended engine. Operate the hoist carefully without jerking it. Remember, sudden impact of loads can cause serious accidents.

1.4 Exhaust fumesExhaust fumes

Operate the engine in safe areas only! Operate the engine in a well ventilated area. Never operate it in an enclosed area. In particular, do not operate it near an air inlet port on the downwind side.

1.5 Prevention of cuts and other injuriesStay clear of all rotating and moving parts!

The rotating parts of the engine are dangerous. Always stay clear of them during operation.


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SAFETY

Use care during checking and servicing!

Before performing maintenance, remove the starter switch key and turn OFF the battery switch. Attach a "DO NOT OPERATE" or similar warning tag to the starter switch.

Ensure that everything is in order before restarting the engine!

Before starting the engine, make sure that no one is working on or close to the engine. Remove all foreign material from the engine, such as debris, oil, tools, and other items which are not part of the engine.

lnstall the protective covers!

To prevent personal injury, make sure all protective covers and guards are placed on the rotating parts.

Keep the turning tool disengaged when it is not in use!

When not in use, properly lock the turning gear in the disengaged position. Failure to follow this recommendation can cause personal injury and engine damage.


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SAFETY

1.6 Maintenance precautionsStop the engine before servicing it!

Always stop the engine before adding or changing oil, coolant, or fuel. Check the coolant level only after the engine has been stopped and the radiator filler cap is cool enough to remove it with bare hands. Never attempt to adjust the fan belt while the engine is running.

Handle battery electrolyte carefully!

If battery electrolyte comes into contact with the eyes or skin, wash them clean immediately by using plenty of water. If it comes into contact with the eyes, wash out your eyes immediately and then see a doctor.

Handle antifreeze carefully!

If you accidentally drink antifreeze, make yourself vomit and see a doctor immediately. If antifreeze comes into contact with the eyes, immediately wash them clean by using plenty of water and then go and see a doctor.

Dress properly for the job!

For your own protection, you may need any number of special items - hard hat, face shield, safety shoes, goggles, heavy gloves, ear protectors, etc. Please do use these when required.


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SAFETY

1.7 Operating precautionBe sure to break in the engine!

During the first 50 hours of operation, break in the engine by using lighter loads and lower speeds than normal. A proper break in contributes to the maximum service life of the engine.

Warm up the engine before operation!

After starting the engine, leave it idling for 5 to 10 minutes before operating under full load, for maximum engine life.

NOTE: Long periods of warming up the engine are not recommended. They can deposit carbon in cylinders and cause incomplete fuel combustion.

Stop the engine only after it has cooled down!

Stopping the engine immediately after it has been working under a load, can result in overheating and accelerated wear of the engine components. Before stopping the engine, leave it idling for 5 to 10 minutes. This allows the hot areas in the engine to cool down gradually, which extends engine life. While the engine is running, make a walk-around inspection to make sure everything is functioning properly.

Use the starting motor correctly!

When starting the engine, do not crank it for more than 10 seconds at a time. After every 10 seconds of engine cranking, allow 30 seconds for the starting motor to cool before cranking it again.

Warm-up


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SAFETY

Do not break any seals for settings!

Never attempt to break the seals of the fuel injection pump (governor) controlling injection quantity and minimum and maximum speed settings. Breaking these seals and varying settings could result in:

• Accelerated wear of the engine components• Seizure of or damage to the engine

components• Increase in fuel and oil consumption• Maladjusted injection quantity and poor

engine performance• Violation to emission regulations

Do not turn OFF the battery switch during operation!

To avoid damage to the alternator diodes and the transistors, do not turn OFF the battery switch when the engine is running. This could also result in a failure of instruments to work properly.

AIways keep the engine compartment well ventilated!

Unless the engine compartment is properly ventilated, the air supply will be inadequate, resulting in a shortage of air for fuel combustion and the loss of power.

Avoid overloading!

Overloading can cause incomplete combustion, often indicated by black smoke, high fuel consumption, and carbon deposits in the combustion chambers, adversely affecting the engine lifespan.


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SAFETY

1.8 Maintenance precautionsUse the recommended fuel, oil, and coolant!

Use of any other fuel, oil, or coolant can cause engine damage and reduce the engine service life.

Perform all recommended inspections!

Perform pre-start inspection and periodic inspection on items listed in this manual. Failure to follow this recommendation can cause engine damage, injury, or death.

Keep water out of the engine!

When washing the engine, cover the air inlet and exhaust opening with tape to prevent water or cleaning agent from getting inside the engine. Do not wash the engine while it is running. If water or cleaning agents get inside the combustion chambers, the hammering action of water can damage the engine.

Keep grit-laden air out of the engine!

Dust and dirt entering the engine will cause early wear of the moving parts. This could result in a loss of power, high oil consumption, starting problems, or other failures. Service the air filter as instructed.

1. Do not service the air filter while the engine is running.

2. When removing the air filter element for service, prevent any dust from entering the air intake to the cylinders.

Brand A Brand B


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SAFETY

3. Service the air filter equipped with a dust indicator when red is shown. Under-frequent service can cause damage.

1.9 If any trouble should occurIf the engine suddenly stops:

Do not restart the engine immediately after it has suddenly stopped. Check for the cause and make the necessary repairs before restarting the engine. A failure to follow this precaution can cause serious engine problems.

If the engine oil pressure is low:

Stop the engine immediately and check the lubrication system. Operating the engine with low oil pressure can cause bearings and other parts to seize.

lf the engine overheats:

If the engine overheats, do not turn it off immediately. Suddenly stopping an overheated engine can result in a steep rise in the coolant temperatures and the seizure of running parts. First leave the engine idling to allow the hot areas in the engine to cool down, then gradually add the coolant. Remember, adding coolant to an overheated engine can cause damage to the cylinder head.

If the fan belt is broken:

Stop the engine immediately. Operating the engine with a broken fan belt can cause engine overheating, which, in its turn, can cause the coolant to burst out of the reservoir tank and the radiator cap.

EMERGENCY

SHUT DOWN


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IMPORTANT INFORMATION

2 IMPORTANT INFORMATION

2.1 Operating the engine properly1. Never attempt to break the seals of the

injection pump governor for maximum speed and maximum injection quantity settings. Breaking these seals and varying the settings could result in:• Accelerated wear of engine components• Increase in fuel and oil consumption• Maladjusted injection quantity and poor

engine performance• A violation to emission regulations

2. Always keep the engine room well ventilated. If it is not properly ventilated, the air supply will be inadequate, resulting in lack of air for fuel combustion and loss of power.

3. Start the engine properly. After every 10 seconds of engine cranking, allow 30 seconds for the starting motor to cool before cranking it again.

4. After starting the engine, leave it idling for 5 to 10 minutes before operating it at full load, for maximum engine life.

5. To avoid damage to the alternator, do not turn OFF the battery switch when the engine is running.

6. Avoid overloading. Overloading can cause incomplete combustion, often indicated by black exhaust, high fuel consumption, and carbon deposits in the combustion chambers, affecting engine lifespan.

