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User and maintenance manual for generating sets

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1. Oil level gauge Crankshaft pulley Flywheel housing Oil drain I Fig 2 2 Engine right view 2 1 122 242 Chapter 2 NAME OF PARTS S4L S4L2 left view Oil filler Front aN Exhaust manifold Ne Alternator e uUJj Starter Front iis Flywheel Inl iniacti Rear hanger di Fuel injection pump CU pump Q de Coolant drain plug ii IX 2 O T g L Flywheel housing Crankshaft pulley Oil level gauge Oil drain plug Fig 2 4 Engine right view 2 2 123 242 Chapter 2 NAME OF PARTS S4L2 T left view Oil filler Turbocharger Thermostat Exhaust manifold AAA CC Sy Ra m Alternator S4L2 T right view Inlet cover Rear hanger Stop solenoid
2. The certification measures confirming that the legal emission value limits are respected are performed with certified fuels which conform to the standards and requirements stated above Resistance to low temperatures When the external temperature is low the fluidity of diesel fuel may no longer be sufficient due to paraffin deposits Also in the winter in order to avoid malfunctions for example clogged filters use diesel fuels which are fluid enough in cold weather The requirements to respect for the various geographical regions and various seasons winter summer are specified in the standards and or national regulations Petrol companies should always supply fuels with the correct flow properties regardless of the time of year In general diesel fuel is treated with additives so that the fuel can be used at low temperatures in the region where it is marketed Treating fuel with additives must respect the engine manufacturer s recommendations and maintain a suitable lubricity for the injection systems It is recommended to favour fuels whose additives have been added in a refinery over those modified in the storage tank 22 242 General specifications for diesel fuel The fuel used must have the following characteristics non exhaustive list Sulphur content Viscosity density Lubricity capacity lubrication oiliness Cetane index Water contaminants The sulphur content must meet the current emissions regulations in
3. LEROY 8 SOMER 202 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS Winding 50 Hz 60 Hz 1 phase 6 110 120 or 3 phases 120 130 NES R 220 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 110 V gt T2 6 CAI R 220 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 PARALLEL CONNECTION SERIAL CONNECTION 50 60 Hz voltage Connect L L Mm Da ne T1 T3 T2 a Connections Voltage adjustment via remote potentiometer Space heater 130C blue wire 1506 black wire 180C red white wire LEROY SOMER 9 203 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 3 3 2 Connection checks A Electrical installations must comply with the current legislation in force in the country of use Check that The residual circuit breaker conforms to legislation on protection of personnel in force in the country of use and has been correctly installed on the alternator power output as close as possible to the alternator In this case disconnect the wire of the interference suppression module linking the neutral Any protection devices in place have not been tripped If there is an external AVR the connections between the alternator and the cabinet are made in accordance with the connection diagram There is no short circuit phase phase or phase
4. Resolder the connections Fit a new O ring seal in the shield Refit the NDE shield and pass the bundle of wires between the top bars of the shield Replace the fixing clamps on the cables Replace the terminal box lid 48 housing and immobilising the stator must not be removed bolt of the stator lower LEROY 14 SOMER 208 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 4 6 5 Replacing the NDE bearing on single bearing machines 4 6 5 1 Dismantling Remove the NDE shield 36 see section 4 6 4 1 Remove the ball bearing 70 using a screw puller 4 6 5 2 Reassembly Heat the inner slipring of a new bearing by induction or in a drying oven at 80 C do not use an oil bath and fit it to the alternator Place the preloading wavy washer 79 in the flange and fit a new O ring seal 349 Replace the NDE bracket 36 see section 4 6 4 2 4 6 6 Replacing the bearings ona two bearing alternator 4 6 6 1 Dismantling Uncouple the alternator from the prime mover Remove the 8 assembly screws Remove the DE flange 30 Remove the NDE bracket see section 4 6 4 1 Remove both bearings 60 and 70 using a puller 4 6 6 2 Reassembly Fit new bearings after heating them by induction or in a drying oven at 80 C do not use an oil bath Check that both the preloading wavy washer 79 and new O ring seal have been fitted 349 on the
5. Terminal circuit 3 30mA 30mA 30mA Risk of electric shock The generating set s differential relay is factory set with a current threshold of 0 03 A 30 mA and with an automatic time delay 0 s Any change to the setting on the residual current device could pose a risk to personal safety The user will be held liable any changes must only be made by trained qualified engineers If the setting is modified it is essential to restore the original settings after use 40 242 EN 4 2 2 4 Setting the generating set differential protection The setting of the generating set s residual current device is guaranteed by a differential relay fitted near the control unit type A AC or B depending on the generating sets As a result two parameters relating to the downstream device terminal circuit must be set Current threshold the generating set s differential relay must be three times more sensitive than that of the terminal circuit Time delay the cut off of the generating set s differential relay must be longer than that of the terminal circuit Type A AC differential relay gt Use Differential relay for which operation is guaranteed e for residual sinusoidal alternating currents e for continuous pulsed residual currents e for continuous pulsed residual currents with a continuous component of 0 006 A with or without phase check independent of the polarity gt Setting 123456 7 LO 4 Use a s
6. Interference suppression conforms with standard EN 55011 group 1 class B 2 1 1 Electrical options Stator temperature detection probes Space heaters 2 2 Mechanical characteristics Steel frame End shields in cast iron SHUNT version MAIN FIELD Exciter Armature AREP version MAIN FIELD Exciter Armature Greasable ball bearings Mounting arrangement MD 35 single bearing with standard feet and SAE flanges coupling discs B34 two bearing with SAE flange and standard cylindrical shaft extension Drip proof machine self cooled 2 1 1 Mechanical options Protection against harsh environmentsh Air input filter air output labyrinth cowling Alternators fitted with air inlet filters should be derated by 5 power To prevent excessive temperature rise caused by clogged filters itis advisable to fit the stator winding with thermal sensors PTC STATOR 12 wires T1 to T12 identification T1 T7 T2 18 T3 T9 T4 T10 TS T11 T6 T12 e Voltage reference STATOR 12 wires T1 to T 12 identification Aux windings ES T2 T8 T3 T9 T4 T10 TS 111 T6 T12 Voltage reference LEROY SOMER 199 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 3 INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electri cal hazards 3 1
7. Ph 1 Ph 2 Ph 3 PE Ground connected to earth T Neutral earth Ground earth A Equipment Figure 15 TT earthing system The alternator neutral is earthed the grounds of the user equipment have their own earth connection 39 242 4 2 2 3 Installing the differential protection The generating set is equipped with a residual current device in order to guarantee individuals are protected from electric shocks with the TT system This may be fixed vigi unit or adjustable Resys depending on the option chosen Ifthe generating set s residual current device is fixed and the activation threshold is set to 30 mA it is guaranteed to protect people If the generating set s residual current device is fixed and the activation threshold has been set at 300 mA a 30mA residual current device must be added to each of the circuit outlets in use If the generating set s residual current device is adjustable located upstream this must be above those devices located downstream terminal circuits this means that continuity on clean circuits will be maintained in the event of a fault on one of the terminal circuits see the following point on setting the residual current device Example Generating set 0 3A Generating sets residual 300mA current device Residual current device Residual current device Residual current device 0 03A Terminal circuit 1 0 03A Terminal circuit 2 0 03A
8. 1 y PR ame ame sam sama ame amme ame amn sam same ome same ame oam mn a A A Risk of electric shock The generating set s differential relay is factory set with a current threshold of 0 03 A 30 mA and with an automatic time delay 0 s Any change to the setting on the residual current device could pose a risk to personal safety The user will be held liable any changes must only be made by trained qualified engineers If the setting is modified it is essential to restore the original settings after use 42 242 4 2 2 5 Earthing the generating set A RISK OF ELECTRIC SHOCK Before use the generating set must always be earthed Protection against electric shocks is only effective once the earthing connection has been made Disconnect the battery leads starting with the negative lead or use the battery isolating switch before carrying out any operations on the generating set 1 Open the access door to the cable router flap and to the connection terminal box no 1 2 Connect the earth cable supplied to the terminal no 2 on the generating set located on the connection terminal box 43 242 Nature of ground Length of earthing rod in metres 3 Check the length of the earthing rod depending on the nature of the ground and adapt if necessary Thick arable land damp 4 compact backfill The equipment supplied is not suitable for Thin arable land gravel rough D bare stony soils d
9. AUTOMATIC STOP Operation mode operation in AUTO mode IN PROGRESS Genset cooling in progress Countdown of the Engine Stop delay cooling OR G10 COOLING Gradual Stop delay Water temperature OR Overload Gradual Stop delay OR No Load Test 1min30 delay Date and time depending on settings 24 08 2005 COUPLING Operation mode operation in AUTO mode IN PROGRESS Synchronisation of the genset with the grid or another genset Date and time depending on settings 24 08 2005 POWER TRANSFER Grid Generating set Operation mode operation in AUTO mode FIR Transfer of power from the generating set to the grid M Date and time depending on settings 24 08 2005 POWER TRANSFER Grid Generating set Operation mode operation in AUTO mode Transfer of power from the grid to the generating set Date and time depending on settings 74 242 Generating set stoppage G 11 STOPPAGE Genset stoppage IN PROGRESS Date and time depending on settings 24 08 2005 Change of operation mode switch from MAN mode to AUTO mode when an automatic start demand is issued AUTOMATIC start demand Do you want to switch G12 to AUTO mode Operation mode operation in MAN mode IMPORTANT AUTOMATIC start demand Immediate start OK Esc Generating set stop demand if a fault occurs or if STOP is pressed in AUTO mode MAN mode activated l Operation mode operation in AUTO mode genset G13 to AUTOMATIC mode Warning message fo
10. If the starter is dusty blow dirt using compressed air Note If the starter is defective consult a dealer of Mit subishi Heavy Industries Ltd Alternator Inspect Visually check the alternator for damage If the alternator is dusty blow foreign material using Altemator compressed air Remove the belt and check that the movement is smooth when rotating the pulley by hand Note If the alternator is defectiv e consult a dealer of Mitsubishi Heavy Industries Ltd Fig 8 30 Alternator Inspect 171 242 Chapter 9 LONG TERM STORAGE Long term storage The following describes how to store the engine in a non operable condition for 3 months or more and in an opera ble condition for 3 months or more If the engine has been left unattended for 3 months or more the internal engine parts can rust and that may cause damage to the engine When storing the engine for an extended period of time be sure to follow the directions below Storing the engine in a non operable condition for 3 months or more ig ple for storage Drain the engine oil in use pour new oil Prepare a fuel mixture containing 50 rust preventive oil NP 9 and fill the fuel tank with it Operate under non load minimum engine speed for 5 to 10 minutes BON Immediately before stopping the engine spray volatile corrosion inhibitor VCI through the inlet port to prevent rust on the air intake system With the engine stopped drain the fuel mix
11. Note After setting the excitation ceiling as described adjust the voltage again see section 2 1 1 In some countries itis a legal requirement to have a short circuit current of 3 IN so as to offer selective protection 3 2 3 Special type of use WARNING Excitation circuit E E must not be left open when the machine is running AVR damage will occur 3 2 3 1 R438 field weakening SHUNT The exciter is switched off by disconnecting the AVR power supply 1 wire X1 or X2 Contact rating 16 A 250V A C 3 2 3 2 R438 field weakening AREP PMG The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxi liary winding contact rating 16 A 250V A C Connection is identical for resetting the AVR internal protection In case of using the de excitation pro vide a forced excitation 3 2 3 3 R438 field forcing 400V 10A pg Diode Exciter field Forced excitation Time Guaranteed voltage build up Parallel operation de energized Parallel operation at standstill Frequency starting Sustained voltage on overload LEROY SOMER 11 237 242 LEROY SOMER R438 3 3 Electrical faults Action A V R Effect Check Cause No voltage at no load on start up Connect a new battery of 4 to 12 volts to terminals E and E respecting the polarity for 2 to 3 seconds The alternator builds up and its vo
12. ON pe AN AN Figure 17 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 OO 000 6 2 1 1 Introduction to pictograms The pictograms are as follows Operating temperature Symbols for electric and mechanical sizes Overspeed Non starting fault ere Starting on external command g Battery Preheating __ gt Air intake x _ Delay Oil pressure Figure 18 View of pictograms The fuel level pictogram is used to display the fault the alarm and the fuel level The operating temperature and oil pressure pictograms are used to display the fault and analog value 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 VVVV 54 242 EN 6 2 2 Manual starting A Check that the generating set circuit breaker has triggered 0 connect the generating set battery 0 turn the key switch to the ON position without forcing it All of the LEDs light up for 2
13. all gt 6 enero etl ene eee os 78 6 3 4 3 ACtiVatIOn Ol an ala hin arid al see readin atc eee OS e rd o e Gt 79 6 3 4 4 ENGine taul codes dl PV A sede 80 6 3 4 5 o O sees E 81 Te Mamenance S CCUG Gucest cance srsag eters hence Meare ate cat llei taS 81 7 1 A A In O A A A O eaten anee 81 L2 Mantenance sde INStTUCIONS enii ea aa a a tii 81 7 3 Table Of MANICURA ista 82 7 4 COVEMMAINISM AN CS tencia 83 1 5 TEME IMAI ANC a edo 83 7 6 Fe CLUE A A EAE ERE TE E E ead eam A T ATEA E eee 84 7 7 No load apa underload testa io a A 84 Ree SEL aE EME E E E N E A O P E A E E E E E E E E E A AS E E E E T E EE E 85 8 1 Ghecking the electrolyie lev l orinar ad 85 8 2 Gheckiing he voltage ad ea ie vend ed 85 8 3 Enargma me Dalley sei daa 86 8 4 Cleaning me Dale Viatri dies a dele 86 8 5 A cence bacnceeee cent acuta cee eal aE an varie ess au eeiesehd camietiea ake Naan eus eure elmer lee eearsea beeen semen 87 OD SC TNO IVS assed et da leaks O A Re satan omnis 88 9 1 GA RSC STACY so set ae ri id dolia ble 88 9 2 A A Si Re ere RT PRT eee tee 91 9 3 A steed eax aceite a naeencecie tel a sae autch sec teectacen a A e a 91 O APEC rs SS E EE ee eee een re ee eee ete ee 93 10 1 Appendix A Engine user and maintenance Manual ccccseecccceeeeeceeeeecceseecceueeeceueeeeseueeessaueeessaseeeseeeeeessaueeesseeeesseneeeens 93 10 2 Appendix B Alternator user and maintenance Manual occcoccnccccnccocnnccnnnconnncnn
14. ccccccccnnccccccoccncnnns 8 9 Oller ci do 8 9 Radiator filler Cap 8 10 Coolant drain cock radiator 8 10 Coolant drain plug engine 8 11 Radiator coolant level 8 12 Reserve tank 2 0 eeeesceeeeeeeesseeeeeeeees 8 12 Radiator fins Clean aeeoea 8 13 Air cleaner Check 0 seeeeeeeees 8 14 Turbocharger Inspect 8 14 Pre cleaner Clean ooooccccccccccccccnnccnnno 8 15 Air cleaner element Remove 8 16 Air cleaner element Clean and A A a 8 16 Air cleaner Check cccoocccccccconccnccco 8 16 Battery electrolyte level Inspect 8 17 Specific gravity of battery electrolyte A E a AAE E E TE A ETE 8 17 Starter InSpeCt oooonnnncccccncnnccccncnnnnnnos 8 18 Alternator INSpecCt cocccoonncnccconccncnc 8 18 O E 10 1 Engine s center of gravity standard specification 10 1 CONTENTS List of tables Table 3 1 Table 3 2 Table 3 3 Table 4 1 Table 5 1 Table 6 1 Table 6 2 Table 6 3 Table 7 1 Table 8 1 Table 9 1 Table 11 1 Table 11 2 Table 11 3 Table 11 4 Table 11 5 Table 11 6 Table 11 7 Table 11 8 Table 11 9 Table 12 1 Preheat duration automatic grow plug cccccooooocconn 3 4 Preheat duration manual grow plug 3 4 Standard values at rated speed 3 6 Recommended limit and use lim
15. Sl A rd ms Ay 8 SAT OCHOA Fuel filter HA In Crankshaft pulley Oil drain plug Fig 2 6 Engine right view 2 3 124 242 Chapter 2 NAME OF PARTS Equipment and instrument The installed equipment and shapes differ on the engine type Starter switch The starter switch is used to start the engine HEAT When the key is turned to this position the glow plugs 7 START become hot and allow easy startup of a cold engine lt OFF When the key is turned to this position power supply to the electric circuits is cut off and the key can be removed and inserted at this position To sotp engine turn the key to this position ON When the key is at this position power is supplied to Fig 2 7 Starter switch the electric circuits After the engine starts the key is set to this position START When the key is turned to this position the starter cranks the engine and the engine starts When the key is released ti automatically returns to the ON position Preheat indicator The preheat indicator shows the condition of the glow plugs Automatic glow type The preheat lamp is on during the set periods of the w QA glow timer and off when the preheating is completed NS J Manual glow type o ones The glow signal turns red to indicate the preheating Glow lamp condition as the glow plug is heated Manual glow type Glow signal Fig 2 8 Preheat indicator 2 4 125 242 Chapter 2 NAME
16. Using the equipment Before starting any operations on the equipment gt Nominate an operations manager gt The role of the operations manager is to monitor either directly or indirectly any operations performed on the equipment and to ensure that the safety and operating instructions are respected gt The operations manager should read and understand all the documentation supplied with the equipment Information for personnel gt Regularly reiterate the safety and operating instructions to the operating personnel gt Contact your dealer if you have any questions regarding the equipment and any training requests for personnel gt Make the manufacturer s instructions available to the users if possible on site Protection for individuals and equipment gt Wear suitable clothing gt Move away from equipment in operation v Ensure that persons who are not authorised to intervene as well as animals are kept away from the equipment Observe this guideline regardless of whether the equipment is in operation or stopped Protect the equipment from any fluid splashes and bad weather Before starting the equipment refit the protective covers and close all the access doors Before starting the engine check that the air filter is present and the correct extraction circuit for the exhaust gas Respect the current regulations relating to fuel use Under no circumstances use seawater or any other corrosive or electrolyt
17. nrs at 230 C 55 carbonization or less Fed 791B 446 F 48 hrs at 180 C Aromatics substances by HPLC 35 by volume or less total of aromatic components Polycyclic aromatic content 8 by volume or less oe Asphaltene 0 1 weight or lower 139 242 Chapter 4 FUEL Table 4 1 Recommended limit and use limit of fuel property Properties Recommended limits Test method Foreign materials JIS B 9931 2000 foreign materials at engine fuel 5 0 mg liter or less ISO 4405 inlet Lubricity MWSD Measured mean 460 um 0 02 in or less a iene calculated wear scar diameter at ISO 12156 1 WS 1 4 kPa 0 0143 kgf cm 0 2031 psi perature BDF quality shall meet JIS K 2390 JIS K 2390 2008 EN14214 or ASTM D6751 FAME for aire peed FAME Fatty BDF blending of 5 by volume or less is approved mixture y Except in cases the value is specified ASTM D 6751 by the emission control EN 14214 Note When using fuel less than use limits white smoke worsening start up or unstable rotation may occur 4 3 140 242 141 242 Chapter 5 ENGINE OIL Recommended engine oil CAUTION Use only the engine oils recommended in this manual Never use other oils The use of inappropriate or inferior oils will result in sticking of piston rings seizure between piston and cylinder or premature wear of bearings and moving parts and significantly shortens the service life of the engine Many oil standards which are establish
18. 4 POLES ALTERNATORS 1 RECEIPT 1 1 Standards and safety measures Our alternators comply with most international standards See the EC Declaration of Incorporation on the last page 1 2 Inspection On receipt of your alternator check that it has not suffered any damage in transit If there are obvious signs of knocks contact the transporter you may be able to claim on their insurance and after a visual check turn the machine by hand to detect any malfunction 1 3 Identification The alternator is identified by means of a nameplate fixed on the machine see drawing Make sure that the nameplate on the machine conforms to your order The machine name is defined according to various Criteria for example LSA 40 S4 J6 4 e LSA name used in the PARTNER range M Marine C Cogeneration T Telecommunications e 40 machine type e S4 model LSA Date N Hz Min 1 R P M Protection Cos P F Cl ther Th class R gulateur A V R Altit _ m Masse Weight RItAV D E bearing RItAR N D E bearing Graisse Grease Valeurs excit Excit values _ en charge full load po vide atnoload e J excitation system C AREP J SHUNT e 6 4 winding number number of poles 1 3 1 Nameplate So that you can identify your machine quickly and accurately we suggest you write its specifications on the nameplat
19. 81 242 7 3 Table of maintenance operations 20 000 h OPERATIONS S 3 years e Check the condition of battery charge e Clean the battery terminals oe aS E EA e Check condition and connections e me o e Clean with compressed air the a relays and contactors bo a SS ESA IN o e Check engine oil and coolant level e Check water bowl e Check air cleaner o e Inspect belt and adjust and belt tension e Inspect and clean solenoid fuel o pump filter e Replace fuel filter POSO AOS IA IO IES IES IES ee Replace solenoid fuel pump filter Ye y Inspect valve clearance eCheckglowplug A elnspectstarter elnspectalternator A y e Retighten bolts and nuts on the ae engine Clean nozzletip A nozzle elnspectturbocharger A eChangecoolant o J To T o S S S e f Alternator e Check the tightening torques e Check the general condition e Check the various electrical connections of the installation AAA E e Grease the bearings i EA After the first 50 service hours for a new or overhauled engine 82 242 7 4 Cover maintenance The sealing between the enclosure and the frame and between the frame and the retention o tank is ensured by a gasket lt is essential to replace the gasket if the enclosure has been removed IMPORTANT Users must maintain the enclosures and base frames to ensure that the paintwork retains all its protective properties 7 5
20. Refer to Fuel system Bleed air 8 3 8 2 155 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system Bleed air When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire When cleaning or replaceing the parts of fuel system perform air bleeding from each parts Note Air in the fuel injection pipe and nozzle is discharged automatically by clanking of engine Fuel filter element Switching cock type Bleed air 1 Turn the fuel filter cock to AIR position 2 Feed fuel using the solenoid fuel pump 3 Return the cock to ON position when the fuel flow from overflow pipe becomes free of bubbles 4 Stop feeding fuel Cock lever Fig 8 4 Fuel filter element switching cock type Bleed air Fuel filters cartridge type Bleed air 1 Loosen air vent plug 1 of fuel filter 2 Feed fuel using the solenoid fuel pump Air vent plug 1 3 When the fuel from the air vent plug 1 becomes free of bubbles stop priming and tighten the air vent plug 1 to the specified torque Air vent plug 2 4 Loosen air vent plug 2 of fuel filter 5 When the fuel from the air vent plug 2 becomes free of bubbles stop priming and tighten an air vent plug 2 to the specified torque 6 Stop feeding fuel Fig 8 5 Fuel filters cartridge type Bleed air 8 3 156 242 Chapter 8 PERIODIC
21. has an equivalent in the J1939 standard SPN However this term corresponds more particularly to a specific component for example a sensor PID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard PPID Parameter Identifier SPN PPID corresponds to PID but is only used by VOLVO This represents the type of fault that has occurred This may be an electrical FMI Failure Mode identifier mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combination Terminology used by JOHN DEERE SPN Suspect Parameter This represents the system or component at fault for example SPN 100 Number indicates an oil pressure problem or a problem with the oil pressure sensor This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault FMI Failure Mode identifier 80 242 In the event of a fault the screen will display the following message Engine fault code Pressing OK will display fault finding information In addition appendix D 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 OK HELP For JOHN DEERE JD and VOLVO VO engines the codes displayed are SPN and FMI codes 6 3 4 5 Horn reset Depending on the settin
22. ity from lowering due to oxidation Engine oil deterioration mechanisms Engine oil deteriorates due to natural deterioration and due to the contamination The natural deteriora tion of oil has two primary causes oneis the degrada tion caused by oxidation reaction or thermo decomposition of base oil and additives and the other is the degradation in the performance due to con sumption of additives during use Contaminants such as fuel and combustion products soot water vapor or oxidation products that intrude into oil have critical influence on oil quality Soot ad heres to the oil film of cylinder wall and is scraped off the cylinder wall by the piston rirg Such soot increas es the rate of insoluble substances in the engine oil and can cause the wear of piston rings and cylinder walls 143 242 Abrasion powder in the engine oil also accelerates deterioration as it can catalyze oxidation reaction Dust and dirt entered from outside deteriorate the en gine oil as well Contamination and deterioration pro cess accelerates with operation time Deterioration products and contaminants in the en gine oil if it is a small amount are harmless as they can be dispersed in oil However if it is a large amount they become harmful Since such products and contaminants flow out of the oil pan and start to accumulate inside the piston and in the oil system they eventually lead to serious problems such as pis ton ring sticki
23. 2 7 Thermo WI Css ETS 2 7 Air cleaner indicator 2 7 Battery electrolyte level Inspect 3 1 Fuel tank oil level Check 3 2 Oil filler and Oil level gauge 3 2 Radiator filler Cap oocccccccccn 3 3 Radiator coolant level 3 3 Reserve tank coolant level 3 3 Recommended fuel ccceeeeeeeeees 4 1 Recommended engine olil 5 1 Selection of oil viscosity 5 1 GLASSY LLG ista E 6 1 Belt and belt tension Inspect and Solenoid fuel pump filter Inspect and cea meet lee ie eae 8 2 Fuel filter element switching cock type Bleed air 8 3 Fuel filters cartridge type Bleed air 8 3 Water sedimenter Bleed air 8 4 Water sedimenter Drain water 8 5 Fuel filter cartridge type Replace 8 5 Fuel filter element switching cock type Replace 8 6 Solenoid fuel pump filter Replace 8 6 CONTENTS 4 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 8 11 8 12 8 13 8 14 8 15 8 16 8 17 8 18 8 19 8 20 8 21 8 22 8 23 8 24 8 25 8 26 8 27 8 28 8 29 8 30 10 1 10 2 Engine oil drain plug oooooccccnccc 8 7 Engine oil Refill 8 8 Oil filter Change
24. 3 2 Fuel tank oil level Check Engine oil level Check For engine oil to be used refer to ENGINE OIL 5 1 1 Pull out the oil level gauge and wipe it clean using Oil filler a waste cloth Oil level gauge 2 Insert the oil level gauge fully into the oil level e gauge guide then pull out the gauge again 3 The proper oil level is between the high and low marks on the oil level gauge If the oil level is low add engine oil of the specified type 4 Install the oil filler cap after refilling P z Improper Proper 5 Check the oil pan and other area for oil leakage re Oil level gauge Fig 3 3 Oil filler and Oil level gauge 3 2 131 242 Chapter 3 OPERATION Coolant level Check Remove the radiator filler cap only after the engine Turn the cap about Stand the lever to half a turn the upright position has cooled to room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it 1 Open the radiator filler cap and check the coolant level 2 Ifthe coolant level is low add coolant to the speci fied level Always use the coolant with the same LLC concen tration Note Determine the quantities of LLC based on the coolant capacity and the LLC c
25. 4 2 Connecting the Generating Sica bs ri 38 A a r resent edema seateati on 38 4 2 2 Protecting people and equipment inina aiani a iaaa n aa ainan a an Eai EE aiani nkan EEN inea pia ana 39 4 2 2 1 EarnNNO SySlenm DINCD Encan a 39 4 2 2 2 A a R E T E E 39 4 2 2 3 Installing the differential protec a aa 40 4 2 2 4 Setting the generating set differential protectiON oooccccnccccocoonncnnnnnonononnnnnnnnnnnnonnnnnnnonononannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 41 422o Earning ine genera lla Sl eS accent a htt tule Meiers inate Ned cll salu eh hacia O 43 42 WAKING me COMEN Sit da 44 4 2 3 1 Connections Generali ON diia cule 44 4 2 3 2 Selecing ihe power cable std a A A A A A A A eae eonse 45 4 2 3 3 Connecting the generating set to the installation cccccccccoocnnnccnnncccononnncnnnnonononannnnnnnonnnnonnnnnnnnnnonononnnennnnnnnnnnnos 46 4 2 3 4 Connecting the battery or batteries to the generating Set cccccoonncnncccconcnnccnnnnnnncnnnnncnnnnnnannnnnnnnnnnnnnnnnanrrnnnnonanenaness 48 AN A 48 SA SL A A O A A 48 IL Warnings concerning Commissioning 0 A A aii AA A a 48 52 Checking the generating Set installation c oooonccnnccconnnnncconnnnnnnnoncnnnnnnnncnnnnonancnnnnonnnnnnnnnnnnrnnnnnonnnnnnnnrnnnnrnnnnnnnnnnnnnnnanennns 48 So Preparing for operation of the generating Selina litis 49 5 4 Checking the generating set before Startup cccccccssseecccceeeeeceeceeuseceeceeaeeeeesseueeeess
26. A 60 Hz Frequency Hz 60 Hz 2 3 LAM Load Acceptance Module characteristics 2 3 1 Voltage drop The LAM system is integrated in the R 438 AVR as standard Role of the LAM Load Adjustment Mo dule On application of a load the rotation speed of the generator set decreases When it passes below the preset frequency thres hold the LAM causes the voltage to drop by approximately 13 or 25 and conse quently the amount of active load applied is reduced by approximately 25 to 50 until the speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its dura tion for a given applied load or to increase the applied load possible for one speed va riation turbo charged engine To avoid voltage oscillations the trip thres hold for the LAM function should be set ap proximately 2 Hz below the lowest frequen cy in steady state LEROY 6 SOMER 232 242 LEROY SOMER Installation and maintenance R438 A V R LAM action eliminated by cutting the ST5 2 4 Typical effects of the LAM with jumper a diesel engine with or without a Voltage LAM U F only Underspeed and LAM ST5 disconnected UN ca ce Be cs 2 4 1 Voltage U f without LAM i 2 3 2 Gradual voltage return function During load impacts the function helps the genset to return to its rated speed faster thanks to a gradual increase in vol
27. INSPECTION AND MAINTENANCE PROCEDURES Water sedimenter Bleed air 1 Loosen the fuel inlet port air vent plug of water sed imenter Feed fuel using the solenoid fuel pump When the fuel from the fuel inlet air vent plug be comes free of bubbles stop priming and tighten the plug to the specified torque Loosen the fuel outlet air vent plug When the fuel from the fuel outlet air vent plug be comes free of air bubbles stop priming and tighten the plug to the specified torque Stop feeding fuel 8 4 157 242 Air bleed plug at fuel inlet side Air bleed plug at fuel outlet side Fig 8 6 Water sedimenter Bleed air Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Water sedimenter Drain water When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Clean around the water sedimenter 2 Place a fuel tray under the water sedimenter Cock 3 Turn the cock to C close position stop the flow of fuel Element 4 Remove ring nut and cup O ring 5 Drain water inthe cup and soak the element in fuel TAO O pen N Ring nut to clean 6 Install filter element and cup with careful attention to O ring and then fix with ring nut C7 7 Bleed air of water sedimenter Refer to Water sedimenter Bleed air 8 4 Fig 8 7 Water sedimenter Drain water 8 Turn the coc
28. Indication High temperature HT coolant temperature Cl indication units as per settings menu 2 F A A 0 A Battery Voltage indication rag Y c Oil Temperature Indication units as per settings O menu Genset start up or genset started or genset stoppage in progress Engine Speed Indication High temperature HT coolant temperature indication units as per settings menu Oil Pressure Indication units as per settings menu Oil Temperature Indication units as per settings menu Fuel Level Indication P3 Alternator Compound Voltage Indication Operation default screen Total Active Power Indication Alternator Frequency Indication Alternator U12 compound Voltage Indication Alternator U23 compound Voltage Indication Alternator U31 compound Voltage Indication Alternator Frequency Indication 69 242 Alternator V1 single Voltage Indication Alternator V2 single Voltage Indication Alternator V3 single Voltage Indication Alternator Frequency Indication Alternator U12 compound Voltage Indication Alternator V2 single Voltage Indication Alternator V1 single Voltage Indication Alternator Frequency Indication Alternator V1 single Voltage Indication Alternator phase 1 Current Indication Alternator Frequency Indication Alternator phase 1 Current Indication Alternator phase 2 Current Indication Alternator phase 3 Current Indication Alternator Neutral Current Indication Total Activ
29. NDE bracket 36 Replace the DE flange 30 and tighten the 8 fixing screws Check that the whole alternator is correctly assembled and that all screws are fully tightened 4 6 7 Accessing the main field and stator 4 6 7 1 Dismantling Follow the procedure for dismantling bearings see sections 4 6 6 Remove the coupling discs single bearing alternator or the DE flange two bearing alternator and insert a tube of the corresponding diameter on the shaft end or a support made according the following bellow lt lt ES al Jf ASESINO SA o Ch O ws Fd I y M A S E E ES SS J Rest the rotor on one of its poles then slide it out Use the tube as a lever arm to assist dismantling After extraction be careful with the fan Itis necessary to replace the fan in case of disassembling NOTE If intervention is required on the main field rewinding replacement of components the rotor assembly must be rebalanced LEROY SOMER 15 209 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS 4 6 7 2 Reassembly Follow the dismantling procedure in reverse order Take care not to knock the windings when refitting the rotor in the stator If you replace the fan respect the assembly guide according the following bellow Use a tube and a screw J E AO Follow the procedure for reassembling the bearings see sectio
30. Recommended LLC concentration Lowest ambient temperature Ner Type External 10 C 14 F 20 C 4 F 30 C 22 F 45 C 40 F or above or above or above or above H Pears ra o s 7 Note a If the outside air temperature is 30 C or less use GLASSY b The concentration above is based on Mitsubishi Heavy Industries Ltd genuine LLC GLASSY long life coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type For determining the accurate LLC concentration refer to the instructions for the LLC used 150 242 Chapter 6 COOLANT Importance of LLC Today s trend is toward smaller and lighter engines offering greater output lower fuel consumption and lower exhaust emission levels Conditions to which engine coolant is subjected therefore are becoming severer due to longer operat ing hours higher coolant temperature and higher cool ant circulating speed Many different materials such as steel aluminum copper solder and rubber are used in the cooling sys tem and they are also subjected to the severe condi tions described above Those materials have different ionization characteristics and this difference acceler ates corrosion through the medium of engine coolant To prevent such a problem the use of LLC that con tained the additive to prevent rust is very important Characteristics of LLC additive and important notes LLC contains several chemicals in such pro
31. Trailer maintenance When commissioning General condition of the Tyre pressure o AAA CI Efficiency of the automatic AN brake Efficiency of the parking A Check brake Braking adjustment and distribution across all wheels a drums O O O SE A Play in the clamping tube Play in the ball socket or ring A Braking control hinges and O Lubricate joints Stabilising IO Lubricate or grease the moving parts on the coupling device see lubrication point examples in the Figure 23 v Recommended lubricant general purpose grease compliant with DIN 51825 KTA 3KA No play in the hubs Figure 23 Trailer lubrication greasing points 83 242 EN 7 6 Fault finding Refer to the user manual and engine and alternator maintenance manuals appended Additionally in the event of an abnormal rise in engine temperature check that the radiator is clean 7 7 No load and under load tests Notes on operation at no load and under load When operating at no load or low load lt 30 of nominal power the operating conditions do not allow optimum running of the engine The main causes are as follows Y The low volume of fuel burned in the combustion chamber leads to incomplete combustion the resulting thermal energy means that the optimum engine operating temperature cannot be reached Y Overheated engines have lower compression ratios low compression ratio without turbocharging which are defined for full load and not suit
32. Use correct tools and perform work with utmost cau tion Be sure to accurately estimate the weight of the part being dismounted If the removed part is much heavier than you have estimated it may fall down during lifting and can result in the damage to the parts or personal injury Chapter 11 TROUBLESHOOTING Troubleshooting The starter does not crank or cranks slowly resulting in start failure Table 11 1 The starter does not crank or cranks slowly resulting in start failure Cause Remedies Check the DC fuse Faulty wire connection Check wiring connection between battery starter and starter switch a Check alternator Refer to P8 18 Insufficiently charged battery Electrical Check and adjust belt Refer to P8 1 system Check specific gravity of battery electrolyte Refer to P8 17 Faulty battery Charge battery Change battery Faulty starter or starter relay Consult a dealer of Mitsubishi Heavy Industries Ltd Oil viscosity too high Use appropriate engine oil Refer to P5 1 Lubricating a Check amount of engine oil and lubrication system system Excessive oil 9 y Refer to P3 2 Engine Rapid wear of sliding parts or Consult a dealer of Mitsubishi Heavy Industries Ltd mechanical locked The starter cranks but the engine does not start Table 11 2 The starter cranks but the engine does not start Cause Remedies Inspect fuel tank supply fuel bleed air Refer to P8 2 Run out