7. It is advised to break in the engine within the first 50 hours of operation. The way to do this is by operating the engine under a lighter load and lower speeds than normal. When an engine is properly broken in, it contributes to the maximum service life of the engine.

8. Stopping the engine immediately after it has been working under load can result in accelerated wear of engine components. Before stopping, leave the engine idling for about 5 minutes. This allows hot areas of the engine to cool down gradually, extending the engine life. Whilst the engine is running, make a walk-around inspection and check for oil, fuel, or coolant leaks.

2.2 Service the engine properly1. Use the recommended fuel, oil, and coolant

listed in this manual. The use of any other fuel, oil, or coolant can result in higher maintenance costs and can reduce the engine service life.

2. Be sure to perform pre-start inspection and periodic service on items specified in this manual. Improper inspection or service is dangerous and could result in damage to the engine, injury, or death.

3. At the end of each day of operation, check the engine for broken, defective, or missing parts. If you discover any items that need attention, repair, replacement, or adjustment after your daily check, report it as soon as possible. Keep in mind that even minor defects could result in very serious trouble.

4. When washing the engine, cover the air inlet and the exhaust openings with tape to prevent water or cleaning agent from getting inside the engine. Do not attempt to wash the engine when it is running. If water or cleaning agent gets inside the combustion chambers, the hammering action of water could cause damage to the engine.

5. Clean air is essential to a satisfactory engine operation and to a long engine life. This is also the reason why it is very important to service the air cleaner properly. The air cleaner prevents dust and grit-laden air from getting into the engine. Dust and dirt entering the engine will cause rapid wear of piston rings, cylinders, and pistons, resulting in loss of power and high oil consumption. Also, if dust and dirt are allowed to build up in the air cleaner passages, then this will eventually restrict the air supply to the engine and result in heavy carbon deposits on the pistons and valves due to an incomplete combustion. Therefore:• Do not service the air cleaner when the

engine is running.• When removing the air cleaner from the

engine for servicing, prevent dust from entering the air passage to the cylinders.

• Service the air cleaner element at reasonable intervals, or whenever the signal of the indicator is visible. That is, if your engine is equipped with an indicator signal.

• Do not use the element if any tears, rips, or damage are evident.

NOTELong periods of warming up the engine are not recommended. They can result in carbon deposits in the combustion chambers and incomplete fuel combustion.


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IMPORTANT INFORMATION

2.3 If any trouble should occur1. If the engine stops abruptly, try to find the

problem and its source and make the necessary repairs before starting the engine again.

2. If the engine overheats, a warning light will come on and, at the same time, the engine will stop. When this happens, do not ever add coolant to the overheated engine. First allow the engine to cool down, then add the coolant gradually.

3. If the engine oil pressure becomes low, stop the engine and check for the cause. Operating the engine while the oil pressure is low can cause seizure of the bearings and other parts.


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ENGLISH

SPECIFICATIONS

3 SPECIFICATIONS1

1 All specifications are subject to change without any prior notice.

System ItemModel

S4Q S4Q2

ENGINE PROPER

Type 4-cycle, water-cooled, vertical, overhead valve, diesel engine

Combustion chamber Swirl chamber type

No. of cylinders 4

Bore x Stroke (mm) 88x95 88x103

Total displacement (l) 2.311 2.505

Compression ratio 22

Firing order 1 - 3 - 4 - 2

Dry weight (kg) 195

LUBRICATING SYSTEM

Lubricating method Forced lubrication

Oil pump Trochoid pump

Oil filter Paper element type

Oil capacity: FULL level/EMPTY level (l)(Exclusive of oil filter capacity 0.5 l)

Shallow type oil pan: 5.5/4.0Deep type oil pan: 7.0/5.5

FUEL SYSTEM

Fuel injection pump Bosch A or VE type

Nozzle Throttle type

Fuel injection pressure 120 kgf/cm2

Fuel to be used Diesel fuel; see chapter 7

Governor Centrifugal weight type

INTAKE SYSTEM Air cleaner Paper-element type

COOLING SYSTEM

Cooling method Forced circulation of water

Water pump Centrifugal type

Coolant capacity (l)(Engine proper only) 4

ELECTRICAL SYSTEM

Starter (V - kW) 12 - 2.0

Alternator (V - A) AC generator (12 - 50)

Glow plug Sheathed type

Battery(capacity depends on application) 12V, 100 Ah or more

Table 1 Specifications

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NOMENCLATURE

ENGLISH

4 NOMENCLATURE

4.1 Engine S4Q/S4Q2

Thermostat

Hanger

Alternator

Crankshaft pulley

RIGHT SIDE VIEW

Oil filter

Exhaust manifold

Engine serial number

Oil pressure switch

Flywheel housing

REAR

LEFT SIDE VIEW

REARFRONT

Inlet cover

Air vent screw

Oil pan

Speed control lever

Top oil filler

Stop solenoid

FRONT

Dipstick

Fan

Hanger

Water pump

Fuel injection pump

Fuel filter

V-belt

Oil drain plug

Fuel feed pumpCoolant drain plug

Starter

Flywheel

Air inlet elbow

Fuel injector

Flywheel housing

Thermoswitch

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OPERATION

5 OPERATION

5.1 Pre-start inspection5.1.1 Walk-around Inspection

Look around for items such as loose bolts, debris build-up, oil, fuel, or coolant leaks, broken or worn parts.

5.1.2 Check engine oil level

Maintain the engine oil level between the MAX and MIN marks on the dipstick. Add oil if necessary (see page 32).

5.1.3 Check fuel level

Make sure that the fuel level is at the FULL mark in the sight gauge.

5.1.4 Check the coolant level

Maintain the coolant level to the FULL mark on the reservoir tank (when the engine is cold). Add coolant when necessary.

NOTEThe engine should be put in the horizontal position to check the oil level. The dipstick should be withdrawn, wiped clean, re-inserted in the oil level guide for 2 seconds, and again withdrawn so that the oil level on the dipstick can be seen.

NOTEWhen adding coolant, maintain the recommended concentration of Long Life Coolant (see page 34). Do not add water. This dilutes Long Life Coolant and adversely affects the freeze protection.

CAUTIONCheck the coolant level only when the engine is cold.


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OPERATION

5.2 Starting the engineThe engine can be equipped with or without a glow timer. For starting instructions, please consult the chapter which specially applies to your engine.

5.2.1 Engine with glow timer

1. Move the speed control lever to the HIGH SPEED position.

2. Turn the starter switch key to the ON position and make sure that the oil pressure, coolant temperature, and glow plug indicators are lit. See Table 2 Starting Aid Chart for heating time.

3. When the glow plug indicator goes off, turn the key to the START position.

4. Release the key when the engine starts. The key will return to the ON position when released.

5. Move the speed control lever to the idling position.

5.2.2 Engine without glow timer

1. Move the speed control lever to the FULL THROTTLE position.

2. Turn the starter switch key to the HEAT position and continue to hold it there for approximately 6 seconds. Do not use the glow plugs for more than 15 seconds at a time.

3. Turn the key to the START position and release the key when the engine starts. The key will return to the ON position when released.

4. Move the speed control lever to the idling position.

Glow plug type

Coolant temperature

Heating time

Quick-heating

type

Below 5°C (41°F) About 3 seconds

Above 5°C (41°F) About 1 second

Standard type Normally About 6 seconds

Table 2 Starting Aid Chart

Engine with glow timer Engine without glow timer

HIGH SPEED IDLING

START

WARNINGBefore starting the engine, make sure that no one is working on or close to the engine. Keep the engine free of foreign material such as debris, oil, tools, and other items which are not part of the engine.

CAUTION• After every 10 seconds of engine cranking,

allow 30 seconds for the starter to cool down before cranking again.

• To avoid damage to the starter, do not turn the starter switch key to the START position while the engine is running.

• When cranking the engine for starting, do not apply any load to the engine (disengage the clutch if the engine is equipped with a clutch).

ON


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OPERATION

5.3 Warming up the engineAllow the engine to leave it idling for 5 to 10 minutes. A proper warm-up is absolutely essential to a maximum service life and performance and it minimalizes the operation costs of the engine.

.

5.4 Starting the loadWhen the engine has been running long enough to warm up, apply the load. During the operation, check that:

1. All alarm indicators are OFF.2. The engine is free from any abrupt noises and

vibrations.3. Exhaust smoke is normal.

5.5 Stopping the engine5.5.1 Engine with a keystop device

Turn the starter switch key to the OFF position. The engine will take approximately 5 seconds to stop after the key has been turned to the OFF position.

NOTELong periods of warming up the engine are not recommended. They can result in carbon deposits in the combustion chambers and incomplete fuel combustion.

WARNING• Stay clear of all rotating and moving objects

during the operation.• At operating temperature, the engine is very

hot. Any contact with the engine can cause severe burns.

Warm-up

CAUTION• Always keep the engine room well

ventilated. Unless it is properly ventilated, the air supply will be inadequate, resulting in lack of air for fuel combustion and a loss of power.

• During the first 50 hours of operation, operate the engine under a lighter load and lower speed than normal. A proper break in contributes to the maximum service life of the engine.

• Avoid overloading. This can cause incomplete combustion, often indicated by black exhaust smoke, high fuel consumption, and carbon deposits in the combustion chambers, affecting the engine’s lifespan.

• To avoid damage to the alternator, do not turn OFF the battery switch when the engine is still running.

• To avoid damage to the starter, do not turn the starter switch key to the START position when the engine is still running.

OFF


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OPERATION

NOTEIf the electrical system includes a control timer for engine shutdown, the starter switch should be kept in the "OFF" position for at least 10 seconds before making another start attempt (to restart the engine once the engine stopped or has been stopped) in order to reset the control timer automatically.

CAUTION• Leave the engine idling for 5 minutes. This

allows hot areas in the engine to cool down gradually, which extends engine life. While the engine is still running, make a walk-around inspection, and check for oil, fuel, or coolant leaks.

• If the engine stops abruptly, try to find the problem and its source and make the necessary repairs before starting it again. After starting the engine, check to be sure that the engine has no problems.

• Remove the key from the starter switch, because leaving it in the ON position after the engine has stopped, can cause the battery to discharge.


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MAINTENANCE

6 MAINTENANCE

1. Service the engine in accordance with the "Lubrication and Maintenance Chart." Under extreme, severe, or dusty operating conditions, service the engine more frequently than is specified in the "Lubrication and Maintenance Chart."

2. Perform service on items at multiples of the original requirement. For example, at Every 500 Service Hours, also service those items listed under Every 250 Service Hours, Every

50 Service Hours and Every 10 Service Hours [pre-start inspection].

3. For special items marked with an asterisk (*), rely on the expert knowledge of the service men and the service facilities offered to you at your Mitsubishi dealer.

Interval Item Remarks (specifications) Page

Every 10 Service Hours [Pre-Start Inspection]

Walk-around inspection 18

Check engine oil level 18

Check fuel level 18

Check coolant level 18

Every 50 Service Hours

Drain water and sediment from the fuel tank and water separator 23

Check the battery electrolyte level and specific gravity 23

First 50 Service Hours of New or

Reconditioned Engine

Change engine oil See SPECIFICATIONS (page 16) 24

Change oil filter 24

Retighten nuts and bolts *

Every 250 Service Hours or once a year

Change engine oil See SPECIFICATIONS (page 16) 24

Change oil filter 24

Clean fuel filter element After cleaning, prime (page 29) 25

Clean radiator fins 25


Check and adjust valve clearance 0.25 mm (0.0098 in.) for both inlet and exhaust valves *

Change fuel filter element After changing, prime (page 29) 25

Check and adjust injection pressure See SPECIFICATIONS (page 16) *

Check and adjust fan belt Deflection: 13 mm (0.5 in.) 26

Check glow plugs *


Retighten nuts and bolts *

Check starter 27

Check alternator 27

Every 2 Years Change coolant See SPECIFICATIONS (page 16) 27

Table 3 Lubrication and maintenance charts


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MAINTENANCE

6.1 Every 50 service hours6.1.1 Drain water and sediment from the

fuel tank and water separator

Remove the drain plug and allow any water and sediment to drain. Drain at least 1 or 2 liters (0.3 to 0.5 U.S. gal) of fuel to remove the water and sediment.

It is evident that invisible particles of dirt in sediment which might pass through the filter will damage the finely finished parts of the fuel injection system.

6.1.2 Check the battery electrolyte level and specific gravity

1. Maintain the electrolyte level between UPPER and LOWER marks on the case. If the battery has not got any level marks, maintain the level 10 to 15 mm (0.4 to 0.6 in.) above the cells. Remove the filler caps and add distilled water when necessary.

2. Test the specific gravity of the battery electrolyte with a battery hydrometer. The

following chart of specific gravity reading gives a general idea of the battery condition.

.

When Required

Prime fuel system 29

Clean air cleaner element 29

Change air cleaner element 29

Interval Item Remarks (specifications) Page

Table 3 Lubrication and maintenance charts

DANGERDo not smoke while draining out the water and sediment. Keep flames and sparking devices away from this area. Clean up any spillage before starting the engine.

Specific gravity at 20°C (68°F) Battery condition

1.26 to 1.28 Fully charged

1.22 to 1.26 Three-fourths charged (To be recharged)

Below 1.22 One-fourth charged (To be recharged)

Table 4 Specific gravity reading

WARNING• Battery gives off flammable fumes that are

explosive.• Do not smoke when observing the battery

electrolyte level.• Electrolyte is an acid and can cause

personal injury if it comes into contact with the skin or eyes.