33. at least 30 minutes 8 2 Checking the voltage acid density Every 2 months the following checks must be performed 1 Check the density of the acid contained in the cells all the battery cells must have the same density if this is not the case the battery must be replaced 2 Check the voltage when idle Acid density Charge status Voltage when idle Observation action The results of the density and voltage measurements make it possible to define the charge status of the battery If the charge status is less than 60 the battery must be recharged 85 242 8 3 Charging the battery Highly discharged or sulphated batteries formation of whitish lead sulphate deposit on the plates which becomes hard can no longer regenerate or be charged in a generating set A discharged battery should be recharged immediately or else it will suffer irreparable damage IMPORTANT Battery charge Example of charge nore 12V 60 Ah battery 6 A charging current A Charge status 50 acid density 1 19 and voltage when idle 12 30V W ES The battery is short 30 Ah and this must be recharged Charge factor 1 2 30 Ah x 1 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required the charging current must always be 1 1 0 of the nominal capacity of the battery Recharging is complete when the battery voltage and the acid density stop increasing The power of the charger must be suitable fo
34. be closed when the alternator is not being driven 3 2 1 2 R220 field forcing 400V 10A Diode Battery B Volt Exciter field Battery must be isolated from the earth Exciter field may be at line potential LEROY SOMER 5 223 242 LEROY SOMER R220 3 3 Electrical faults No voltage at Connect a new battery no load on start up of 4 to 12 volts to terminals E and E respecting the polarity for 2 to 3 seconds A V R Effect The alternator builds up and its voltage is still correct when the battery is removed The alternator builds up but its voltage does not reach the rated value when the battery is removed Check Cause Lack of residual magnetism Check the connection of the voltage reference to the AVR Faulty diodes Armature short circuit The alternator builds up but its voltage disappears when the battery is removed Faulty AVR Field windings disconnected Main field winding open circuit check the resistance Voltage too low Check the drive speed Correct speed Check the AVR connections AVR may be faulty Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the AVR voltage pot P2 before running at the correct speed Voltage too high Adjust AVR voltage potentiometer Adjust
35. current parameters The orange LED will light up when an alarm code is displayed engine does not stop the red LED will light up when a fault code is displayed SPN and FMI codes are used in standard J1939 to identify faulty equipment SPN Suspect Parameter Number FMI Failure Mode Indicator Enter Srvccode First SPN FMI combination Alvi alv Exit Fla ai fal Last SPN FMI combination In the event that there are no active fault codes the following screen will appear Depending on the SPN FMI code refer to the attached List of engine fault codes and Engine user and maintenance manual for help on fault finding and maintenance Note that the manufacturer documents do not always stipulate the SPN used for example Volvo uses a set of codes called PID Parameter Identifier or SID System Identifier these two names relate to standards J1587 or J1979 but in the case of VOLVO engines they relate to standard J1587 These two codes find their equivalent in standard J1939 SPN The attached List of engine fault codes indicates the SPN equivalent to Volvo s SID and PID John DEERE complies with standard J1939 and uses SPN codes 61 242 E display of machine codes programmed The MDDM can display the codes of services programmed in the ECU memory These programmed service codes are useful for generating set fault finding and maintenance To display the programmed codes scroll through t
36. e AA e A e 4 A A cannes iene ss teeennedeench edo E AEEA EET 4 120 ADICON nenas bois 4 1 6 Contraindications tO US Ospino ro sosittisaos 4 2 TECHNICAL CHARACTERISTICS nociones eibn 5 2 1 Ele trical characteristiCS etario era 5 2 2 Mechanical characteristics rms siii 5 gt INSTALLATION cascara clas poleas 6 e EOI EE T 6 3 2 Checks prior to first use sicario ies T 3 3 Terminal connection UAC FAIS rada area aaa T A nn 10 ds CNO UN nad E 10 4 SERVICING MAINTENANCE oocccccocccccncncononanononanonnnnnnnnnnnnnnnanennnarennnnrnrnnnnernnnrennnnenenannns 11 4 1 Safety measures essa ctecccsancaupdeniciaecbcenenscdensdbscecndceitedatuanseasinndeotiaantedartanectadaassoredsecbeuscds 11 4 2 Routine maintenance uni es 11 4 3 Fault GOTO COM sisi aorta 11 4 4 Mechanical defects uste 12 o Soccer etedate ceseste tec teciesaaceqeencseande2enccesasacetusasasanemeseneicedeboc ienien ani ii 12 4 6 Dismantling reassembly arial ari ici 14 4 7 Table of characteristiCS ooooncccocnnnccocnnoccnnnononcnnnancnnnonononononononnnononnnnnnnnnnnoncnnnnaninns 16 SS SPARE PARES cocida anta aa 18 5 1 First maintenance DO AING omita 18 5 2 Technical support service msrorrdiias diiniita 18 5 3 Exploded views parts list and tightening torque cooccccoccccccnccoocconcnonacnnoncncnaconononons 19 EC declaration of incorporation siinsiinacialiisrni tciridiiia ce eiiic lion 22 LEROY SOMER 3 197 242 LEROY SOMER LSA 40
37. e ara 22 SNA UE S OSCIIC alon Sn aa a a aa a a a e asa 22 232 UDCA SPCCINCAN ONS sra a a a a a R a aa 24 25 3 GOOlANE SPOCCIICANON Ss rna a A ete rete es 25 3 Hansportina the SQUIDINGIM s 25 226 coh a a a 27 3 1 Wamings concerning TAS bl a 27 3 2 Preparing TOR TAMS DOM ee characte ni il iia 27 3 3 Poad ello A A a a a a a a A taceastaree eee 27 3 3 1 Generating sets with and without AN ENCIOSULE orisii paie a a it ae E EEE E E AE a a a Ea aE 27 A E o a a E lL ole didnt 28 332 1 Hitening And nhitehing the talar arsane n asia 28 sE CNCR A a e ion cas aa iects Nhs 32 E A AEE A E R EEE A OEE E E E A EN EEEN E EE E EEEE E 32 3 4 a E E Ae ae E E E oh mance aul 33 3 4 1 Generating sets with and without AN enclosure cccccccccsseeeeecceeeeeeeeeseceeeeeesaeeeeeeeeeeeseeeeceeeesseseessseeeeeeeeseeaaasseeeeeeessaaageeeeeees 33 3 5 SAPONO es raa aa eR Re e re eee eee 34 3 5 1 Generating sets with and without an enclosure ccccccccccesseseecceeeeeaeeeeeceeeeeeeaesseeeeeeesseeeeeeeeeessseuseeseceeeeessaaseeeeeeessaaaseeeeeees 34 3 6 AANS DO a A A E a E 34 A mstallation COMME HONS cessaria a iia buda 35 4 1 WO AGING UE GENEVATING o 35 41 GMOOSING Me local eeo a EN E E E e uas 35 AND Sale QUIN UNO AN a e al E leo 36 Sun io acia ne deneraino Sii a e 36 4 1 3 1 A E ss let ro soe seekers aac See eae N 36 4 1 3 2 FOTK MIM TRUCK 22s teet a te ld tio ee e ee ian e e le o tee ol le oe 37 Ala MOVING the generating SO o tt ii 37
38. engine 2 6 127 242 Stop solenoid ETS Fig 2 12 Stop solenoid Chapter 2 NAME OF PARTS Engine protection devices The engine protection device is a device to prevent the engine from the accident by generating the alarm when abnormality occurs Stop the engine if the protection device is activated investigate the cause of abnormality and restore it When the cause of abnormality is unknown contact a dealer of Mitsubishi Heavy Industries Ltd The installed protection devices type set value or shapes varies according to the specifications Oil pressure switch The oil pressure switch activates the alarm system or stops the engine suddenly when the engine oil pres Oil pressure sure becomes abnormally low switch Thermo switch The oil pressure switch generates an alarm when the engine coolant temperature becomes high and reaches the specified temperature Air cleaner indicator The air cleaner indicator alarms with its red signal when air cleaner elements become clogged the differ ence in pressure between front air cleaner and rear air cleaner and reaches the specified value The signal indicates only and does not generate an alarm Therefore the periodic visually inspection is needed Press the reset button on the top of air cleaner indica tor and restore the signal after cleaned the air cleaner indicator or replaced with a new one Fig 2 15 Air cleaner indicator 2 1 128 242 129 242 Ch
39. engine in low gear immedi ately until the engine temperature becomes normal Then perform cooling operation for 5 or 6 minutes before stopping the engine Be sure to locate the cause of problem and cor rect it before restarting the engine Chapter 3 OPERATION Stopping CAUTION Stopping the engine abruptly while engine parts are hot due to high speed operation can be a cause for heat up of the engine parts and shorten the engine life Before stopping the engine idle the engine in low gear immediately until the engine temperature becomes normal except in an emergency Then perform cooling operation for 5 or 6 minutes before stopping the engine and inspect the whole engine Never accelerate the engine immediately before shutting it down Do not restart the engine immediately after abnormal shut down When the engine stops with alarms be sure to locate the cause of the problem and correct the problem before restarting the engine After restarting the opera tion inspect the whole engine for any abnormalities again If the engine has an abnormality repair it immediately Engine stopping method may differ depending on the specifications Follow the instructions according to the specifications of the equipment Inspection after stopping Inspect the engine for fuel oil or coolant leakage If any leakage is found repair the leakage or contact a dealer of Mitsubishi Heavy Industries Ltd 3 136 242 137 242 Chapter 4 FUEL Rec
40. envi ronmentally hazardous waste in accordance with the applicable law and regulations 118 242 When abnormality occurs MA CAUTION Do not add coolant immediately after a sudden stop due to over heating If the engine stops suddenly or if you have no choice but stop the engine suddenly due to overheating do not add coolant immediately Adding water while the engine is hot can damage parts such as cylinder heads due to a sudden drop of temperature Add coolant gradually after the engine has completely cooled Avoid immediate restart after abnormal stop If the engine stops abnormally do not restart the engine immediately If the engine stops with an alarm check and remedy the cause of the problem before restarting Sustained use of the engine without any remedy could result in serious engine problems Avoid continuous engine oper ation at low oil pressure If an abnormal engine oil pressure drop is indicated stop the engine immediately and inspect the lubrica tion system to locate the cause Continuous engine operation with low oil pressure could cause bearings and other parts to seize If belt breaks stop engine immediately If the belt breaks stop the engine immediately Con tinuous engine operation with the broken belt could cause the engine to overheat and thereby the coolant to boil into steam which may gush out from the reserve tank or radiator and you may be scalded with it 1 5 Chapter 1 BAS
41. free operation 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 Ourtechnical support service willbe pleased to provide any additional infor mation you may require The various operations described in this manual are accompanied by recommen da tions or symbols to alert the user to potential risks of accidents It is vital that you unders tand and take notice of the following warning symbols This A V R can be incorporated in a machine marked C E WARNING Warning symbol for an operation capable of damaging or destroying the machine or surround ing equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note All rights are reserved to modify the characteristics of the products at any time in order to incorporate the latest technological developments The information contained in this document may therefore be changed without notice LEROY 2 SOMER 220 242 LEROY SOMER R220 A V R CONTENTS A tere PP A O A 4 1 1 SHUNT excitation system cscccsssecicccsanatencessiancdeasaisdeexiacenessceesteseceicdbedccndedeneedenexbaidedxeue 4 LR OAN R oee E S 4 Aa EA e 4 A A eas Seats ete eae seat Ei 4 3 INSTALLATION COMMISSIONING oocccoccccconcccccncccccnnncon
42. fuel engine oil or LLC Use only specified fuel engine oil and LLC Use fuel oil and LLC specified in this manual and handle them carefully Use of any other fuel oil or LLC or improper handling may cause various engine problems and malfunc tions Obtain the MSDS issued by the fuel oil and LLC sup pliers and follow the directions in the MSDSs for proper handling Handle LLC carefully When handling LLC always wear rubber gloves and a protective face mask If LLC or cooling water contain ing LLC comes into contact with your skin or eyes or if it is swallowed you would suffer from inflammation irritation or poisoning Should LLC be accidentally swallowed induce vomit ing immediately and seek medical attention Should LLC enter your eyes flush them immediately with plenty of water and seek medical attention If LLC splashes onto your skin or clothing wash it away immediately with plenty of water Keep flames away from LLC The LLC can catch flames causing a fire Coolant containing LLC drained from the engine is toxic Never dispose of coolant into regular sewage Abide by the applicable law and regulations when discarding drained coolant Proper disposal of waste oil LLC and coolant Do not discharge waste engine oil LLC and coolant into sewerage river lake or other similar places Such a way of disposal is strictly prohibited by laws and reg ulations Dispose of waste oil LLC and coolant and other
43. is drawn in freely the protective grilles and housing are cor rectly in place the standard direction of rotation is clock wise as seen from the shaft end phase rotation in order 1 2 3 For anti clockwise rotation swap 2 and 3 the winding connection corresponds to the site operating voltage see section 3 3 3 3 Terminal connection diagrams To modify the connection change the position ofthe stator cables on the terminals The winding code is specified on the nameplate Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped LEROY SOMER 7 201 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS L L voltage Factory connection 3 phases 6 190 208 190 240 R 220 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 3 phases 380 415 380 480 R 220 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 380 V gt T2 1 phase 220 240 220 240 0 gt T1 110 V gt T4 l _ l R 438 voltage sensing Mvollage 1 2 LL voltage 0 gt T8 220 V gt T11 Winding 1 phase 1 220 240 220 240 or 3 phases 250 260 NES R 220 voltage sensing 0 gt T8 110 V gt T11 Tension LM 1 2 tension LL R 438 voltage sensing LM voltage 1 2 LL voltage 0 gt T3 1 220 V gt T2
44. of fuel blocked pipe Check fuel pipes valves Use appropriate fuel Refer to P4 1 Improper fuel property a Remove dust water impurities Refer to P8 2 Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system l Inspect and replace fuel filter Refer to P8 5 or Refer to P8 6 Clogged fuel filter l Gauze filter Clean Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd ee Check the rack movement Faulty fuel injection pump l o l Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd ir i Clean inspect and replace pre cleaner Refer to P8 15 Air intake Insufficient amount of air l p p p system Clean inspect and replace air cleaner element Refer to P8 16 Fuel control link Check Control Faulty governor l o system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Consult a dealer of Mitsubishi Heavy Industries Ltd 11 2 177 242 Chapter 11 TROUBLESHOOTING Output decrease Table 11 3 Output decrease Cause Remedies Improper fuel property Use appropriate fuel Refer to P4 1 Inspect and replace fuel filter Refer to P8 5 or Clogged fuel filter Refer to P8 6 Gauze filter Clean Consult a dealer of Mitsubishi Heavy Industries Ltd PAER
45. oooccccccconccnncccnnccnncnnnnnnonononnncnnnnoncnnnnnnnnnnnnn nor nnnnnnnnnnnnrnnnnrnnnrnnnnrnnnrrnnnnnnnnass 35 Figure 14 Points used for lifting and MOMIA ii 37 Figure TS ai Feann SM A do lid 39 Foure 16 View OF me TRON SIC rotas a A a N a A 53 Foure T7 Desciptiomro FNE LED Su a a A 54 FUT VIEW OF DIGIOOIAINS oinean E a EE E a E a O a E ta 54 Fig re 19 View 0f the front paneli sescca i E E a 64 PIQUE 20 s Descrip OMS LEDS earnen a a a 65 Figure 21 2 Close up ODU SB PONS ioma ill E liada sana ER 65 Figure 22 Description ofthe Screen Example recen a a a a e a a eel a a E E aE cies 66 Figure 23 Trailer lubrication greasing PONS 1 ia 83 3 242 1 Preface 1 1 General recommendations The information contained in this manual is taken from technical data available at the time of print In line with our policy of continually improving the quality of our products this information may be amended without warning Read the safety instructions attentively in order to prevent any accident incident or damage These instructions must be adhered to constantly In order to obtain optimum efficiency and the longest possible service life for the generating sets maintenance operations must be carried out according to the periods indicated in the attached maintenance tables If the 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 personn
46. service life of the engine Never knock or hit the element Cleaning inspecting and replacing procedure described below is a commonly used procedure Some application may be equipped with different air cleaner Remove the air cleaner cap and wing bolt Remove the air cleaner element from the body Blow compressed air 0 69 MPa 7 kgf cm 100 psi or lower onto the inside surface of the element to remove foreign materials Wing 4 To remove dust stuck on the air cleaner element blow dry compressed air onto the outside surface S Air cleaner from a distance s element Blow compressed air on the inside surface toward the outside along the pleats Then blow com pressed air on the outside and inside surface again 5 After cleaning hold the air cleaner element near a light bulb to illuminate the inside to check for de fects such as cuts pinholes or local wear 6 If any defect is found replace the air cleaner ele ment with a new one 7 Reassemble the air cleaner element as it is If defects such as cuts pinholes or local wear are found in the element or if the air cleaner indicator shows a red sign soon after the cleaned element is installed change it for new one After cleaning or replacing the air cleaner element press the reset button to reset the indicator Fig 8 26 Air cleaner Check 8 16 169 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical system Battery Inspec
47. starter switch key to ON position Table 3 1 Preheat duration automatic grow plug Specifications Water temperature Preheat duration Low water temperature 5 C 41 F or below Approx 3 seconds Quick type bimaterial High water temperature Approx 1 seconds 5 C 41 F or above Standard type Approx 6 or 10 seconds 2 After the preheat lamp goes off turn the starter key to START position and start up the engine The preheat lamp turns on at START position as well 3 Release your hand from the key when the engine starts up The key returns to ON operating position auto matically Manual glow plug 1 Turn the starter key to HEAT position The preheat duration is as follows Table 3 2 Preheat duration manual grow plug Ambient temperature Preheat duration 5 C 41 F or higher Approx 10 seconds 5 C 23 F or higher less than 5 C 41 F Approx 15 seconds less than 5 C 41 F Approx 20 seconds 2 After the preheat lamp glows turn the starter key to START position and start up the engine 3 Release your hand from the key when the engine starts up The key returns to ON operating position auto matically 3 4 133 242 Chapter 3 OPERATION Warm up operation WARNING Do not approach rotating parts during operation Entanglement by rotating parts can cause serious injury After the engine starts operate the engine in a no load condition at low idling speed for 5 to 1
48. that the ST3 frequency selection jumper is on the correct frequency setting Check whether the ST4 jumper or the remote adjustment potentiometer have been connected 3 2 Settings The machine is tested and set at the factory When first used with no load make sure that the drive speed is correct and stable see the nameplate After operational testing replace all access panels or covers The only possible adjustments to the machine should be made on the AVR 3 2 1 R 220 setting shunt system Initial potentiometer settings P4 potentiometer AVR voltage adjustment fully anti clockwise Remote voltage adjustment potentiometer centre position Run the alternator at its rated speed If the voltage does not increase the magnetic circuit should be remagnetized see section 3 3 Turn the AVR voltage adjustment potentiometer P1 slowly until the output voltage rated value is obtained Adjust the stability setting using P2 Clockwise increase the rapidity Anti clockwise decrease the rapidity 3 2 2 Special type of use WARNING Excitation circuit E E must not be left open when the machine is running AVR damage will occur 3 2 1 1 R220 field weakening SHUNT 110 OV E E Ela He el 101 to VOLT POT 1K The exciter is switched off by disconnecting the AVR power supply 1 wire O or 110V Contact rating 16A 250V alt The power supply contactor must only