• Always wear goggles when working with the battery.


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MAINTENANCE

6.2 Every 250 service hours or once a year

6.2.1 Change engine oil and oil filter; draining oil

To avoid burns, drain the oil after the engine has cooled down to the extend that it can be touched with your bare hands. Allow the oil to drain into a container.

6.2.2 Changing the oil filter

1. Remove the used oil filter with a filter wrench.

2. Make sure that the formerly used packaging is removed from the filter base and clean the base with a clean cloth.

3. Check the new oil filter and make sure that the packing is fitted in the groove.

4. Apply a thin coat of engine oil to the packing of the new filter.

5. Install the new filter by hand until its packing touches the base. Tighten it by 3/4 to 1 turn.

6.2.3 Filling with oil

1. Install the drain plug and tighten it to the specified torque.

2. Fill the crankcase with oil.

DANGERHot oil and components can cause personal injury. Do not allow hot oil or components to come into contact with the skin.

NOTECheck particles collected in the used oil filter. If they are metallic particles, you should consult your Mitsubishi dealer.

Torque

4.5 ± 0.5 kgf/m(33 ± 4 lbf/ft)[44 ± 5 N/m]

Table 5 Specified torque

Refill capacity See SPECIFICATIONS

API Service Classification CF or CF-4

Table 6 Fill crankcase

Packing


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MAINTENANCE

3. Start the engine, leave it idling for a few minutes, and check for leaks. Re-tighten the filter in case of leakage.

4. Stop the engine and leave it inert for about 30 minutes; then re-check the oil level. Maintain the oil level between the MAX and MIN marks on the dipstick. Add oil only if necessary.

6.2.4 Cleaning the fuel filter with cut off valve

1. Turn the valve to the OFF position.2. Loosen the ring nut and remove the cup.3. Wash the element in kerosene or diesel fuel.4. Put the cleaned element in the cup and install

the cup, making sure the O-ring is properly fitted into place. Tighten the ring nut.

5. Turn the valve to the ON position and prime the fuel system (see page 29).

6.2.5 Clean the radiator

Direct the pressurized air to the fins in the opposite direction of the fan’s air flow.

6.3 Every 500 service hours6.3.1 Change fuel filter element

Water separator element

1. Turn the lever to CLOSE (C) position to shutt off fuel supply.

2. Loosen the ring nut and remove the cup.3. Remove and discard the element.4. Put the new element in the cup and install the

cup, making sure the O-ring is properly fitted in place. Tighten the ring nut.

5. Turn the lever to OPEN (O) position.

Fuel filter element (A-type)

1. Loosen the drain plug and allow the fuel to drain.

2. Loosen the plug that holds the bowl and element. Remove the bowl and element. Discard the element.

3. Install the new element and bowl with the plug. Make sure the seal rings are properly fitted in place.

4. Tighten te drain plug.

Fuel filter element (B-type)

1. Loosen the drain plug and allow the fuel to drain.

2. Loosen the connector from the level sensor.3. Remove the element from the body.

Valve

Element

O-ring

Ring nut

Element

Ring nut

Cup

Lever

Element

Bowl

Drain plug


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MAINTENANCE

4. Remove the level sensor from the element. Discard the element.

5. Install the level sensor to the new element.6. Install the new element to the body.7. Install the connector to the level sensor.8. Tighten te drain plug.

Fuel filter (cartridge type)

1. Remove the cartrigde with a filter wrench.2. Apply a small amount of fuel to the O-ring of

the new cartrigde.3. Install new cartrigde by hand.4. After replacing the cartridge, be sure to prime

the fuel system. See page 29 for priming.

6.3.2 Check and adjust the fan belt

Checking

Correct adjustment exists when the belt can be pushed inward about 13 mm with 100 N thumb pressure exerted midway between the alternator and crankshaft pulley as shown.

Adjusting

1. Loosen the adjusting plate bolt and the mounting bolt.

2. Insert a bar between the alternator and the cylinder block to move the alternator to obtain the required belt deflection.

3. Tighten the mounting bolt and the adjusting bolt.

NOTEAfter replacing the elements, be sure to prime the fuel system. See page 29 for priming.

NOTEDo not add fuel to the new cartridge. Invisible particles of dirt which might get inside the injection pump can damage its finely finished parts.

Drain plug

Level sensor

Body

CAUTION• If the fan belt is too tight, excessive stress is

put on to the fan bearings and belt, which might shorten the life of both. If it is too loose, it will slap against the pulleys, causing unnecessary wear and tear to the belt, which could cause possible slipping, to the extent that the engine will overheat.

• Keep the belt free from oil or grease.

Water pump pulley

Mounting bolt

Adjusting bolt

Adjusting plate

Alternator pulley 13 mm(0.5 in.)

Crankshaft pulley


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MAINTENANCE

6.4 Every 1000 service hours6.4.1 Check the starter

1. Check for visual defects.2. Check to see if the pinion is shifted into mesh

with the flywheel ring gear when the starter is energized. If the pinion does not shift properly, consult your Mitsubishi dealer.

6.4.2 Check the alternator

1. Check for visual defects.2. Remove the belt from the alternator. Turn the

pulley by hand to check the alternator for smooth rotation. If the alternator fails to rotate smoothly, consult your Mitsubishi dealer.

6.5 Every 2 years6.5.1 Change coolant

Long Life Coolant (LLC) used in your engine retains its efficiency for 2 years. Be sure to change the coolant every 2 years.

6.5.2 Draining

1. Start and operate the engine until the coolant temperature is 70°C to 80°C (158°F to 176°F). Then stop the engine.

2. Remove the filIer cap only after the engine has been stopped and the cap is cool enough to remove with your bare hands.

3. Open the radiator drain valve and remove the engine drain plug.

4. Then allow the coolant to drain into the containers.

6.5.3 Flushing

1. Close the radiator drain valve and install the engine drain plug.

2. Fill the cooling system with a cleaning solution which does not chemically attack rubber or metal surfaces. Start and operate the engine at 800 to 900 rpm and let the engine run for 15 minutes. Stop the engine and drain the cleaning solution.

3. Fill the system with clean water and operate the engine at 800 to 900 rpm for 10 minutes. Continue to flush the system until the draining water is clear.

6.5.4 Refilling

1. Tighten the radiator drain valve and the engine drain plug.

2. Remove the by-pass hose (A) at the thermostat housing.

Water drain cock


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MAINTENANCE

3. Remove the cabin heater hose (B) at the thermostat housing (if installed).

4. Pour pure, undiluted LLC into the radiator; see COOLANT AND ANTIFREEZE SPECIFICATIONS on page 34. The recommended concentration of LLC is illustrated in the chart below:

5. Fill the cooling system slowly with coolant through the radiator cap opening to avoid air being trapped in the system.