49. the LCD screen gt message on graphic display example representing the circuit affected by the fault and the associated indicator if present FAULT example 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 FAULT ALARM FAULT Low coolant Level Emergency Stop 06 10 06 10 30 06 10 06 15 30 OK HELP Esc RESET OK HELP Press OK on the scrolling and selection wheel to access the help message if it is available example below 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 78 242 6 3 4 3 Activation of an alarm and a fault The appearance of an alarm and a fault causes gt The yellow and red LEDs to flash gt the related screen to be displayed example below FAULTS 1 2 Emergency Stop If several faults are present the number of faults is 25 12 05 15 30 displayed at the top of the screen Esc RESET OK LIST The faults list can be accessed by pressing OK of the scrolling and selection wheel example
50. the guide wheel handle jockey wheel 3 Place the hitching ring above the towing vehicle s hitching system After this adjustment the trailer must remain parallel to the ground Make any necessary height adjustments to the towbar using the jockey wheel to enable hitching IMPORTANT Remove the safety pin from the towbar 3 Undo the nut with the lever 4 Use the adjustable towbar handle to place the ring above the hitching system Tighten the nut to lock the towbar Fit the towbar safety pin 4 Attach the ring to the hitching system Lower the trailer by moving the jockey wheel away from the ground using its handle 5 5 Lock the jockey wheel in the towing position When in the towing position the jockey wheel must not obstruct the unlocking cable s movement trap any electrical cables IMPORTANT M3126 M3127 type trailers M3128 M3129 type trailers Position the jockey wheel at the rear Remove the safety pin from the position lock 8 Raise the jockey wheel with its handle 5 into the Remove the position lock 8 NOLENS OMIS Ae Place the jockey wheel in the towing position Loosen the jaw of the tube 7 with its lever Fit the position lock 8 Raise the tube fully Fit the safety pin in the position lock 8 HSE ne aoe In Raise the jockey wheel with its handle fully and at right angles to the towbar y 29 242 EN 6 Attach the unlocking cable
51. the region where the generating set is used For the United States and countries respecting the EPA regulation Only use Ultra Low Sulphur Diesel ULSD fuel with a maximum sulphur content of 15 mg kg for Interim Tier 4 and Tier 4 certified engines For the European Union Directive 2009 30 CE whose aim is to limit atmospheric pollution imposes the use of a diesel fuel with a very low sulphur content of 10 mg kg for non road mobile machinery In France this obligation has resulted in the development of a diesel fuel called off road diesel fuel or GNA The maximum admissible sulphur content is 10 mg kg However member states allow these diesel fuels to contain up to 20 mg kg of sulphur when they are distributed to the final users It is recommendable to avoid storing off road diesel fuel for long periods of time over 6 months The viscosity and density directly affect the performance power and fuel consumption emissions and service life of the engine A low level of viscosity and density reduces engine power and increases fuel consumption Too high a level of viscosity and density seriously reduces the service life and operation of the fuel injection system In order to maintain adequate technical and environmental performance the viscosity and density must conform to the specifications indicated in the manufacturer s instructions for the engines fitted to our generating sets In order to protect the fuel injection system agains
52. the safety guarantees in terms of load bearing capacity and of the securing devices Chock and fix the generating sets to the floor of the transport equipment Strap the generating sets to the transport equipment Select a transport route which makes it possible to travel on roads suitable for vehicles and whose quality will not damage the on board generating sets 27 242 3 3 2 Generating sets on trailers 3 3 2 1 Hitching and unhitching the trailer Jockey wheel for M3128 o wheel for and M3129 and M3127 gt ia type trailers type trailers Mana Before hitching the trailer check the hitching system on the towing vehicle this must be perfectly compatible with the trailer Towing a trailer with a non compliant device bar cables lashing etc runs the risk of serious accidents Also check That there are no incipient ruptures or significant wear on the hitching system That the locking system is working properly IMPORTANT 28 242 EN Hitching a trailer fitted with a hitching ring 1 Drive the towing vehicle or bring the trailer up to the hitching point then With the jockey wheel touching the ground place the stabiliser 1 in the top position gt Loosen the jaw of the stabiliser 2 with its lever gt Raise the stabiliser fully gt Tighten the jaw of the stabiliser 2 with its lever Remove the wheel chocks if necessary and store them Position the trailer parallel to the ground using
53. through DC voltage used monito ring apply to the terminals for connection of a potentiometer DC voltage e internal impedance 1 5 kQ e 0 5V enable a voltage setting of 10 LEROY SOMER 234 242 LEROY SOMER R438 A V R 3 INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wi ring diagram Check that the ST3 frequency selection jumper is on the correct frequency setting Check whether the ST4 jumper or the re mote adjustment potentiometer have been connected Optional operating modes e ST1 jumper open to connect the R 7310r R 734 3 phase sensing module e ST2 jumper open if rapid response time used e ST5 jumper open to suppress the LAM function 3 2 Settings The machine is tested and set at the fac tory When first used with no load make sure that the drive speed is correct and stable see the nameplate After opera tional testing replace all access panels or covers The only possible adjustments to the machine should be made on the AVR 3 2 1 R438 settings AREP or PMG system WARNING Before any intervention on the A V R make sure that the ST9 jumper is closed with AREP excitation and disconnected with PMG or SHUNT or separate excita tion a Initial potentiometer settings see table below Remote voltage adjustment potentiometer centre ST4 jumper removed 400V
54. your attention to the following 2 safety measures which must be complied with a During operation do not allow anyone to stand in front of the air outlet guards in case anything is ejected from them b Do not allow children younger than 14 to go near the air outlet guards Aset of self adhesive stickers depicting the various warning symbols is included with this maintenance manual They should be positioned as shown in the drawing below once the machine has been fully installed WARNING The alternators must not be put into service until the machines in which they are to be incorporated have been declared compliant with Directives EC and plus any other directives that may be applicable Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The informa tion contained in this document may therefore be changed without notice Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY 2 SOMER 196 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS CONTENTS 1RECGBIP Pura alot oo 4 1 1 Standards and safety MEASULES ccccssescecceeeeceesceeeeeeceusececcesecessesseeessaaesesseeneeeesas 4 A A A 4
55. 0 one hour every 12 hours is available as per ISO 3046 1 Term of use Standard reference conditions ESP PRP 40 405 Air Intlet Temp 1000m 1000m mA S L 60 relative humidity Engine data Fuel consumption 100 main power 75 main power 50 main power Fuel type High autonomy fuel tank 155 L Oil consumption 100 load Oil sump capacity Type of lubricant 18 242 EN Cooling S O Ventilator air flow 03 m3 s Alternator data e The alternator is protected against short circuits e Vacuum impregnation epoxy winding IP23 protection rating 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 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 19 242 EN 2 3 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 c
56. 0 minutes to warm up the engine Checking engine oil pressure During warm up operation check if the oil pressure is in the range of standard value 0 15 MPa 1 5 kgf cm 21 psi or more Also make sure the oil pressure gauge is operating properly Note The oil pressure gauge may indicate a higher level than normal level immediately after the en gine starts due to the low oil temperature The pressure gradually lowers to the normal level as the oil temperature rises External inspection during warm up Visually check the external view of the engine for fuel engine oil and coolant leakage or exhaust gas leak age from joints 3 5 134 242 Chapter 3 OPERATION Operation Cautions when operating Do not approach rotating parts during operation Entanglement by rotating parts can cause serious injury Do not touch any hot part of the engine such as exhaust pipes during operation or immediately after shut down A hot engine can cause burns Always provide adequate ventilation in the engine room If air supply to the engine room is not sufficient the room temperature rises and can affect engine output and performance For the first 50 hours operate the engine under a light load for break in operation Operating the engine under heavy load or severe conditions during the break in period can shorten the service life of the engine Do not turn the battery switch to OFF position when the engine is runni
57. 170 C 338 F or higher Distillation 90 Y di till t rs distillate A o 3405 temperature 330 to 380 C 626 to 716F Pour point PP 6 C 42 8 F or lower than ambient temperature o Cloud point CP Below ambient temperature ei JIS K 2288 2000 Cold filter plugging point CFPP 3 C 37 4 F or lower than ambient temperature IP 309 96 JIS K 2270 2000 Carbon residue 10 bottom oil 0 1 weight or lower 0 4 weight or lower ISO 6615 ISO 10370 JIS K 2280 1996 Cetane number 45 or higher 40 or higher ISO 5165 Cetane index new type 45 or higher 40 or higher a a 2 0 mm s 0 0031 in s or more at 30 C 86 F JIS K 2283 2000 8 0 mm s 0 0124 in s or more at 30 C 86 F ISO 3104 JIS K 2541 2003 The content Kinematic viscosity 0 2 weight or lower should be as Sulfur content Except in cases the value is specified low as the by the emission control diesel fuel ISO 4260 ISO 8754 p JIS K 2275 1996 Water content and sediment 0 1 volume or lower ISO 3733 E a JIS K 2272 1998 Ash content 0 01 by mass or less 0 03 weight or lower ISO 6245 Copper corrosion _ JIS K 2513 2000 3 hrs at 50 C 122 F Color change Copper plate No 3 or less ISO 2160 0 83 to 0 87 g cm 0 80 to 0 87 g cm JIS K 2249 1995 Density at 15 C 59 F 49 9424 to 54 3123 Ib ft3 49 9424 to 54 3123 lb ft8 ISO 3675 24 hrs at 250 C 482 F 75 carbonization or less 80 carbonization or less Caulking
58. 2 EN 6 2 3 Switching off O 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 8 press the STOP button to stop the generating set switch off the MICS Nexys 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 O LH code along with the SOS message are displayed E LI 0 17 A tif AUT ATA O A 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 Associated pictogram Oil pressure fault Indicates that the oil pressure is incorrect Y Associated pictogram Engine temperature fault Indicates that the engine temperature is too high Associated pictogram UM o b gt Lii Non starting fault Indicates t
59. 2 242 Chapter 9 LONG TERM STORAGE Using the engine after storage 1 Remove the cover from the engine 2 Connect a fully charged battery 3 Remove the covers from the starters and alternator 4 Adjust the tension of belt Note Inspect and adjust V belt tension Refer to Belt and belt tension Inspect and Adjust 8 1 5 Remove sealing tapes from the openings of the engine 6 Connect pipes Note For engine oil refer to ENGINE OIL 5 1 7 Fill the fuel tank with fuel and bleed the fuel system Note For bleeding fuel system refer to Fuel system Bleed air 8 3 8 Inspect the entire engine 9 Remove the rocker covers and lubricate the valve mechanisms 10 Run the engine with starter for approx 10 seconds while pulling the stop lever Stop the operation for approx 1 minute then repeat the operation two or three times 11 Make sure the engine oil pressure rises 12 Conduct a warm up operation for a sufficient duration Note For starting the engine refer to Starting 3 4 13 Apply load and increase the engine speed to the rated speed Storing the engine in an operable condition for 3 months or more When the engine is not operated during storage of 3 months or more internal engine parts can rust and lose oil film As a result the engine can seize when it is started after storage To prevent such a risk the engine must be oper ated periodically during storage Operating the engine for mai
60. 50 Hz Input O 380 V Voltage minimum fully anti clockwise Stability Nobel centre position Voltage quadrature droop Not set operation with C T fully anti O quadrature loop fully clockwise anti clockwise Excitation ceiling Limit of excitation and 10A short circuit current maximum minimum fully anti clockwise Stability adjustments in standalone operation b Install a D C analogue voltmeter needle dial cal 50V on terminals E E and an A C voltmeter cal 300 500 or 1000V on the alternator output terminals c Make sure that the ST3 jumper is positio ned on the desired frequency 50 or 60 Hz d Voltage potentiometer P2 at minimum fully anti clockwise e Stability potentiometer P3 to around 1 3 of the anti clockwise limit f Start the engine and set its speed to a fre quency of 48 Hz for 50 Hz or 58 for 60 Hz g Set the output voltage to the desired va lue using P2 Rated voltage UN for solo operation eg 400 V Or UN 2 to 4 for parallel operation with C T eg 410 V If the voltage oscillates use P3 to make ad justments try both directions observing the voltage between E and E approx 10V D C LEROY SOMER 9 235 242 LEROY SOMER R438 A V R The best response times are obtained at the limit of the instability If no stable position can be obtained try disconnecting or repla cing the ST2 jumper normal fast h Check LAM operation S
61. AVR monitors and corrects the alterna The PMG supplies he Ae with constant pebeta voltage by adjusting the excitation E y current voltage which is independent of the main 50 60 Hz selection via the ST3 jumper STATOR 6 wires marked T1 to T6 MAIN FIELD STATOR 12 wires marked T1 to T12 PMG SYSTEM T3 WES lO x2 21x1 22 E ov 10 220 380 o pa 4 x holes 5 8 x 175x 115 mm Slow fuse F1 250V 8A Ola ST5 ty ue m A witALAM without LAM CIA _ gt ST3 T I I T m da Frequency U50Hz 60Hz STS ra a of ID ST10 a E t LAM 13 25 J dh ra P p P1 Excitation EP53 ceiling pS ST4 Option F Y open External potentiometer ST 1 1 knee point 65 Hz for adjusting the voltage Response FA normal ST2 time ra fast A K P3 Stability N 1 3 SHUNT or separate excitation system A V R can be operated with SHUNT supply with a transformer secondary 50V or a 48V battery L LI Option R731 3 ph detection Ni in 3 ph detection ST1 open Single phase detection LEROY SOMER 231 242 LEROY SOMER R438 A V R 2 R438A V R 2 1 Characteristics Storage 55 C 85 C Operation 40 C 70 C Standard power supply AREP or PMG Rated overload current 8A 10s Electronic protection overload short cir cui
62. Assembly A All mechanical handling operations must be undertaken using suitable equipment and the machine must be horizontal Check how muchthe machine weighs see 4 7 before choosing the lifting tool During this operation do not allow anyone to stand under the load 3 1 1 Handling The generously sized lifting rings are for handling the alternator alone They must not be used to lift the genset The choice of liftinghooksorhandlesshouldbe determined by the shape of these rings Choose a lifting system which respects the integrity and the environment of the machine WARNING After handling the machine using the lifting ring snap on the plastic cover provided in the maintenance manual wallet 3 1 2 Coupling 3 1 2 1 Single bearing alternator Before coupling the machines check that they are compatible by undertaking a torsional analysis of the transmission checking the dimensions of the flywheel and its housing the flange coupling discs and offset WARNING When coupling the alternator to the prime mover do not use the fan to turn the alternator or rotor The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Make sure the machine is securely bedded in position during coupling Check that there is lateral play on the crankshaft 3 1 2 2 Double bearing alternator Semi flexible coupling Careful alignment of the machines is recommended c
63. B Intake manifold C Heat riser valve and assembly D Turbocharger supercharger systems E Charged air cooling systems 3 Exhaust gas recirculation EGR system A EGR valve body and carburetor spacer if applicable B EGR rate feedback and control system 4 Air injection system A Air pump or pulse valve B Valves affecting distribution of flow C Distribution manifold 5 Catalyst or thermal reactor system A Catalytic converter B Thermal reactor C Exhaust manifold 6 Particulate controls A Traps filters precipitators and any other devices used to capture particulate emissions B Regenerators oxidizers fuel additive devices and any other device used to regenerate or aid in the regeneration of the particulate control device C Control device enclosures and manifolding D Smoke puff limiters 7 Advances oxides of nitrogen NOx controls A NOx absorbers B Lean NOx catalysts C Selective catalyst reduction D Reductant urea fuel containers dispensing systems 8 Positive crankcase ventilation PCV system A PCV valve B Oil filler cap VI 103 242 FOREWORD 9 Miscellaneous items used in above systems A Vacuum temperature and time sensitive valves and switches B Electronic control units sensors solenoids and wiring harnesses C Hoses belts connectors assemblies clamps fittings tubing sealing gaskets or devices and mount ing hardware D Pulleys belt
64. B ports USB key connection HOST file transfer between USB key and TELYS and vice versa Connection for microcomputer DEVICE gt file transfer between PC and TELYS and vice versa gt main module power supply Protective cover 65 242 6 3 1 2 Description of the screen The screen is backlit and requires no contrast adjustments This screen is divided into 4 zones k Dae HHA zie Figure 22 Description of the screen example O Zone 1 in this zone the status of the generating set is displayed O 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 O 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 66 242 N 6 3 1 3 Description of the pictograms in zone 1 Zone 1 pictograms Display Activation conditions TES TELYS in manual mode MAN Flashing For 5 seconds when switching from MAN mode AUTO to MAN mode TELYS in automatic mode AUTO For 5 seconds when switching from MAN to AUTO mode Flashing Ge
65. ER LSA 40 4 POLES ALTERNATORS 4 4 Mechanical defects Excessive overheating of one or both bearings bearing temperature 80 C above the ambient temperature With or without abnormal bearing noise If the bearing has turned blue or if the grease has turned black change the bearing Bearing not fully locked abnormal play in the bearing cage End shields incorrectly aligned Bearing Air flow inlet outlet partially clogged or hot air is being recycled from the alternator or engine Alternator operating at too high a voltage gt 105 of Un on load Alternator overloaded Excessive overheating of alternator frame more than 40 C above the ambient temperature Abnormal temperature Misalignment coupling Too much vibration Defective mounting or play in coupling Vibrations Rotor balancing fault Engine Alternator Excessive vibration and humming noise Phase imbalance coming from the machine Stator short circuit System short circuit Misparalleling Possible consequences Alternator damaged by a significant impact Broken or damaged coupling followed by humming and vibration Broken or bent shaft end Shifting and short circuit of main field Fan fractured or coming loose on shaft Irreparable damage to rotating diodes AVR surge suppressor 4 5 Electrical faults Fault Action Effect Check Cause __ ___ The alternator builds up and its voltage is still co