6. Re-install the by-pass and cabin heater hoses, if coolant reaches the top level and tighten the clamps.

7. Bleed the air at the cabin heater system.8. Run the engine for a few minutes at low idle

with the radiator cap open.9. Stop the engine and check the coolant level;

fill-up if necessary, re-install the radiator cap.

10. Start and operate the engine until the coolant temperature is between 70°C and 80°C (158°F to 176°F). Check for any leaks. Then stop the engine. Repair any leakage if necessary.

11. Check the coolant level in the reservoir tank and add water if the coolant level is low. Maintain the coolant level to FULL line on the tank when the engine is cold.

AmbientTemperature, °C (°F)

-10(14)

-20(-4)

-30(-22)

-45(-49)

LLC concentration, % 30 40 50 60

Table 7 Recommended LLC Concentrations (reference)


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MAINTENANCE

6.6 When required6.6.1 Prime fuel system

Air in the lines may cause the fuel system to become air bound, resulting in an inability to start the engine or the misfiring of one or more cylinders. Prime the fuel system:

1. After the engine has been fueled for the first time after installation.

2. After the engine has been refueled after running out of fuel.

3. After the fuel filter element has been cleaned or replaced.

6.6.2 Procedure

Fuel filter

1. Loosen the air vent plug on the fuel filter (by turning it 1.5 turns).

2. Unlock the priming pump plunger by turning it to the left, and operate the pump.

3. Tighten the air vent plug when the fuel flows free of bubbles.

Fuel injection pump

1. Loosen the air vent plug on the injection pump (by turning it 1.5 turns).

2. Unlock the priming pump plunger by turning it to the left, and operate the pump.

3. Tighten the air vent plug when the fuel flows free of bubbles.

6.6.3 Clean/change air cleaner element

Service the air cleaner only when it is necessary, or when the dust indicator indicates RED.

6.6.4 Cleaning

1. Direct air — 7 kgf/cm2 (100 psi) [686 kPa] maximum — inside the element along the length of pleats.

2. Insert a light inside the clean element and check. Replace the element if rips or tears are found.

.

.

Air vent plug

Priming button

NOTE1. If the vent plug is tightened before the

priming pump plunger is locked, fuel pressure acts on the feed pump, making it difficult to restore the plunger.

2. Clean up fuel spillage.

NOTEReplace the element if it is excessively dirty.

Air vent plug

Priming button


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MAINTENANCE

CAUTION• Never service the air cleaner when the

engine is running. Without the air cleaner, dust and dirt can enter the engine and can cause rapid wear of the engine parts resulting in loss of power and high oil consumption.

• Do not clean the element by bumping or tapping it.

WARNINGWhen using compressed air for cleaning, wear a protective face shield, protective clothing, and protective shoes.


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FUEL SPECIFICATIONS

ENGLISH

7 FUEL SPECIFICATIONS

7.1 Recommended types of fuelsThe quality of fuel is a very important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels.

This engine is designed to burn fuels marketed to meet ASTM Designation D 975 (grade No. 2-D).

7.2 Caring for the diesel fuel tankFill the diesel fuel tank at the end of the day, because the incoming fuel will drive out the moisture-laden air and prevent condensation. Before starting the engine after 50 service hours, remove the drain plug and drain off any sediment or water which may have accumulated.

7.3 Caring for the fuel supplyIt is important to buy clean fuel and keep it clean. Natural settling is an effective method of cleaning fuel. Allow the fuel to stand for at least 10 days in the fuel storage tank after the tank has been filled and before the fuel is transferred to the diesel fuel tank. Be sure to drain all the water and sediment that has settled in the bottom of the tank before the tank is refilled. Occasionally, drain all of the fuel and clean the tank thoroughly.

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LUBRICANT SPECIFICATIONS

8 LUBRICANT SPECIFICATIONS

8.1 Recommended types of engine oils

Use oils that meet the API engine oil classification CF or CF-4 class. Proper oil selection assures cranking ability by maintaining an oil film on the cylinder walls and bearing surfaces in conditions which provide low friction and therefore less cranking effort to achieve cranking speeds necessary for reliable starting. Improper oil selection may result in congealed oil film on the cylinder walls and the bearing surfaces. This can result in high friction loads and more cranking effort, thus standing in the way of achieving sufficient cranking speeds for reliable starting and affecting engine life.

8.2 Recommended oil viscositiesThere are two important considerations related to satisfactory engine operation under ambient temperature conditions — (1) the ability to crank the engine fast enough to assure starting, and (2) adequate lubrication of internal wearing surfaces during starting and warm-up. These considerations can be adequately met through proper grade selection. Recommended oil viscosities are shown in the chart below:

Mitsubishi recommends the all-season type engine oil of SAE 10W-30.

CF or CF-4

Starting temperature, °C (°F)

-30(-22)

-25(-13)

-20(-4)

-15(5)

-10(14)

-5(23)

0(32)

10(50)

20(68)

30(86)

40(104)

Oil viscosities

S A E 3 0

S A E 40

S A E 15 W - 4 0

S A E 1 0 W - 3 0

S A E 5 W - 2 0

Table 8 Recommended oil viscosities


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LUBRICANT SPECIFICATIONS

8.3 Limiting requirements for engine oils

If a used oil analysis program is conducted in order to determine the condition of the oil, consult the chart below. Change the oil if any of these requirements are not met.

CAUTIONAvoid mixing oils with different brands. In most cases, oils with different brands are not compatible and, when mixed, they can seize parts such as piston rings, cylinders, etc. and cause wear to moving parts. It is best to stick with the same brand and one type of oil at successive service intervals.

A oil B oil

NOTE• Oil change intervals depends on the fuel

properties. Be sure to use the recommended fuels only.

• The limit of total base number is 1/2 of that of a new oil in case of a perchloric-acid analysis method.

Property Unit Test Method Limit

Viscosity cSt @ 100°C (212°F) JISK 2283

+30% / -15% , max. of new oil

Total base number (HCl) mgKOH/g JISK 2501

2.0, min.

Total acid number mgKOH/g +3.0, max. of new oil

Water content Vol% JISK 2275

0.2, max.

Flash point °C (°F) JIS K 2265

180 (356), min.

Pentane insolubles Wt% ASTM D 893

0.5, max.

Pentane insolubles coagulated Wt% 3.0, max.

Table 9 Limiting requirements for engine oils


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COOLANT AND ANTIFREEZE SPECIFICATIONS

9 COOLANT AND ANTIFREEZE SPECIFICATIONS

9.1 Coolant specificationsWater used in the engine cooling system must be soft, or as free from scale forming minerals as possible and it has to meet the requirements shown in the "Coolant Specifications" chart.

The values indicated in ( ) are the limits set forth by Mitsubishi. In addition to the items specified above, turbidity is specified to be <15 mg/l.

9.2 Recommended types of LLC's (Long Life Coolant)

For Mitsubishi diesel engines, all-season, non-amine type LLC's or equivalents are recommended.