66. ERVICING MAINTENANCE 4 1 Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state LN All such operations performed on the alternator should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components who must wear personal protective equipment appropriate for mechanical and electrical hazards Before any intervention on the machine ensure that it cannot be started by a manual or automatic system and that you have understood the operating principles of the system A Warning During and after running the alternator will reach temperatures hot enough to cause injury such as burns 4 2 Routine maintenance 4 2 1 Checks after start up After approximately 20 hours of operation check that all fixing screws on the machine are still tight plus the general state of the machine and the various electrical connections in the installation 4 2 2 Bearings The bearings are greased for life approximate life of the grease depending on use 20 000 hours or 3 years Monitor the temperature rise in the bearings which should not exceed 90 C above the ambient temperature Shouldthis value be exceeded the alternator must be stopped and checks carried out 4 2 3 Electrical servicing Commercially available volatile de
67. Exhaust smoke is black or charcoal 11 5 Fuel consumption is high ooocccocccncnoo 11 6 Engine oil consumption is high 11 7 Overeating acia dd 11 8 Low engine Oil pressure ecceeeeeeeeeeeee ees 11 8 When fuel has run OUt occcccccc o 11 9 Chapter 12 MAIN SPECIFICATIONS Main specificatiONS oocccooccooo 12 1 CONTENTS 3 CONTENTS List of illustrations Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 3 1 3 2 3 3 3 4 3 5 3 6 4 1 5 1 5 2 6 1 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 Engine left view cccccssseeeeseseeeeeees 2 1 Engine right Vie W ooocccnccncnccnncononcnnos 2 1 Engine left view ooccccoconcncccoonnnnns 2 2 Engine right ViOW cccccsesseeeeseeseeeeees 2 2 Engine left ViOW ccccccseeeeeesseseeeeees 2 3 Engine right ViOW cccccssseeeeeseeeeeeeees 2 3 Starter SWIICN ccesseeeeeeeeeeeeeeees 2 4 Preheat indicator ooooocncnnccconmo mo 2 4 Water temperature meter and thermo A AE A E E EE 2 5 AMM 2 5 A 2 5 SODOM cai cose eiete 2 6 Oil pressure Switch ooococccccncncnnnnns
68. IC SAFETY PRECAUTIONS Service battery Handle the battery correctly Never use flames or allow sparks to generate near the battery The bat tery releases flammable hydrogen gas and oxygen gas Any flames or sparks in the vicinity could cause an explosion Do not use the battery when the battery electrolyte level of which is below LOWER LEVEL line Sus tained use of the battery could result in an explosion Do not short the battery terminals with a tool or other metal object When removing battery always remove the plug from the negative terminal first When connecting bat tery always connect the plug to the positive termi nal first Remove all plugs then charge the battery in a well ventilated area Make sure the cable clamps are securely installed on the battery terminals A loose cable clamp can cause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the battery switch to the Open OFF position or remove the plug from the negative terminal to cut off the electrical current Battery electrolyte contains dilute sulfuric acid Care less handling of the battery can cause the loss of sight and or skin burns Also do not consume the battery electrolyte Wear protective goggles and rubber gloves when working with the battery when adding water charg ing etc lf battery electrolyte is spilled onto the skin or cloth
69. ISHI DIESEL ENGINES SL SERIES The operator and supervisor are requested to read this Oper ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance Never operate the engine or conduct maintenance work with out completely understanding this manual MITSUBISHI wo HEAVY INDUSTRIES LTD Pub No 99610 31120 97 242 INTRODUCTION This operation and maintenance manual contains detailed operation inspection and maintenance information for engines from Mitsubishi Heavy Industries Lid Please read this manual thoroughly before proceeding with operation inspection and maintenance work for correct use and servicing Failure to follow directions in this manual may result in serious accidents 98 242 FOREWORD Limited warranty Mitsubishi Heavy Indusiries Lid will repair or replace parts returned to us when we judges that the parts are defec tive in material and or workmanship after conducting inspection Mitsubishi Heavy Industries Ltd s warranty is limited to the compensation work of repair or replacement of parts The warranty coverage Is effective for the original purchaser only Those to whom ownership is later transferred are not provided with the warranty Mitsubishi Heavy Industries Ltd s makes no warranties either expressed or implied except as provided in this manual including but not limited to warranties as to market ability
70. Inspect 1 Inspect the belt visually for separation or damage If any abnormality is found replace the belt with a new one 2 Inspect belt tension deflection Push the belt downward at the midway between pulleys If the deflection is 12 mm 0 47 in the tension is correct Belt pushing force Approx 98 N 10 kgf 22 Ibf If the deflection of belt is not within the standard adjust the belt tension Belt tension Alternator side Adjust 1 Remove the belt cover 2 Loosen all retaining bolts of the alternator and ad justing plate 3 Move the alternator to adjust the belt tension 4 After adjusting the belt tension tighten all retaining bolts of the alternator and adjusting plate 5 Install the belt cover Fig 8 1 Belt and belt tension Inspect and Adjust 8 1 154 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system Fuel tank Drain water When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not remove the strainer when filling the fuel For fuel to be used refer to FUEL 4 1 Bleeding water procedure described below is a commonly used procedure Some application may be equipped with different fuel tank If fuel gets mixed with particles of foreign materials such as dust dirt or water it can cause not only decrease of output but also malfunctions of th
71. MPORTANT 4 242 1 3 Pictograms and their meanings The aim of the pictograms is as follows To draw the attention of the operator or maintenance technician to the potential dangers To explain how to act in the interest of personal safety and to avoid damaging the equipment The safety pictograms present on the equipment are explained below Important i re Important Electrical risk Je k risk of explosion Warning danger Important rotating or moving parts Important pressurised fluids Important toxic materials Important o h Important Danger automatic high temperature Y ON corrosive product start up Figure 1 Warning pictograms Entry prohibited to Jet washing prohibited unauthorised persons Figure 2 Pictograms indicating prohibited activities 5 242 Reading the manual for equipment IS compulsory Wearing suitable protective goggles and ear defenders is compulsory Wearing suitable protective clothing is compulsory Lifting Forklift required for A Battery charge required lifting must be checked Periodic maintenance compulsory Figure 3 Pictograms indicating compulsory operations Battery isolating External fuel switch L y connections Diesel fuel Drain the fuel m Inspection flap Mains supply connection prohibited before filling with water Fill the coolant w Drain the coolant Fill the oil Drain the oil Retention container Drain t
72. N Never service the pre cleaner while the engine is running Servicing the air cleaner while the engine is running can cause particles of foreign matter to enter the engine and result in rapid wear of parts leading Wash v2 Rinse to a shorter service life of the engine NX The pre cleaner is equipped to the silencer of the tur ANS Install bocharger to prevent foreign items from sucking and Dry keep the engine clean for optimum performance Be sure to clean the pre cleaner as described below Fig 8 23 Pre cleaner Clean 1 Remove the pre cleaner from the silencer and hand wash the pre cleaner with a mild detergent Rinse the pre cleaner with fresh water After drying thoroughly inspect the pre cleaner for defect If any defect are found replace the pre cleaner with a new one oN 4 After cleaning inspecting or changing the pre cleaner reinstall it to the silencer 8 15 168 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air cleaner element Clean Check and Replace When handling compressed air wear safety goggles a dust mask a hardhat gloves and other necessary protec tive gear Works without wearing proper protective gear could result in serious injuries Never service the air cleaner while the engine is running Servicing the air cleaner while the engine is running can cause particles of foreign material to enter the engine and result in rapid wear of parts leading to a shorter
73. NS RISK OF FIRE RISK OF EXPLOSION 1 Before starting the equipment move any flammable or explosive products away petrol oil cloth etc It is prohibited to put combustible materials on the hot parts of the equipment for example exhaust pipe Avoid any contact with the hot parts of the equipment for example exhaust pipe Use appropriate ventilation to allow the equipment to cool correctly Wait for the engine to stop and cool down completely before removing the radiator cap Wait for the equipment to stop and cool down completely before covering the equipment if necessary Depressurise the air oil and cooling circuits before removing or disconnecting all the fittings pipes or connected components St Se A A N Ensure that the equipment in operation is fixed in a stationary position When installing the equipment on a vehicle or other mobile equipment a study must be conducted beforehand in order to take into account the various specific uses of the generating set IMPORTANT 11 242 Fuels Respect current local regulations regarding the equipment and fuel used petrol diesel and gas Top up the engine with fuel when the engine has stopped except for equipment with an automatic filling system Smoking using a flame or producing sparks are forbidden while the fuel tank is being filled Use protection suitable against fires and explosions Pipes must be replaced as soon as their
74. OA Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Check fuel injection pump rack stroke Improper amount of injected fuel ia Consult a dealer of Mitsubishi Heavy Industries Ltd Check fan and radiator a Overheat overcooled Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Insufficient amount of air Refer to P8 16 Inlet and Check intake air pressure and leakage of intake air a Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd si Faulty governor control Consult a dealer of Mitsubishi Heavy Industries Ltd 11 3 178 242 Chapter 11 TROUBLESHOOTING Exhaust smoke is white or blue Table 11 4 Exhaust smoke is white or blue Cause Remedies Improper fuel prop
75. OF PARTS Water temperature meter and thermo unit The engine coolant temperature detected by the thermo unit is displayed by the water temperature Thermo unit meter When the water temperature meter shows 95 C 203 F idle the engine in low gear until the tempera ture becomes normal After the temperature becomes normal perform cooling operation for 5 or 6 minutes and then inspect the cooling system Fig 2 9 Water temperature meter and thermo unit Ammeter It indicates the battery charging condition while the engine is running When the battery is charged the pointer swings to the positive side When the battery is discharged the pointer swings negative side Fig 2 10 Ammeter Hour meter It indicates the operating time of the engine When performing the periodic inspection and mainte nance check the time interval with this meter OJOJOJOJ1 1 10 e O HOUR METER Fig 2 11 Hour meter 2 5 126 242 Chapter 2 NAME OF PARTS Stop solenoid The stop solenoid operates for normal shutdown of engine operation The stop solenoid moves the rack of fuel injection pump to cut the fuel and consequently stops the engine Two types of stop solenoids are available RUN OFF ETS Energized To Stop type Not energized while the engine is running Energized by a stop signal to stop the engine RUN ON ETR Energized To Run type Energized while the engine is running and de ener gized to stop the
76. PARTS GENLUB TDX 15W40 GenPARTS GENLUB TDX 15W40 Perkins Doosan GenPARTS GENLUB TDX 15W40 PORC ni GenPARTS GENLUB TDX 15W40 or Kohler 5W40 Kohler or Kohler according to the model of the engine Viscosity Viscosity is a measure of the flow resistance of a fluid The viscosity of an engine oil is expressed by 2 SAE Society of Automotive Engineers grades One grade for cold weather and one grade for hot weather The grade for cold weather appears before the letter W The 1st grade represents dynamic viscosity in cold weather namely the ability to start the engine and to prime the oil pump and therefore to lubricate the various components quickly The lower the number the more fluid the oil The 2nd grade represents the kinematic viscosity in hot weather The higher the number the thicker the film of oil when hot which aids protection and sealing The lower the number the less friction there will be in hot weather it helps to save fuel In order to ensure immediate protection when starting the engine the choice of viscosity grade when cold is essential More fluid oil is quicker to flow when oil begins to circulate through the engine It should be selected according to the ambient temperature See the table below 405 ir Sai 1 SAE T LAF Si d EME Ti E BAP OW 30 5 Il i qs 24 242 Characteristics of GENLUB TDX 15W40 oil Performance GENLUB TDX oil is a 15W40 multigrade miner
77. R14C 185 70R13 215R14C 175R14C 4 5 215 75R14C 45 TIGHTENING TORQUE WHEELS Axis of 10 Axis of 14 and 16 120 Nm 3 3 2 3 Operation The driving speed must be suited to the condition of the road and the handling of the trailer Maximal speed on road 140km h Driving at high speed causes the tyres to heat it is therefore important to stop from time to time and check them Excessive heating may cause a puncture and therefore a serious accident For reversing manoeuvres remember to lock the inertia brake Particular attention must be paid to the tightness of the wheels on new vehicles In the first few miles driving heating of the brake hubs and drums will actually reduce the wheel tightness It is therefore essential to check the tightness every 6 miles 10 kilometres until no further loosening is noted IMPORTANT The tightness check must nonetheless be carried out whenever you have towed the trailer 32 242 Lights signalling Warning lights are obligatory for on road driving Signalling must comply with regulations in force in the country of use Front reflective devices white Red rear lights direction indicators stop lights Rear reflective devices red triangle Side reflective devices orange Figure 12 Example of French signalling 3 4 Rail transport 3 4 1 Generating sets with and without an enclosure Generating sets must be transported by rail in accordance with the specific rules gove
78. REP SYSTEM MAIN FIELD Slow fuse F1 250V 8A STs ff aie with LAM without LAM ST3 mA d Frequency 50Hz 60Hz LAM 13 25 Excitation P5 3 ceiling open knee point 65 Hz Response f 1 normal ST2 time FA fast K P3 Stability Single phase detection Aux windings 10 Yellow to that of the alternator characteristic Shunt the second has a voltage in propor tion to the stator current compound charac teristic Booster effect The power supply voltage is rectified and filtered before being used by the AVR moni toring transistor This principle ensures that regulation is not affected by distortions ge nerated by the load STATOR 6 wires marked T1 to T6 STATOR 12 wires marked T1 to T12 according voltage 4 x holes 5 8 x 175x 115 mm 200 mm pros ST9 aE Ph 1 P1 ST4 Option External potentiometer for adjusting the voltage P2 1 Option R731 3 ph x A in 3 ph detection ST1 open E voltage LEROY SOMER 230 242 LEROY SOMER R438 A V R 1 2 PMG excitation system alternator winding As a result the machine veer has a short circuit current capacity and This excitation system consists of a PMG l permanent magnet generator This is fitted a e to distortions generated by a Ea i Mac e an 1 The
79. T5 closed i Vary the frequency speed around 48 or 58 Hz according to the operating frequency and check the change in voltage from that observed previously 15 j Readjust the speed of the unit to its rated no load value Adjustments in parallel operation Before any intervention on the alterna tor make sure that the speed droop is identical for all engines k Preset for parallel operation with C T connected to S1 S2 Potentiometer P1 quadrature droop in centre position Apply the rated load cos y 0 8 inductive The voltage should drop by 2 to 3 If it in creases check that V and W and also S1 and S2 have not been reversed I The no load voltages should be identical for all the alternators intended to run in pa rallel Couple the machines in parallel By adjusting the speed try to obtain 0 KW power exchange By altering the voltage setting P2 on one of the machines try to cancel or minimise the current circulating between the machines From now on do not touch the voltage set tings m Apply the available load the setting is only correct if a reactive load is available By altering the speed match the kW or di vide the rated power of the units proportionally By altering the quadrature droop potentiome ter P1 match or divide the currents 3 2 2 Max excitation setting excitation ceiling Depending on Main the mains frequency 50 60 Hz supply A Max excitati
80. User and maintenance manual for generating sets Translation of the original instructions R1 6CC 33504027301NE 2 1 CONTENTS o A eee 4 1 1 General SCO MINS UO Sist rta ltda 4 1 2 A e e Gans ans cesecae 4 1 3 Pictograms ana Meme ANN Sprinter bete 5 1 4 SMN IAS US o e ee Sole cent eel bale LOS 8 4 General Guidelines it E A A A A DI EE eee meee 8 114 2 Electrical Sale PrecaltOnS pa a a a a E A E 10 1 4 3 Safety precautions in case of electrical SHOCK cccccccseeeeececeeeceeeeeeeceeeeeeeeeeeeceeeeeeseeeseeeeeesseeesseeeeeeeessaseeeeeeeeesssaeeeseeeesesaas 11 1 4 4 Safety precautions relating to fire burns and EXPIOSIONS cccceeccccecseeeeececeeeeeeeeceeeeeeeeeseuseeeeseeeeeeeeeeseeeeeeesseaeeeeeesaaeeeeeesaaees 11 124 5 TOXICS Sk Salely precautions meid akak ae a a a a a a 13 1 4 6 Precautions for risks relating to handling PNASES cccseeccccseeecceeeecceeseecceueeeceaceeseeeeesaueeecsaeeeeseueeeesaueeessuseesseeeeessneeeseaes 14 1 4 7 Precautions forrisks relating to NOISE as casens tid wacccdeac iaceden sedate a E a i ee RE de 14 2 General CESChIDUON asane a cd sanaadeoceddasdbaamaacoastoaeds 15 21 yo e CA PE O E A Mere 15 2d PSC MIMIGAl SOCCMIGATIONS osa 18 23 Ident SES eee rns TP Peer TPO rice ne Pere E eae ree ame epee A ee E A eee ane eee 20 2 4 Fud OTS OMA eenei a aon cet E Glin weenie 15a eats fale 5 laa o al AE a se rats fle Beis 21 2 5 Ruel IUBRCaniscana COO ANTS aneen a a area cont a a
81. able for good combustion at low load All of these factors lead to choking of the engine in particular the piston rings and valves which leads to v Accelerated wear and glazing of the cylinder liners v Loss of sealing of seats and sometimes sticking of valve stems Consequently operating any turbocharged engine at low load lt 30 can only have adverse repercussions on an engine s operation and its service life Maintenance intervals will have to be shortened to accompany harsh operating conditions Shortening draining intervals among other things will enable you to change the oil more frequently which will tend to be choked with unburnt particles and contaminated with fuel Adding a load bench is generally used to limit low load phases and obtain the periodic full loads necessary to unchoke the engine Finally when operating under load we advise vigilance towards the oil breather circuit and more particularly towards engines which have the crankcase vent connected to the turbocharger inlet risk of oil or oil vapour absorption and accelerated engine speed On load tests lt is recommended to conduct an on load test on the generating set monthly for a period of around 1 hour after stabilisation of the parameters The load must be greater than 50 of nominal power ideally 80 to ensure unchoking of the engine and to obtain a decent picture of the generating set operation Off load test no load This test is not recommend
82. al fault for example interruption and low electrolyte level Incorrect battery part no Short service life The battery explodes 87 242 9 Options 9 1 Dual frequency This operation must be carried out by a qualified electrician These operations must only be carried out when the generating set is stopped until you are instructed to start up the generating set IMPORTANT e Close the battery isolating switch to turn on the TELYS 2 e Turn the supply switch of the TELYS 2 to the ON position e Press the MENU key MENU e Using the knob select 3 SETTINGS and press the knob to confirm 3 4 pH 1 ACTIONS 2 INFORMATION 3 SETTINGS 4 COUNTRY G5 OK Esc 88 242 EN e As not all the settings are available go to the 37 INSTALLER ACCESS menu to enter the code 1966 using the knob to call up the desired menus 3 SETTINGS 4 7 34 50Hz lt gt 60Hz 35 NOMINAL VOLTAGE 36 PARAMETERS 37 INSTALLER ACCESS 65 OK Esc INSTALLER ACCESS Enter password GS OK e Using the knob select 34 50Hz lt gt 60Hz and press the 3 SETTINGS knob to confirm 2 2 31 COMMUNICATION 32 FREQUENCY 33 VOLTAGE 34 50Hz lt gt 60Hz G5 OK Esc e Select and confirm the desired frequency using the 50Hz lt gt 60Hz knob to scroll and confirm 50 Hz or 60 Hz GS OK e Return to the 3 SETTINGS screen and use the knob 3 SETTINGS to select 35 NOMINAL VOLTAGE then press the 47 kn
83. al oil which meets the following specifications ACEA E3 and API CG 4 ACEA E3 oil with superior viscosity stability suited to extended oil change intervals and severe conditions of use API CG 4 oil particularly effective to meet the emissions requirements ACEA European Automobile Manufacturers Association API American Petroleum Institute Specifications Density at 15 C kg m Flash point Typical values given for information purposes TBN Total Base Number degree of alkalinity a measure of a lubricant s reserve alkalinity according to standard ASTMD 2896 This check makes it possible to assess the ability of the product to remain in service and to check the capacity of the lubricant to neutralise the acidity contained in the oil which may corrode the metallic elements of the lubricated component 2 5 3 Coolant specifications The engine s internal cooling system allows the engine to operate at a precise temperature The table below lists the coolants recommended for each engine manufacturer Make ep Mitsubishi GenPARTS GENCOOL PC 26 al a ae e Ce w e ae Com m es ae 25 242 Specifications of GENCOOL PC 26 coolant Performance GENCOOL PC 26 coolant is a ready to use cooling fluid which provides a high level of protection and is produced from an antifreeze approved by the majority of manufacturers Power Cooling concentrated antifreeze It offers the following Improved anticorr
84. apter 3 OPERATION Preparations for operation CAUTION Should an engine abnormality be observed during operation stop the engine and correct the problem or contact a dealer of Mitsubishi Heavy Industries Ltd Always conduct the following inspection before starting the engine Engine external Inspect Be sure to keep combustible materials away from the engine especially from the hot engine parts such as exhaust manifolds or the battery Check for fuel and oil leakage Clean the top surface of the battery A fire can be caused by combustible materials placed near hot engine parts If any abnormality is found be sure to repair it or contact a dealer of Mitsubishi Heavy Industries Ltd Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure that the engine and battery are clean If combustible materials or dust are found near the engine or battery remove them 2 Check the electrical wiring for such components as the starter and alternator for looseness 3 Check the entire engine for fuel leakage engine oil or coolant If leakages are found repair or contact a dealer of Mitsubishi Heavy Industries Ltd 4 Make sure the following valves plugs and cocks are open or closed tightened properly Fuel feed valve Open Coolant drain cock plug Closed Tightened Oil drain valve Closed Battery electrolyte level Inspect If battery e
85. ation plate Choose the corresponding cable size Three phase Permitted drop in voltage 5 Multi core conductors or connected single core conductors where rating 4X 1 Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C Circuit breaker rating 2 5 12 4 10 po eG Se BDB S OBR 4X 1X50 0 4X 1X50 0 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM Single phase Permitted drop in voltage 5 Multi core conductors Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C Circuit breaker 50 0 95 4 0 120 2250MCM AWG American Wire Gauge American standard for electrical cables 45 242 EN 4 2 3 3 Connecting the generating set to the installation RISK OF ELECTRIC SHOCK Before use the generating set must always be earthed Protection against electric shocks is only effective once the earthing connection has been made Disconnect the battery leads starting with the negative lead or use the battery isolating switch before carrying out any operations on the generating set 1 Open the access door to the power connection cable router flap and to the connection terminal box no 1 2 Loosen the two knobs no 2 on either side of the power connection cable router flap then slide the flap no 3 towards the outside
86. ation system Engine oil temperature is high Refer to P3 2 Consult a dealer of Mitsubishi Heavy Industries Ltd Check radiator Refer to P8 13 Cooling eCheck control system Overheatin system 9 Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd o Check oil leakage to the turbocharger Inlet and Spread oil to intake part a exhaust Consult a dealer of Mitsubishi Heavy Industries Ltd a Wear of valve operating system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Control Check control system Increase in load o system Consult a dealer of Mitsubishi Heavy Industries Ltd 182 242 Chapter 11 TROUBLESHOOTING Overheating Table 11 8 Overheating Cause Remedies Check coolant leakage Check coolant level Refer to P3 3 Low coolant level Cooling sys Faulty water pump operation Consult a dealer of Mitsubishi Heavy Industries Ltd tem Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries Ltd Check and clean radiator and radiator filler cap Faulty radiator operation Refer to P8 13 Check fuel injection pump rack stroke Control system Increase in load eCheck control system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Low engine o
87. ator user and maintenance manual 191 242 192 242 User guide and maintenance manual LEROY SOMER Alternator LSA40 4 POLES SHUNT amp AREP 4455_b 01 02 2011 339022922601_0 1 193 242 194 242 LEROY SOMER 4455 en 2011 02 b LSA 40 4 POLES ALTERNATORS Installation and maintenance 195 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased We wish to draw your attention to the contents of this maintenance manual 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 Ourtechnical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommenda tions or symbols to alert the user to the potential risk of accidents It is vital that you understand and take notice of the different warning symbols used WARNING Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment A Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel WARNING SYMBOLS We wish to draw
88. blow compressed air from the opposite direction of the normal air flow Fig 8 20 Radiator fins Clean 8 13 166 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet and exhaust systems Air cleaner Check Reset button Checking procedure described below is a commonly used procedure Some application may be equipped with different air cleaner 1 Check the air cleaner indicator for the element clog 2 Ifthe element is clogged the red signal mark is vis ible 3 Immediately clean or replace the air cleaner ele ment when the signal turns red Fig 8 21 Air cleaner Check Note For cleaning of the air cleaner element refer to Air cleaner element Clean Check and Re place 8 16 Turbocharger Inspect Check the turbocharger when the engine is cold Also make sure that the compressor wheel is not rotating before inspecting the turbocharger If the color of the exhaust gas is abnormal also inspect the turbocharger Disconnect the pipe from the air inlet side Hold the compressor wheel nut by hand and turn the wheel to check for looseness or abnormal noise Replace the Fig 8 22 Turbocharger Inspect turbocharger if looseness or abnormal noise is found Note When removing and inspecting turbocharger contact a dealer of Mitsubishi Heavy Industries Ltd 167 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Pre cleaner Clean Inspect and Replace a M CAUTIO
89. cessary Insufficient charge Short circuit in the power circuit Consumption fault Recharge the battery Check the electrical installation Acid level too low Incorrect operation from start up Reduce the acid level and fill with distilled water Repeat the operation if necessary Battery empty Recharge the battery Starting problems Battery exhausted or faulty Starting test incorrect Capacity too low Replace the battery Battery sulphated The battery has been filled with acid Acid density too high instead of water Tighten the ends of the battery cables or Incorrect electrical connection Batterv cabling incorrect replace them if necessary and replace oli the battery One or two cells release a lot of gas at high charge Faulty cell s Replace the battery Charge status too low Check the load Battery terminals melted Short circuit in the power circuit The battery discharges very quickly High self discharge for example through electrolyte contamination Replace the battery Sulphation storage of discharged battery Define the correct battery part no for the recommended use Repeated deep discharging It is recommended to charge the battery Battery stored too long without charge f using a regulator Overload High water consumption Charging voltage too high Check the charger voltage regulator Sparks after battery charging Short circuit Connection or disconnection during Replace the battery charging Intern
90. ck and io A 8 16 El ciMcalS St Miura 8 17 Starter InSpeCt ccccccnnnnccococcnnnccccnnnoconnnnnnnnos 8 18 Alternator INSpeCt ooncccccnncccconncocaconocononnnos 8 18 Chapter 9 LONG TERM STORAGE Long term storage oocccccccconnononncnonos 9 1 Storing the engine in a non operable condition for 3 months or more 9 1 Preparation for Storage ooocccccoccnccnccncnnncnnnnnos 9 1 Maintenance during Storage ccccooccnccccncccnnn 9 1 Using the engine after storage 9 2 Storing the engine in an operable condition for 3 months or more 9 2 Operating the engine for maintenance 9 2 110 242 Chapter 10 TRANSPORTATION Lifting the engine 10 1 Chapter 11 TROUBLESHOOTING General precautiOnS coocccconcnnco 11 1 Contact a dealer of Mitsubishi Heavy Industries Ltd for repair Service 11 1 Considerations before work cccconnncccccomm o 11 1 Cautions against contamination 11 1 Cautions regarding parts handling 11 1 Work safety ccccsesceceeeeeseeeeeeeeeeeseeeesseeeeeas 11 1 Troubleshooting ccoocccoccccccnnccccnnno 11 2 The starter does not crank or cranks slowly resulting in start failure occocooncccococinccncononos 11 2 The starter cranks but the engine does not O IN A 11 2 Output decrease unica 11 3 Exhaust smoke is white or blue 11 4
91. closed Keep engine surrounding area tidy and clean Do not leave combustible or explosive materials such as fuel engine oil and LLC near the engine Such substances can cause fire or explosion Remove dust dirt and other foreign materials accu mulated on the engine and surrounding parts thor oughly Such materials can cause fire or the engine to overheat In particular clean the top surface of the battery thoroughly Dust can cause a short circuit Care for fuel oil and exhaust gas leakage If any fuel oil or exhaust gas leakage is found imme diately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equipment Use explosion proof lighting apparatus When inspecting fuel engine oil coolant battery elec trolyte etc use a flameproof light An ordinary light ing apparatus may ignite gas and cause it to explode Prevent electrical wires from short circuiting Avoid inspecting or servicing the electrical system with the ground cable connected to the battery Otherwise a fire could result from short circuiting Be sure to dis connect the battery cable from the negative termi nal before beginning with the work procedure Short circuits possibly resulting in fire may be caused by a loose terminal or damaged cable wire Inspect th
92. condition demands it Oils 1 Check that the system is no longer pressurised before carrying out any procedures 2 Avoid contact with hot oil 3 Wait for the engine to stop and cool down completely before topping up the oil 4 Before starting the engine refit the oil filler cap 5 It is prohibited to cover the generating set with a fine layer of oil for anti rust protection Battery Smoking using a flame or producing sparks are forbidden close to batteries particularly when the batteries are being charged Supply gas concerns generating sets running on gas Request the user technical notes and LPG or NG safety data sheets from your gas supplier For any operation on a gas installation ask a recognised specialist to intervene Gas supply procedures must be carried out in the open air outside in accordance with local regulations in an area well away from fires people or animals Check the sealing of the gas supply circuit using soapy water with the circuit pressurised or using a leak detector Itis forbidden to smoke bring flames near or create sparks when the tank is being filled and near to the generating set 12 242 N 1 4 5 Toxic risk safety precautions DANGER EXHAUST GAS TOXIC PRODUCTS TOXIC RISK Exhaust gas Use suitable ventilation to release the exhaust gas outside and prevent it from accumulating Respect current local regulations regarding the equipme
93. coolant temperature OrOpped ccooccncccccocnnccccnccnncnnancnnnos 1 4 Be careful when handling fuel engine A eRe ne CR nS eae ar Cr an 1 5 Use only specified fuel engine oil and LLC 1 5 Handle LLC carefully oooccoooonccononncononnoo 1 5 Proper disposal of waste oil LLC and CONAM 1 5 When abnormality OCCUFS 1 5 Do not add coolant immediately after a sudden stop due to overheatino 1 5 108 242 CONTENTS Avoid immediate restart after abnormal stop 1 5 Avoid continuous engine operation at low oil DIGS SUNG ir 1 5 If belt breaks stop engine immediately 1 5 Service Dattery iienaa 1 6 Handle the battery correctly oo ccccooo 1 6 Other cations rindas 1 7 Never modify engine cccccsseeeecesseeeeseeeeeees 1 7 Observe safety rules at work site 1 7 Work clothing and protective gear 1 7 Never break Seals ccooocccocccococccoconoconinnnnoss 1 7 Perform all specified pre operation inspections and periodic INSPECTIONS cceeeeeeeeeeeeeeeeeees 1 7 Break in the engine cccccsssseeceeeeeeeeeeneees 1 7 Warm up the engine before USE 00000 1 7 Never operate the engine in an overloaded CON GION rea 1 7 Conduct cooling operation before stopping the CMON art 1 8 Protection of the engine against water entry 1 8 Properly maintain the air cleaner and
94. crewdriver to set the current threshold potentiometer 1 to 0 03 A 30 mA 2 Use a screwdriver to set the time delay Test Button potentiometer 2 to Os automatic 3 3 Test the residual current device using the Time setting potentiometer Test button on the relay 3 2 Current threshold potentiometer 41 242 Type B differential relay gt Use Differential relay for which operation is guaranteed e asin the case of type A e for residual sinusoidal currents up to 1000 Hz for residual sinusoidal currents superimposed on a pure continuous current for continuous pulsed currents superimposed on a pure continuous current for residual currents which could come from rectifier circuits e three phase half wave rectifier or a three phase full wave bridge rectifier full wave bridge rectifier between phases with or without phase angle check independent of the polarity gt Setting geom a a am am ee 1 Use a screwdriver to adjust the current threshold using the setting potentiometer 1 and the micro switcthes 4 to 0 03 A 30 mA 2 Use a screwdriver to adjust the time delay using the setting potentiometer 2 and the micro switches 4 to Os automatic 3 Test the residual current device using the Test button on the relay Test Bution 3 Sensitive area 4 white position of micro switches Time setting potentiometer 2 Current threshold potentiometer
95. d that such diagnostic work is performed at a warranty station 7 Mitsubishi Heavy Industries Ltd shall be liabldor damages to other engine components proxmately caused by failure under warranty of any warranted part 8 Throughout the engine s warranty period defined in Subsecton b 2 Mitsubishi Heavy Industries Ltd shall maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any maintenance or repairs and must be provided without charge to the owner Such use shall not reduce the warranty obligations of Mitsubishi Heavy Indus tries Ltd 102 242 FOREWORD 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified p arts shall be grounds for disallowing a warranty claim Mitsubishi Heavy Industries Ltd shall not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part 11 The Air Resources Board may request and in such case Mitsubishi Heavy Industries Ltd shall provide any documents which describe that Mitsubishi Heavy Industries Ltd s warranty procedures or policies d Warranted parts list 1 Fuel metering system A Fuel injection system B Air fuel ratio feedback and control system C Cold start enrichment system 2 Air induction system A Controlled hot air intake system
96. d up the high alkalinity causes chemical attacks on aluminum To prevent this problem proper maintenance of the coolant is required For case example rapid wear of mechanical seals in the water pump due to secondary effects of silicate gel formed Corrosion of aluminum parts after silicate is consumed Pitting and clogging of the radi ator When LLC deteriorates or when its concentration in the coolant is too low the anti corrosion performance of LLC lowers and results in the corrosion of met als Brass and solder tend to corrode faster than other metals and corrosion of these metals is said to cause water leakage and clogs Example Holes and clogs in radiator Chapter 7 MAINTENANCE SCHEDULE How to use the maintenance schedule Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation Be sure to conduct inspections and maintenance according to the maintenance schedule The maintenance schedule shows the standard service intervals If you notice any abnormalities such as abnormal noise black exhaust smoke white exhaust smoke extremely high temperature of exhaust gas abnormal vibration and fuel oil or exhaust gas leakage make sure to conduct the inspection and maintenance work regardless of rec ommended service intervals in the Maintenance schedule Note Appropriate service intervals vary depending on the usage and operating conditions as well as consumption of fuel oil a
97. e below 1 4 Storage Prior to commissioning machines should be stored away from humidity lt 90 after a long period of storage check the machine insulation section 3 2 1 To prevent the bearings from becoming marked do not store in an environment with significant vibration 1 5 Application These alternators are mainly designed to produce electricity in the context of applications involving the use of generators 1 6 Contraindications to use Use of the machine is restricted to operating conditions environment speed voltage power etc compatible with the characteri stics indicated on the nameplate e Q SM arreenarzues 2 NUIT ALTERNATORS PUISSANCE RATING Tension v Voltage O Th x Connex GE o ZAS Continue kVA N Continuous kW 40C la Secours kVA Std by 7 Do Po kW 27C Tension maxi maximum voltage A 166631 C Conforme a C E I 60034 1 According to I E C 60034 1 Cc US LEROY SOMER 198 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 2 TECHNICAL CHARACTERISTICS 1 1 Electrical characteristics The PARTNER LSA 40 alternator is generator without sliprings and revolving field brushes wound as 2 3 pitch 12 wire with class H insulation and a field excitation system available in either SHUNT or AREP version
98. e Power Indication Total Reactive Power Indication Total Apparent Power Indication Total Output Factor Indication inductive or Capacitive 70 242 Fuel Level Indication Battery Voltage indication Battery Ammeter Indication Total Reactive Power Indication Alternator U12 compound Voltage Indication Total Active Power Indication Alternator Frequency Indication P3 if genset started P3 if genset P3 if genset started P3 if genset started P11 if genset started P11 if genset P11 if genset coupled P11 if genset coupled coupled coupled po PO E oo P8 PS oo P9 PR P10 7 P10 The screen is changed using the scrolling and validation wheel When the wheel is turned clockwise the screens scroll upwards and backwards The screens scroll in a loop Example in a 3P N network after screen 7 then screen 1 and in reverse 6 3 1 6 Display of messages in zone 4 The graphic zone zone 4 is used to display messages relating to the generating set s operation These messages are as follows Initialisation of the TELYS Data displayed Initialisation of the TELYS when switching on and or when loading a configuration SERIAL No 08030010000 SOFTWARE 6 1 0 NOMINAL VOLTAGE 400V FREQUENCY 50Hz NOMINAL KW 320kW EARTH SYSTEM TNS Generating set serial number TELYS software version Alternator nominal voltage Alternator nominal frequency Nominal active power Neutral speed Bar graph indicating the scr