9.2.1 Features of recommended brands

• No amines (methyl amines, ethyl amines, n-propyl amines, etc., all being derivatives of ammonia, NH3) are contained.

• Silicate and borate are not contained.• Close to neutral on the pH scale, and hence,

slightly basic (alkaline).• Balanced additive ingredients; some being

substitutes for amines.• Long life (the coolant with 30% concentration,

for example, retains its effectiveness for more than 2 years).

NOTEHarmful chemical properties and substances contained in water (as coolant) must not exceed the Mitsubishi limits. They are tolerable up to the limits shown in the chart below.

Item Chemical symbol Unit Recommended

limit

Main malign effect

Corrosion and rust

Scale formation

pH, 25°C (77°F) - - 6.5 to 8.5(6.5 to 8.0) O O

Electrical conductivity, 25°C (77°F) - µ /cm < 400

(< 250) O O

Total hardness CaCO3 PPM < 100(< 95) - O

M alkalinity CaCO3 PPM < 150(< 70) - O

Chlorine ion Cl- PPM < 100(< 100) -

Sulfuric acid ion SO PPM < 100(< 50) O -

Total iron Fe PPM < 1.0(< 1.0) - O

Silica SiO2 PPM < 50(-) - O

Residue from evaporation - PPM < 400

(< 250) - O

Table 10 Coolant specifications

Ω

24

–


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)

9.3 How to use non-amine type LLC

1. The engine coolant with any of the recommended additives should be changed every 2 years.

2. The proper concentration of LLC is from 30% to 60% all year round. Aim at a temperature level which is 5°C (9°F) lower than the expected lowest temperature. LLC of less than 30% concentration does not provide sufficient corrosion protection. Concentrations over 60% adversely affect freeze protection and heat transfer rates. When adding coolant, use LLC of the same concentration.

9.4 Why LLC?Today's full-blown trend is toward smaller and more lightweight engines, higher output, lower fuel consumption, and lower exhaust emission levels. Engine application has also expanded. In most applications, the engine coolant is compelled to withstand severe conditions such as continuous high-power operation with a higher coolant temperature and a higher speed of coolant recirculation in the cooling circuit. Many materials involved in the circuit (such as steel, aluminum, copper, solder, and rubber) are also subject to severe servicing. These materials differ in ionizing tendency and this difference promotes cavitation and deterioration through the medium of engine coolant. The ideal of breaking the link between cause and effect to preserve the circuit can be realized by using LLC.

9.5 How LLC worksLLC contains several chemicals in such proportions as to produce a chemical reaction that suppresses corrosion of the engine parts in contact with coolant. "Corrosion" is the result of a phenomenon called "ionization."

The power of LLC to defeat the ionic reaction is generally subject to wear and the engine coolant becomes increasingly weak at that time.

Moreover, if its chemicals are not properly proportioned to match the circuit metals which

WARNINGLLC is toxic and can cause personal injury if it comes into contact with the skin or the eyes. If LLC gets in your eyes, wash them with water immediately and see a doctor at once.

NOTEWhen using any other LLC, refer to the coolant mixture chart shown on the container.

WARNINGConsult your Mitsubishi dealer for disposal of a used coolant containing LLC.

Non

-am

ine

type

Ambient temperature, °C (°F)

-10(14)

-20(-4)

-30(-22)

-45(-49)

LLC concentration, % 30 40 50 60

Table 11 Recommended LLC concentrations (reference)


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they are meant to protect, they are used up due to aging and this allows some metals to precipitate into the coolant or to form new compounds which can result in rusty surface deposits. Some chemicals, calculated to inhibit this ionic reaction, might accelerate the reaction of those metals that have already begun to react.

The worse case scenario is that the process of the ionic reaction or corrosion will go on faster than when the coolant is straight water without additives, if there is not a good match between the chemical proportions and the circuit metals.

9.6 Practical reported cases of circuit trouble for which additive is blamed

Case 1:

Amines are generally effective in suppressing the rusting of ferrous metals but are said to be problematic for copper and cupric metals because of copper involvement in pittings reported on Fe metals. The mechanism of Fe-surface pitting may be explained as that of galvanic or local-cell action. Suppose a cluster of copper molecules precipitates and deposits itself on a surface of Fe, a base metal relative to copper. The copper deposit introduces a localized galvanic cell which, by its ionic action, rapidly eats into the Fe surface to result in a pit.

Case 2:

A silicate (there are several types of silicate) is highly effective in protecting aluminium against rusting. This compound of silicon is unstable in a solution whose pH is 9 or less: it is prone to turn to gel and settle down in the solution. For this reason, the pH is usually specified to be 10 or so. This means that the silicate has to be used in a high-alkalinity coolant. When the silicate is used up, the high alkalinity starts chemically attacking the aluminium.

Example

The mechanical seal of the water pump may rapidly wear down as the secondary effect of silicate gel in the above context.

Case 3:

As the additive as a whole deteriorates or when its concentration in the coolant is too low, its anti-corrosion performance falls and consequently the circuit metals begin to corrode. Of those metals

badly affected in such a condition, brass and solder — the materials used in the cores of the radiator — become particularly victimized. The cause of coolant leakage from and clogging of the coolant circuit in the radiator is usually traceable to such a malcondition of the coolant.


ENGLISH

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STORAGE

ENGLISH

10 STORAGE

10.1 Storage of the engine in a non-operational condition

10.1.1 Preparation

1. Drain the engine oil and put a preservative into the engine (up to the high level on the dipstick).

2. Make a mixture of preservative and fuel oil in a 50-to-50 ratio and put the mixture into the fuel tank.

3. Start and leave the engine idling for 5 to 10 minutes.

4. Stop the engine and spray volatile preservative (VCI) into the opening of the air inlet.

5. Drain the preservative-fuel mixture.6. Apply a coat of preservative to the exposed

machined surfaces of the engine.7. Cover the air inlet, the exhaust openings, and

the breather by taping them.8. Loosen the fan belt.9. Tape the starter and the alternator terminals.

Cover the starter and alternator with a polyethylene sheet and put a desiccant inside.

10. Disconnect the cables from the battery and charge the battery. Flush the top of the battery with clean water and coat the poles with acid-free vaseline to prevent further corrosion. Keep the battery in a cool, dry place.

11. Cover the engine to protect it against the weather.

10.1.2 Service during storage

Charge the battery at least once a month.

10.1.3 Remove the engine from storage

1. Remove the covers from the engine.2. Connect a fully charged battery to the engine.3. Remove the covers from the starter and the

alternator.

4. Adjust the fan belt.5. Remove the covering and the taping from the

various ports.6. Drain the preservative and fill the engine with

the recommended engine oil.7. Fill the fuel tank and prime the fuel system.8. Check under and around the engine for items

such as loose or missing bolts, oil, fuel, or coolant leaks.