99. e damage to the electrical equipment IMPORTANT To connect the battery 1 Connect the red connecting cable to the positive battery terminal 2 Then connect the black cable to the negative battery terminal To disconnect the battery 1 First disconnect the black cable 2 Then disconnect the red cable 4 2 4 Overvoltage Generating sets are not equipped with devices that protect against voltage surges from atmospheric discharges or due to handling operations The company disclaims all liability for any accidents caused by these phenomena However it is possible to install surge protectors considering that this assembly does not provide complete protection 5 Installation 5 1 Warnings concerning commissioning The inspections referred to in this section enable the electrical generator set to operate Specific skills are required to carry out these operations They must only be entrusted to personnel with the necessary skills IMPORTANT Failure to follow these instructions in any way could result in malfunction or very serious accidents 5 2 Checking the generating set installation Check the position of the generating set stability mounting available space ventilation exhaust etc Check the electrical connections gt earthing gt electrical control connections gt electrical power connections gt starter battery charging system rating and voltage if fitted to the
100. e fuel system To avoid such a problem drain fuel tank as described below 1 Place a fuel tray capacity of 2 L 0 5 U S gal or Drain cock more under the drain cock of fuel tank 2 Open the drain cock of fuel tank and drain fuel at least 1 to 2 L 0 3 to 0 5 U S gal 3 Make sure that water and particles of foreign mate rials discharged with fuel Close the drain cock Fig 8 2 Fuel tank Drain water Solenoid fuel pump filter Inspect and clean When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire 1 Clean around the solenoid fuel pump 2 Check the starter key is at the OFF position Caket 3 Place a fuel tray under the solenoid fuel pump 4 Close the valve to stop fuel flow Filter 5 Remove the lower solenoid fuel pump cover 6 Soak the gaskets filter magnet and cover in fuel to a Gasket clean ey Magnet 7 Inspect if there is any damaged part and if so change it for a new one Cover 8 Put all the parts back together in a reverse way 9 Open the main valve of the fuel tank Fig 8 3 Solenoid fuel pump filter Inspect and clean 10 Turn the starter switch to the ON position 11 Make sure that solenoid fuel pump clicks and fuel starts to flow 12 Check the solenoid fuel pump for fuel leakage If leakage is found reassemble again 13 Bleed air from the fuel system
101. e fuel filter Refer to Fuel system Bleed air 8 3 ping net 6 Turnthe cock to ON position start the engine and let it idle for several minutes 7 Check the fuel filter for fuel leakage If leakage is found loosen ring nut and check O ring for dam Fig 8 9 Fuel filter element switching cock type Replace age Solenoid fuel pump filter Replace When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire 1 Clean around the solenoid fuel pump 2 Check the starter key is at the OFF position Casal 3 Place a fuel tray under the solenoid fuel pump 4 Close the valve to stop fuel flow Filter 5 Remove the lower solenoid fuel pump cover 6 Change the element for a new one Gasket 7 Inspect if there is any damaged part and if so Magnet change it for a new one 8 Put all the parts back together in a reverse way SONET 9 Open the main valve of the fuel tank 10 Turn the starter switch to the ON position Fig 8 10 Solenoid fuel pump filter Replace 11 Make sure that solenoid fuel pump clicks and fuel starts to flow 12 Check the solenoid fuel pump for fuel leakage If leakage is found reassemble again 13 Bleed air from the fuel system Refer to Fuel system Bleed air 8 3 8 6 159 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubricating syste
102. e s center of gravity standard specification 10 1 174 242 175 242 Chapter 11 TROUBLESHOOTING General precautions Contact a dealer of Mitsubishi Heavy Industries Lid for repair service Repairing a malfunctioning engine may require special equipment or involve potentially dangerous work except for relatively simple procedures such as the change and addition of fuel engine oil and coolant In the event of the engine failure contact a dealer of Mit subishi Heavy Industries Ltd Considerations before work Before troubleshooting consider possible causes of the problem and try to find out if the same problem has occurred in the past Check the parts that may be causing the problem in the most efficient order When disassembling a component pay close atten tion to the disassembly sequence so that you can reassemble the component in reverse order of disas sembly 176 242 Cautions against contamination Dust and foreign materials are the most common cause of rapid wear of parts When disassembling a component take measures to prevent dust and foreign materials from entering the component being disassembled Cautions regarding parts han dling Handle parts carefully When replacing parts use only genuine parts by refer ring to the parts catalogue Work safety Be sure to use wrenches of the correct size Using a wrench of the wrong size not only damages nuts but can also cause the personal injury
103. e terminals cables and wires and repair or replace the faulty parts before beginning with the ser vice procedure Keep fire extinguishers and a first aid kit handy Keep fire extinguishers handy and become familiar with their usage Keep a first aid kit at the designated place where it is easily accessible by anyone at any time Establish response procedures to follow in the event of fire or accident Provide an emergency evacuation route and contact points and means of communication in case of emergency 1 1 114 242 Chapter 1 BASIC SAFETY PRECAUTIONS Stay clear of all rotating and moving parts Install protective covers around rotating parts Make sure the protective covers of the engine are correctly installed Repair any damaged or loose covers Never remove the covers such as damper cover camshaft cover or rocker cover that enclose the revolving parts during operation When the engine is coupled to driven equipment be sure to provide protective covers over the parts such as the connecting belts and couplings that are exposed Never remove protective covers Check work area for safety Before starting the engine make sure no one is near the engine and tools are not left on or near the engine Verbally notify persons within the immediate area when starting the engine When the starter device is posted with a sign that pro hibits startup operation do not operate the engine Stay clear
104. ear of engine parts Insoluble Insoluble includes acid products of engine oil imper fect combustion products sludge or soot metal abra sive particles and dust Insoluble is an indication of degradation contamination of oil Dispersant detergent which is an additive in engine oil absorbs sludge particles and disperses them as fine particles in oil Total insoluble density and remain ing dispersibility can be obtained by measuring insolu ble and coagulated insoluble using chemical specialities to stop action of disperse detergent and to collect the sludge dispersed in oil by which piston ring seizure or premature wear can be prevented before it occurs 5 3 Chapter 5 ENGINE OIL Service Limits of engine oil Engine oil degrades through the use and by lapse of time To determine the timing of engine oil replacement analyze the used oil and understand the condition of oil deterio ration and oil defacement It is also required to compare the oil analysis results and the engine analysis results including inside contamination and wear condition of engine and to consider the engine operating condition The engine oil affects the engine oil quality to use the engine operating condition and the quality of fuel Analyze the used oil and understand the condition of oil deterioration and oil defacement To determine the timing of engine oil replacement the stabiration of engine is required Refer to the following table for the det
105. ed it must not exceed 10 minutes and must not be repeated without a monthly on load test This test only allows you to check for correct engine start up It does not allow you to check that the generating set is working properly 84 242 8 Starter batteries DANGER Risk of explosion or fire oxygen and hydrogen present The battery must never be exposed to any naked flames or sparks Risk of sparks forming and an explosion When fitting the battery never invert the polarities Do not short the battery terminals with a tool or other metal object Risk of injury Battery electrolyte is extremely corrosive Always protect your eyes skin and clothing when handling batteries Always wear protective goggles and gloves In the event of contact with the skin wash thoroughly with water and soap If the eyes are splashed rinse thoroughly with water and consult a doctor immediately 8 1 Checking the electrolyte level AN The electrolyte level must be approximately 10 mm above the battery plates Pa i y 1 Top up with distilled water if necessary ie all a ro 2 Pour the distilled water carefully to avoid any splashes mz ZA _ gt dB a Kae Wear protective goggles and rubber gloves when handling the battery adding water ae MO charging etc i Note some batteries requiring no maintenance form the subject of specific instructions which must be respected After the battery has been topped up it must be recharged for
106. ed through special engine tests are available to determine the quality of oil depending on the engines to which they will be applied and on operating conditions Among those standards API American Petroleum Institute service classifications are mostly used to classify Class OF Class CH 4 engine oils SAE specifies the viscosity only while the oe API service classification indicates the quality level of engine oil OIL OIL API Service API Service Classification Classification For engine lubrication oil please use API service clas sification CF Fig 5 1 Recommended engine oil Selection of oil viscosity Use the following chart to select the appropriate oil viscosity according to the ambient temperature Excessively high oil viscosity causes power loss and Temperature 39 20 10 0 10 20 30 40 50 i C F 21 4 14 82 50 68 86 104 122 an abnormal rise of oil temperature while excessively low oil viscosity accelerates wear due to inadequate lubrication and also causes a decrease in engine out Engine oil SAR viscosity put due to leakage of combustion gas Fig 5 2 Selection of oil viscosity Handling engine oil Before filling the engine with engine oil stop the engine and make sure there are no open flames and other fire hazards near the engine Leaked or spilled oil on hot surfaces or electrical components can cause a fire Wipe off any spilled oil immediately and thoroughly After filli
107. een display time 71 242 Generating set stopped MANUAL OPERATION Press START Operation mode genset in MAN mode ready to start to start Date and time depending on settings 24 08 2005 IMPORTANT Operation mode genset in AUTO mode with AUTOMATIC starting programmed start 19min30 Countdown of micro disconnection delay OR EJP for France only Date and time depending on settings 24 08 2005 AUTOMATIC OPERATION IMPORTANT Operation mode genset in AUTO mode ready to G4 7 start dame ella ur Date and time depending on settings 24 08 2005 13 12 72 242 EN Generating set start up G6 STARTING Operating phase genset starting IN PROGRESS Date and time depending on settings 24 08 2005 AIR PREHEATING Operating phase air preheating prior to genset starting Countdown of the air preheating delay 10sec Date and time depending on settings G7 24 08 2005 Generating set started AVAILABLE POWER Operating phase genset operating stable voltage whe 79 and frequency poa A Available power screen Date and time depending on settings 24 08 2005 AUTOMATIC STOP Operation mode operation in AUTO mode IN PROGRESS Power supply device opens motorised circuit breaker or changeover switch controlled by the G9 TELYS LOAD SUPPRESSION Countdown of the Mains Return delay OR Test on 1min30 load delay Date and time depending on settings 24 08 2005 13 12 73 242 EN O
108. el Aluminum Cast ae E iron Steel Brass 0 30 mg cm Test piece Solder Copper External of test piece after the Not corrosion on surface excluding between examination test piece and spacer Discoloration is OK Circulation metallic causticity 7 0to 9 0 98 2 C 208 36 Fl pH change 1 0 1000 Hr Pre alkalinit o ke y change 15 30 vol E G Properties of 50 vol P G liquid after the Precipitation 1 0 vol examination NE Not remarkable discoloration separation External of liquid and gel Density Fe Cu Al Zn Pb 6 3 148 242 Chapter 6 COOLANT Table 6 2 LLC specification Property Standard Test piece Brass 0 30 mg cm Circulation metallic causticity 0 30 mg cm 8843 C External of test piece after the Not corrosion on surface excluding between do examination test piece and spacer Discoloration is OK 30 vol E G IL 6 5 to 11 0 Properties of liquid after the pH change Maximum 1 0 examination Not remarkable discoloration separation and gel Condition of Pump seal Not trouble while the examination parts Inside of pump case and blade Not remarkable corrosion Tensile strength change 60 to 0 Elongation change 40 to 20 Silicon Volume change O to 40 Hardness change 20 to 10 External of liquid Tensile strength change 0to 10 Rubber o adaptability Acrylonitrile Elongation change 15 to 15 30 vol butadiene 115 C 239 F rubber Vol
109. el gauge guide then pull out the gauge again The proper oil level is between the high and low marks on the oil level gauge If the oil level is low add engine oil O install the oil filler cap after refilling Check the oil pan and other area for oil leakage Oil filler Oil level gauge Improper Proper Improper 50 242 Checking the coolant level over the cap and loosen the cap about a half turn or stand the lever to the upright position to release internal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it A Remove the radiator filler cap only after the engine has cooled to room temperature Place a waste cloth Turn the cap aboul Stand the lever to half a turn the upright phaitinn O Open the radiator filler cap and check the coolant level if the coolant level is low add coolant to the speci fied level Check for leaks in the cooling circuit Checking the air filter A clogged filter element limits the engine s air intake and a reduced air supply to the engine Important If the air filter is fitted with a dust control valve A press the tip of the valve to evacuate any accumulated dust particles Check the air filter clogging indicator B If the indicator is red clean the air filter 51 242 Checking the fuel filters A When handling fuel make sure there are no open flames or oth
110. el who have received appropriate training Our agents possess this qualification and can answer all of your questions They can also supply you with spare parts and other services and they have qualified staff to carry out preventive and corrective maintenance or even total reconditioning of generating sets The left and right sides can be seen from the back of the generating set the radiator is at the front Note some user and maintenance manuals for engines fitted to generating sets cover control units and include the start up and shut down procedures for the engines As our generating sets are fitted with control units that are specific to the generating sets only the information that appears in the documentation for the generating set control units should be taken into consideration In addition depending on the manufacturing criteria of the generating sets some engines may be fitted with specific electrical wiring different to that described in the engine documentation 1 2 Warnings In this manual the warning messages are used as follows A Immediate danger Indicates an imminent danger which may result in death or serious injury Failure to follow the instruction shown may pose serious risks to the health and life of those concerned Potential danger Indicates a dangerous situation if the warning is not heeded Failure to follow the instruction indicated may cause minor injuries to those concerned or damage to equipment I
111. eplace equipment that provides protection against electric shock with identical equipment specifications and nominal values Only use flexible durable cables with a rubber covering which conform to ECI 245 4 or equivalent cables Refit the protective plates blanking covers after each maintenance operation Note The electrical equipment supplied with the equipment complies with standard NF C 15 100 France or with the standards of the countries in question 10 242 1 4 3 Safety precautions in case of electrical shock In the event of an electric shock observe the following instructions 1 Avoid direct contact both with the live conductor and the victim s body 2 Shut off the power immediately and activate the emergency stop for the equipment concerned Note the live wire may be cut with an axe Take extreme care to avoid the electric arc that will be generated by this 3 If it is impossible to access the equipment move the victim away from the live conductor using a dry piece of wood dry clothing or other non conducting material Move the victim away from any situations where there is a danger of death Contact the emergency services If breathing has stopped begin artificial respiration at once aO E SS In the event of cardiac arrest carry out cardiac massage 1 4 4 Safety precautions relating to fire burns and explosions A DANGER FUELS FLAMMABLE PRODUCTS PRESSURISED FLUID RISK OF BUR
112. er fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire The fuel prefilter draining should be performed when the engine is cold and stopped Check the absence of water or sediments in the sediment bowl A of the prefilter If necessary drain by implementing the following procedure O Unscrew the draining tap B at the bottom of the prefilter by rotating two or three turns Check the absence of leak Collect the water and or the sediments in a suitable receptacle When fuel starts flowing screw and tighten the draining tap 0 If necessary fetch the fuel system again 52 242 6 2 Generator set with NEXYS control panel 6 2 1 Control panel presentation SO OVOOHOD a Figure 16 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 53 242
113. erial number and the information given on the nameplate Address your enquiry to your usual contact Part numbers should be identified from the exploded views and their description from the parts list Our extensive network of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts 18 In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage A After operational testing itis essential to replace all access panels or covers LEROY SOMER 212 242 LSA 40 4 POLES ALTERNATORS 5 3 Exploded view parts list and tightening torque 5 3 1 Single bearing AREP or SHUNT LEROY SOMER 19 213 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 5 3 2 Two bearing AREP or SHUNT ASS LEROY 20 SOMER 214 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS Description Stator assembly Description Wound exciter field Rotor assembly Field fixing screw Fan Exciter armature Earth terminal Terminal plate support DE flange Terminal plate Air outlet grille Regulator AVR N D E bracket Coupling disc Tie rod Terminal box lid Fixin
114. ermination of engine oil performance degradation If any of the following devi ate the limit replace the engine oil with new oil Table 5 1 Engine oil properties Properties Standard Test method JIS K 2283 2007 30 or less Viscosity 100 C 21 gt oF 15 or more Of new oil ie ee 2 0 or more with hydrochloric acid HCL method JIS K 2501 2003 TOIA DATE DUMOR mgKOH g 1 2 of new oil or more with perchlo ISO 3771 ric acid PCA method Total acid number mgKOH g Up to 3 0 of new oil aap 1 2008 JIS K 2265 2007 Flash point open cup C F 180 356 or higher ISO 3769 ISO 2719 ulate mm s in s 5 4 145 242 Chapter 6 COOLANT Note In this operation manual the word coolant represents the liquid combined water and LLC Recommended water for coolant Use soft water for the engine cooling system The water quality must meet the requirements in the Table below Basically the water quality should be within the recommended value however up to the limit is acceptable Table 6 1 Water quality standards Chemical Recommend ae pH 25 C 77 F yee 6 5t08 0 6 51085 alee an tae Electrical conductivity Corrosion and rust scale Total hardness Scale formation M alkalinity Scale formation Chlorine ion Corrosion and rust Sulfuric acid ion Corrosion and rust Total iron Scale formation Silica Scale formation Residue from evaporation ppm lt 250 lt 400 Scale formation Note Figures in pa