9. Remove the rocker cover and lubricate the valve mechanism.

10. Crank the engine 3 times, 10 seconds each time, at intervals of 1 minute, with the fuel supply shut off.

11. Make sure the engine oil pressure rises properly.

12. Open the fuel supply valve and start the engine.

13. Allow the engine to leave it idling.14. When the engine has run long enough to

warm up, apply the load and bring it to an operating speed.

10.2 Storage of the engine in an operational condition

10.2.1 Follow steps 1 through 3 mentioned below once a month:

1. Crank the engine 2 times, for 10 seconds each time, with the starter at intervals of 30 seconds, with the fuel supply shut off. Open the fuel supply valve afterwards.

2. Start and operate the engine at 800 rpm under no-load condition for 5 minutes.

3. Increase the engine speed from 1000 to 1200 rpm and operate the engine under no-load condition for 10 minutes.

NOTE• Store the engine in a well-ventilated room.• It is not necessary to drain the coolant if it

contains LLC.• Attach a "DO NOT OPERATE" sign or

similar warning tag to the starter switch or any of the controls.

• New engine oil may be used instead of preservative.

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TROUBLESHOOTING

11 TROUBLESHOOTING

11.1 General11.1.1 Think before you act

Upon noting a defective indication, recall what you did the last time when you came across the same indication. If what you did was correct and successful, do the same again. If the symptom noted is new to you, think of a possible cause in accordance with the troubleshooting procedure which follows.

11.1.2 Dust and dirt are often the main causes

“Wear” is usually the result of abrasive particles. When disconnecting or disassembling a part or component, be sure to keep out dust and dirt.

11.1.3 Use original parts

Use only original parts to replace those that have failed or reached their service limits. When

ordering, specify the needed replacement parts by referring to the Parts Catalogue.

11.1.4 Perform servicing work safely

Use the right kind of hand tools to carry out each working step in repair work. Avoid injury to yourself and damage to the parts by using proper tools. When lifting or carrying a part that is too heavy for one person to handle, get another person’s help and, if necessary, use a jack or a hoisting device.

CAUTION• Never attempt to break the seals of the

governor for maximum speed setting or maximum injection quantity setting.

• The maximum injection quantity of the injection pump has been set on the basis of the output power of each engine verified at the bench test. Never attempt to vary this injection quantity in the field.


ENGLISH

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TROUBLESHOOTING

11.2 ProblemsFor special servicing jobs on your engine, rely on the expert knowledge of the servicemen and the service facilities provided by your Mitsubishi dealer.

Problem Cause Correction

Engine will not start Fuse off Replace

Defective starter switch Repair or replace*

Slow cranking speed Recharge battery

Wrong viscosity grade of oil Change correct oil

Seized running parts Repair*

Air in fuel system Prime

No fuel in tank Refuel

Bad quality fuel Change fuel

Clogged fuel filter Clean or replace

Defective fuel injection pump Repair or replace*

Defective control timer unit Replace*

Clogged air cleaner Clean or replace

Defective starter or relay Repair or replace*

Open electrical circuit Repair

Not enough power Wrong viscosity grade of oil Change oil


Clogged fuel filter Clean or replace


Defective fuel injection nozzles Repair or replace*

Wrong injection timing Adjust*

Bad quality fuel Change correct fuel

Overheating Flush cooling system and replace parts

Wrong valve clearance Adjust

Poor compression (cylinders, piston, rings, etc. worn)

Repair or replace*

Table 12 Troubleshooting


ENGLISH

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TROUBLESHOOTING

Overheating Not enough coolant in system Add coolant

Leaks in cooling system Retighten or repair

Loose fan belt Adjust

Restriction to air flow through radiator Remove restrictions

Defective water pump Replace

Defective thermostat Replace

Defective fan Replace

High LLC concentration Adjust LLC concentration

Too much white or blue smoke

Too much oil in engine Drain to correct level

Oil viscosity too low Change oil

Defective thermostat (coolant temperature too low)

Replace



Wrong fuel cetane number Change fuel

Poor compression (cylinders, piston rings, etc. worn)

Repair or replace*

Too much black or gray smoke






Wrong valve clearance Adjust


Repair or replace*

Fuel consumption too high







Repair or replace*




ENGLISH

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TROUBLESHOOTING

Remarks:

1. Consult your Mitsubishi dealer for items marked with an asterisk (*).

2. Consult your Mitsubishi dealer for any items other than those listed in the table.

3. When communicating with your Mitsubishi dealer, specify the engine model name, the engine serial number, the application, the rating, and service hour meter reading of your engine.

Oil consumption too high Too much oil in engine Drain to correct level


Leaks in lubrication system Repair or replace

Worn cylinders and piston rings Repair or replace*

Worn valve stem seals Replace*

Oil pressure too low Not enough oil in engine Add oil


Clogged oil filter Replace

Defective oil pump Repair or replace*

Defective relief valve Adjust or replace*

Defective pressure switch Replace*




ENGLISH

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ENGLISH

ADDITIONAL INFORMATION

12 ADDITIONAL INFORMATION

To whom it may concern

EC-declaration of incorporation(Directive 98/37/EC, Annex II, sub B)Ban on putting into service

MHI Equipment Europe B.V.Damsluisweg 21332 EC AlmereThe Netherlands

herewith declares that:

the Mitsubishi diesel engine, SQ-series type

is destined to be incorporated in other machines or to be combined with other machines, and is not (entirely) in compliance with the Machinery Directive (98/37/EC).

Almere, December 17th 2002

R.A.G.L. MandersGeneral ManagerEngine Division

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User's guide and maintenance manual

LLEERROOYY SSOOMMEERR

AALLTTEERRNNAATTOORR

4422--22 SSHHUUNNTT && AARREEPP

3433.en/e 06/2007

33522019901_3_1

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This manual must be supplied

to the end user

LSA 42.2 - 2 & 4 POLEALTERNATORS

Installation and maintenance

3433 en - 06. 2007 / e

343347

1

124

120198

132

430

323324

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2

INSTALLATION AND MAINTENANCE


3433 en - 06. 2007 / eLEROY-SOMER

This manual concerns the alternator whichyou have just purchased.

The latest addition to a whole new generationof alternators, this range benefits from theexperience of the leading manufacturerworldwide, using advanced technology andincorporating strict quality control.

SAFETY MEASURES

Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual.

All necessary operations and interventions on this machine must be performed by a qualified technician.

Our technical support service will be pleased to provide any additional information you may require.

The various operations described in this manual areaccompanied by recommendations or symbols to alert theuser to potential risks of accidents. It is vital that youunderstand and take notice of the following warning symbols.

Warning symbol for an operation capable of damaging ordestroying 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 thecharacteristics of its products at any time in order toincorporate the latest technological developments. Theinformation contained in this document may therefore bechanged without notice.

We wish to draw your attention to the contentsof this maintenance manual. By followingcertain important points during installation,use and servicing of your alternator, you canlook forward to many years of trouble-freeoperation.

WARNING SYMBOLS

A set of self-adhesive stickers depicting the various warningsymbols is included with this maintenance manual. Theyshould be positioned as shown in the drawing below once themachine has been fully installed.

Copyright 2004 : MOTEURS LEROY-SOMERThis document is the property of :MOTEURS LEROY-SOMERIt may not be reproduced in any form without prior authorization. All brands and models have been registered and patentsapplied for.

WARNINGWARNING

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3



CONTENTS

3433 en - 06. 2007 / eLEROY-SOMER

1 - RECEIPT

1.1 - Standards and safety measures ....................4

1.2 - Checks...........................................................4

1.3 - Identification...................................................4

1.4 - Storage ..........................................................4

2 - TECHNICAL CHARACTERISTICS

2.1 - Electrical characteristics ................................5

2.2 - Mechanical characteristics ............................5

3 - INSTALLATION - COMMISSIONING

3.1 - Assembly .......................................................6

3.2 - Inspection prior to first use.............................6

3.3 - Electrical diagram ..........................................7

3.4 - Commissioning ..............................................9

3.5 - Setting up.......................................................9

4 - SERVICING - MAINTENANCE

4.1 - Safety measures ......................................... 10

4.2 - Regular maintenance.................................. 10

4.3 - Fault detection ............................................ 10

4.4 - Mechanical defects ..................................... 11

4.5 - Electrical faults............................................ 11

4.6 - Dismantling, reassembly............................. 13

4.7 - Characteristics table .................................. 15

5 - SPARE PARTS

5.1 - First maintenance parts .............................. 16

5.2 - Description of bearings ............................... 16

5.3 - Technical support service ........................... 16

5.4 - Exploded view, parts list ............................. 17

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4



RECEIPT

3433 en - 06. 2007 / eLEROY-SOMER

1 - RECEIPT

1.1 - Standards and safety measures Our alternators comply with most international standards and are compatible with :- the recommendations of the International Electrotechnical Commission IEC 34-1, (EN 60034).- the recommendations of the International Standards Organisation ISO 8528.- the European Community directive 89/336/EEC on Electromagnetic Compatibility (EMC).- the European Community directives 73/23/EEC and93/68/EEC (Low Voltage Directive).They are CE marked with regard to the LVD (Low Voltage Directive) in their role as a machine component. A declaration of incorporation can be supplied on request.Before using your generator for the first time, read carefully the contents of this installation and maintenance manual, supplied with the machine. All operations performed on the generator should be undertaken by qualified personnel with specialist training in the commissioning, servicing and maintenance of electrical and mechanical machinery. This maintenance manual should be retained for the whole of the machine’s life and be handed over with the contractual file.The various operations described in this manual are accompanied by recommendations or symbols to alert the user to potential risks of accidents. It is vital that you understand and take notice of the different warning symbols.

1.2 - InspectionOn receipt of your alternator, check that it has not sufferedany damage in transit. If there are obvious signs of knocks,contact the transporter (you may able to claim on theirinsurance) and after a visual check, turn the machine by handto detect any malfunction.

1.3 - IdentificationThe alternator is identified by means of a nameplate fixed on the frame.Make sure that the nameplate on the machine conforms to your order.The machine name is defined according to various criteria (see below).Example of description for : LSA 42.2 S4 J6/4 -• LSA : name used in the PARTNER range M : Marine / C : Cogeneration / T : Telecommunications.• 42.2 : machine type• S4 : model• J : field excitation system (C:AREP / J:SHUNT / E:COMPOUND)• 6/4 : winding number / number of poles.

1.3.1 - NameplateSo that you can identify your machine quickly and accurately,we suggest you fill in its specifications on the nameplatebelow.

1.4 - StoragePrior to commissioning, machines should be stored : - Away from humidity : in conditions of relative humidity of more than 90%, the machine insulation can drop very rapidly, to just above zero at around 100%; monitor the state of the anti-rust protection on unpainted parts.For storage over an extended period, the machine can be placed in a sealed enclosure (heatshrunk plastic for example) with dehydrating sachets inside, away from significant and frequent variations in temperature to avoid the risk of condensation during storage.- If the area is affected by vibration, try to reduce the effect ofthese vibrations by placing the generator on a dampersupport (rubber disc or similar) and turn the rotor a fraction ofa turn once a fortnight to avoid marking the bearing rings.

ALTERNATEURS ALTERNATORS

Valeurs excit / Excit. values

en charge / full load

à vide / at no load Mad

e b

y L

ero

y S

om

er -

1 0

24 9

30/bTension

Voltage

SecoursStd by

40C

27C

PUISSANCE / RATING

Conforme à C.E.I 34-1 (1994). According to I.E.C 34-1 (1994).LR 0021

Connex.

kVA

kW

A

kVA

kW

A

V

Ph.

Continue

Continuous

LSA Date N Hz Min-1/R.P.M. Protection Cos ϕ /P.F. Cl. ther. / Th. class Régulateur/A.V.R. Altit. m Masse / Weight Rlt AV/D.E bearing Rlt AR/N.D.E bearing Graisse / Grease

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5



TECHNICAL CHARACTERISTICS

3433 en - 06. 2007 / eLEROY-SOMER

2 - TECHNICAL CHARACTERISTICS 2.1 - Electrical characteristicsThe PARTNER LSA 42.2 alternator is a machine withoutsliprings and revolving field brushes, wound as "2/3 pitch";12-wire, with class H insulation and a field excitation systemavailable in either "SHUNT" or "AREP" version (see sections2.3, 2.4). Interference suppression conforms with standardEN 55011, group 1, class B.

2.1.1 - Options- Stator temperature detection probes.- Space heaters.

2.2 - Mechanical characteristics- Steel frame- End shields in cast iron- Greasable ball bearings- Mounting arrangementMD 35 : single bearing with standard feet and SAE flanges/coupling discs.B 34 :two-bearing with SAE flange and standard cylindrical shaft extension.- Drip-proof machine, self-cooled

- Degree of protection : IP 23

2.2.1 - Options- Protection against harsh environmentsh.- Air input filter, air output labyrinth cowling.Alternators fitted with air inlet filters should be derated by 5% (power)To prevent excessive temperature rise caused by cloggedfilters, it is advisable to fit the stator winding with thermalsensors (PTC or PT100)..

T1 T2 T3

T4 T5 T6

Var

isto

r

+ -Field

STATOR : 12 wires (T1 to T12 identification)

ExciterT7 T8 T9

T10 T11 T12+ -

Armature

MAIN FIELD

R 250 Voltage reference5+

6 -

Red Black

Aux. windings

Gre

en

Yel

low

Red Bla

ck

T1 T2 T3

T4 T5 T6

Var

isto

r

+ -Field

STATOR : 12 wires (T1 to T 12 identification)

Voltage reference5+

Exciter

6-

T7 T8 T9

T10 T11 T12+ -

Armature

MAIN FIELD

R 438

White Blue

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TP6685

Documents

Transcript of TP6685