115. erty Check cetane index and use appropriate fuel Refer to P4 1 Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system ee Check ignition noise exhaust smoke temperature Uneven fuel injection l H l Consult a dealer of Mitsubishi Heavy Industries Ltd Incorrect fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Check amount of engine oil and lubrication system ad Combustion of engine oil Refer to P3 2 Consult a dealer of Mitsubishi Heavy Industries Ltd Check radiator Refer to P8 13 Cooling Check control system system Enercon Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Consult a dealer of Mitsubishi Heavy Industries Ltd 11 4 179 242 Chapter 11 TROUBLESHOOTING Exhaust smoke is black or charcoal Table 11 5 Exhaust smoke is black or charcoal Cause Remedies Use appropriate fuel Refer to P4 1 Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd ae Check exhaust smoke temperature Uneven fuel injection l a l Consult a dea
116. eseeeseeeeeseeeeees 1 1 Keep engine surrounding area tidy and clean 1 1 Care for fuel oil and exhaust gas leakage 1 1 Use explosion proof lighting apparatus 1 1 Prevent electrical wires from short circuiting 1 1 Keep fire extinguishers and a first aid kit NAR OY ora 1 1 Stay clear of all rotating and moving DAN Sinaloa dalla 1 2 Install protective covers around rotating parts 1 2 Check work area for Safety o ooonccccconnncccconm 1 2 Stay clear of moving parts while engine is A tient iibetta antes 1 2 Lockout ANC tAQOUt cccccccoccncccncccnnoconcnnnonononnnnnos 1 2 Keep engine stopped during servicing 1 2 Always restore engine turning tools after use 1 2 Changing the engine speed setting is Pron Orinando 1 2 Be careful of exhaust fume DOISO NIN Osa 1 3 Operate engine in a well ventilated area 1 3 Be careful of falling down 1 3 Lift engine Carefully cccooccocococoncconnnonono 1 3 Do not climb onto the engine occcoooccncccooc 1 3 Always prepare stable scaffold 1 3 Protect ears from noise ooccccoccccncccnn 1 4 Wear ear DIUOS ais aos 1 4 Be careful Of DUMS eaea 1 4 Do not touch the engine during or immediately alter operatividad 1 4 Do not open the radiator filler cap when the engine is A ven oiaceams inn ae 1 4 Do not touch high pressure injection fuel 1 4 Refill coolant only after the
117. finding module cannot find the default addresses an address cannot be found in the correct register Error Code 2 Passive Bus Error this code appears when the fault finding module cannot detect the ECU in this case the CAN Bus is open the CAN_hi and CAN _lo run time bus connection is reversed between the source ECU and the fault finding module Error Code 3 This code is the result of the following problems the CAN_Hi or CAN _lo bus or both are connected to an electrical ground or an external source of current data is being not transmitted at a standard baud rate This type of fault generally requires repairs to be carried out on the CAN BUS connection and therefore involves work on the engine wiring harness i e on the fault finding module extension Run Time Bus Errors Fault codes can only be active if the fault finding module has been able to obtain the network addresses when it was switched on see Address Claim Procedure Errors ACP err Error Code 1 EP Passive Error this screen appears when the fault finding module loses contact with the ECU there may be two causes of this one connector on the bus connection is disconnected the CAN Bus is open Error Code 2 BO Bus Off in this case the case is identical to Error code 3 of the ACP Error Code 3 BR Bus Reset this error code is similar to Error code 3 of the ACP as are its causes In this case the fault finding module has e
118. fuel system refer to Fuel system Bleed air 8 3 4 Restart the engine For starting the engine refer to Starting 3 4 11 9 184 242 185 242 Chapter 12 MAIN SPECIFICATIONS Main specifications Table 12 1 Main specifications ltem Specifications Engine model S3L2 S4L2 S4L2 T Vertical water cooled 4 stroke cycle Type Vertical water cooled 4 stroke cycle diesel engine turbocharged diesel engine No of cylinders fi ah arrangement 3 cylinder in line 4 cylinder in line Cylinder bore x 078 x 78 5mm q 8x 92mm O78 x 78 5 mm stroke 3 07 x 3 09 in 3 07 x 3 62 in 3 07 x 3 09 in 9 8 92 mm 3 07 x 3 62 in 1 125 L 1 318 L 1 500 L Displacement 0 3 U S gal 0 3 U S gal 0 4 U S gal 1 758 L 0 5 U S gal Conbustion type Swirl chamber Compression ratio 22 1 Firing order 1 3 4 2 Direction of rotation Counterclockwise as viewed from flywheel side Dimensions 536 x 433 x 572 mm 620 x 433 x 572 mm 620 x 452 x 640 mm L x W x H 21 10 x 17 05 x 22 52 in 24 41 x 17 05 x 22 52 in 24 41 x 17 80 x 25 20 in Dry weight Approx 140 kg 309 Ib Approx 155 kg 342 Ib Approx 174 kg 384 lb Fuel Diesel fuel equivalent for JIS K 2204 Fuel injection pump PFR type Fuel filter Cartridge or cock type paper element Fuel injection nozzle Throttle type Initial fuel injection 2 i pressure 13 73 MPa 140 kgf cm 1991 psi Lubrication method Forced circulation pressu
119. g screw Clamping washer Plug Direct diode assembly DE bearing O ring seal A A N la aa aj aj xs nz NDE bearing a a NI a l Olalla la a la Ala DE shield _ Preloading wavy washer LEROY SOMER 215 242 00 Fixing screw 21 LEROY SOMER LSA 40 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006 42 CE dated 17 May 2006 MOTEURS LEROY SOMER MLS HOLICE STLO SRO MOTEURS LEROY SOMER Boulevard Marcellin Leroy SLADKOVSKEHO 43 1 rue de la Burelle 16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517 France Czech Republic 45800 St Jean de Braye France Declares hereby that the electric generators of the types LSA 36 37 40 42 2 43 2 44 2 46 2 47 2 49 1 50 2 51 2 as well as their derivatives manufactured by Leroy Somer or on Leroy Somer s behalf comply with the following International Standards and Directive EN and IEC 60034 1 and 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with t
120. generating set 48 242 EN 5 3 Preparing for operation of the generating set Become familiar with the controls useful to operate the generating set Read and understand the user menus of the control unit Become familiar with the maintenance plans for the generating set Become familiar with the operation of the generating set at no load or under load Become familiar with the fluid specifications fuel lubricant and coolant 5 4 Checking the generating set before startup Check that the plugs blanking covers and protective adhesive strips have been removed Ensure that the anti humidity bags have been removed from the electrical sections cabinet or control console alternator etc Check the insulation of the alternator see the alternator s maintenance manual Check the levels see the engine s maintenance manual gt coolant gt oil gt fuel Open the oil filler tap if fitted to the generating set Check the starter battery or batteries connecting and charge see the paragraph entitled Starter batteries Check the starter battery charging system if fitted to the generating set 5 5 Checking the generating set after startup Off load tests Carry out the safety checks emergency shutdown oil pressure coolant temperature etc Check the mechanical parameters gt engine parameters oil pressure coolant temperature gt absence of abnormal vibrations gt absence of abnormal noises gt ab
121. greasing agents can be used WARNING Do not use trichlorethylene perchlo rethylene trichloroethane or any alkaline products These operations must be performed ata cleaning station equipped with a vacuum system that collects and flushes out the products used The insulating components and the impregnation system are not at risk of damage from solvents Avoid letting the cleaning product run into the slots Apply the product with a brush sponging frequently to avoid accumulation in the housing Dry the winding with a dry cloth Let any traces evaporate before reassembling the machine 4 2 4 Mechanical servicing WARNING Cleaning the machine using water or a highpressure washer is strictly prohi bited Any problems arising from such treatment are not covered by our warranty Degreasing Use a brush and detergent suitable for paintwork Dusting Use an air gun Ifthe machine is fitted with air inlet and outlet filters the maintenance personnel should clean them routinely at regular intervals In the case of dry dust the filter can be cleaned using compressed air and or replaced if it is clogged After cleaning the alternator itis essential to check the winding insulation see sections 3 2 and 4 8 4 3 Fault detection If when commissioned the alternator does not work normally the source of the malfunction must be identified see sections 4 4 and 4 5 LEROY SOMER 11 205 242 LEROY SOM
122. gs 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 This screen will display first any messages relating to the alarms and faults that appear as soon as OK is pressed 25 12 2005 15 30 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 Maintenance safety instructions Before each operation please observe the following maintenance safety instructions read the safety instructions carefully chapter 1 refer systematically to the maintenance instructions the battery isolating switch must be in the open position no operations must be carried out while the motor is running wear protective equipment gloves goggles safety shoes etc before operating on a pressurised circuit ensure that the circuit pressure has been reduced atmospheric pressure after the operations ensure that the equipment is clean or clean it if necessary SN NN Oe NS
123. hat there have been three consecutive unsuccessful starting attempts Associated pictogram Overspeed fault Indicates an excessive generating set running speed Associated pictogram SY tar Low fuel level fault Indicates the need to top up the fuel 56 242 EN List of faults which will cause the generating set to stop and generate a fault code Associated message 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 Additional fault linked to message opposite is displayed in the following two cases Associated message gt Differential fault 1 gt 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 Underspeed fault indicates an incorrect rotation speed below 1000 rpm Associated message Emergency stop or external emergency stop fa
124. he Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the following International Directives Machinery Directive Nr 2006 42 CE dated 17 May 2006 EMC Directive Nr 2004 108 CE dated 15 December 2004 as intrinsic levels of emissions and immunity are concerned WARNING The here above mentioned generators should not be commissioned until the corresponding Gen Sets have been declared in compliance with the Directives Nr 2006 42 CE et 2004 108 CE as well as with the other relevant Directives Leroy Somer undertakes to transmit in response to a reasoned request by the national authorities relevant information on the generator Technical Managers P Betge J Begu a gt CON 4152 en 2010 11 d LEROY 22 SOMER 216 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS LEROY SOMER 23 217 242 LEROY SOMER LEROY SOMER 4291 en 2010 11 c XN Y T1 p f O T4 VOLT _POT 1K R220 A V R Installation and maintenance 219 242 LEROY SOMER R220 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your A V R you can look forward to many years of trouble
125. he information indicated on the nameplate Part numbers should be identified from the exploded views and their description in the parts list Our extensive network of service stations can dispatch the necessary parts without delay To ensure correct operation and the safety of our alternators we recommend the use of original manufacture spare parts In the event of failure to comply with this ad vice the manufacturer cannot be held res ponsible for any damage LEROY SOMER T 225 242 LEROY SOMER 226 242 LEROY SOMER 3971 en 2010 11 f T1 T7 T4 T10 R438 A V R Installation and maintenance 227 242 LEROY SOMER R438 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your A V R you can look forward to many years of trouble free operation SAFETY MEASURES Before using your machine for the first time itis important to read the whole of this instal lation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional infor mation you may require The various operations described in
126. he parameters until you reach the following sub menus In the event that there are no programmed codes to display the following screen will appear The purpose of programmed codes is to create a fault log which is used to determine recurrent faults and thereby carry out effective corrective and preventive maintenance on the engine also it not desirable to delete these when the generating set is in operation onsite Note that at the test bench outlets the EEPROM memory in which the programmed codes are stored is reset to zero The following diagram shows the structure of the STORCODE programmed code menu and how to go to each parameter Enter ed SS No irs Codes available a e Lamp status Yes First code ay fa Aly Last code line laly Display if no codes available Exit ine 62 242 EN F Fault finding module internal errors Like any equipment using internal memory and a program the fault finding module generates fault codes Two types of code can be recognised Address Claim Procedure Errors Run Time Bus Errors Address Claim Procedure Errors ACP Err The following fault codes relate to the switching on of the fault finding module Error Code 1 When switched on the fault finding module must issue a request to the ECU for the network addresses used in order to exploit them this screen appears when an address cannot be used the fault
127. he retention high level container Figure 4 Information pictograms 6 242 Flammable product Reading the manual for the equipment is Do not smoke or create sparks or flames compulsory LPR BE ON BF e oe m men Pll LI TAA EPIA Fuel supply Selection valve Securing straps routing point Figure 5 Specific pictograms Rinse any splashes of acid on the skin or in the eyes using clean water Wearing suitable protective clothing and Consult a doctor immediately goggles is compulsory Wash contaminated clothing with water Figure 6 Pictograms relating to battery operations 7 242 EN 1 4 Safety instructions RETAIN THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set and batteries IMPORTANT SAFETY ADVICE If any parts of this manual are not understood or in case of doubt contact your nearest agent in order to receive an explanation or demonstration to allow the equipment to be used correctly The guidelines listed below must always be respected to ensure the safety of personnel and equipment In addition to this information it is essential to refer to the local and national regulations applicable according to the jurisdiction 1 4 1 General guidelines Installing the equipment The installer of the equipment must create a document describing any modifications made to the equipment during installation
128. hecking that the lack of concentricity and parallelism of both parts of the coupling do not exceed 0 1 mm This alternator has been balanced with a 1 2 key 3 1 3 Location The room where the alternator is placed must be ventilated to ensure that the ambient temperature cannot exceed the data on the nameplate LEROY 6 SOMER 200 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 3 2 Checks prior to first use 3 2 1 Electrical checks A Under no circumstances should an alternator new or otherwise be operated if the insulation is less than 1 megohm for the stator and 100 000 ohms for the other windings There are 2 possible methods for restoring the above minimum values a Dry out the machine for 24 hours in a drying oven at a temperature of 110 C without the regulator b Blow hot air into the air intake having made sure that the machine is rotating with the exciter field disconnected Note Prolonged standstill In order to avoid these problems we recommend the use of space heaters as well as turning over the machine from time to time Space heaters are only really effective if they are working continuously while the machine is stopped WARNING Ensure that the alternator has the degree of protection matching the defined environmental conditions 3 2 2 Mechanical checks Before starting the machine for the first time check that all fixing bolts and screws are tight the cooling air
129. ic product in the cooling circuit Adjust the equipment according to the manufacturer s prescriptions Check that the equipment operates correctly V Y Y Y Y Y V Y Engage the parking brake when the equipment is installed on the operating site on its trailer When chocking the trailer on a slope ensure that there is nobody in the path of the trailer 8 242 Maintaining the equipment Personnel skills gt Ensure that the maintenance operations are performed on the equipment by appropriately trained personnel Personnel protection Y VV VV Y Wear suitable clothing and protective goggles Remove any personal belongings that may hinder the operation watch bracelet etc Fit a panel over the controls of the equipment to prevent any attempt to start Disconnect the battery and pneumatic starter if fitted before beginning any maintenance operation Handle the equipment according to best practices using techniques which do not endanger the personnel It is essential to wear gloves when detecting leaks Regularly check that the safety devices are operating correctly Equipment protection gt gt Use tools in good condition and suited to the work to be done Ensure you have understood the instructions before beginning any operation Respect the maintenance table and its recommendations In dusty or unfavourable conditions certain maintenance intervals will need to be reduced Check that the spare parts fitted o
130. ide then pull out the gauge again 7 The proper oil level is between the high and low marks on the oil level gauge If the oil level is low add engine oil of the specified type 8 Check the oil pan and other area for oil leakage Repair any oil leakage found 9 Runthe engine with starter for approx 10 seconds while pulling the stop lever and feed engine oil to all parts of engine Stop the operation for 1 minute then repeat the operation two or three times Cir culate engine oil to all parts of the engine Note Prepare for the Cooling system 10 Check the oil level with the oil level gauge again and add oil to the specified level 8 8 161 242 Oil filler Oil level gauge O OKO Proper o HQ al Improper S i saL e o O O O E Low fF om re Oil level gauge Improper Fig 8 12 Engine oil Refill Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil filter Change Do not use a dented filter cartridge Filter damage or fule leakage may occur while engine is running and it can cause fire hazard CAUTION Oil filter To avoid damage to the filter do not use a filter wrench when installing Tighten the filter by hand 1 Clean around the oil filters 2 Place a drip pan under the oil filter 3 Using a filter wrench remove the oil filter Note Check the element of the oil filter that has been removed If metal particles are found consult a dealer of M
131. igh Voltage between E and E SHUNT gt 30V AREP PMG gt 15V Faulty rotating diodes Short circuit in the main field Check the resistance Faulty exciter armature Caution For single phase operation check that the sensing wires coming from the AVR are correctly connected to the operating terminals Voltage disappears during operation Check the AVR the surge suppressor the rotating diodes and replace any defective components The voltage does not return to the rated value Exciter winding open circuit Faulty exciter armature Faulty AVR Main field open circuit or short circuited Caution Internal protection may be activated overload open circuit short circuit 12 Warning after operational testing replace all access panels or covers LEROY SOMER 238 242 LEROY SOMER R438 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 017 4 2 Technical support service Our technical support service will be happy to provide any information you require When ordering spare parts you should in dicate the complete machine type its serial number and the information indicated on the nameplate Part numbers should be identified from the exploded views and their description in the parts list Our extensive network of service stations can dispatch the necessary parts without delay To ensure co
132. il pressure Table 11 9 Low engine oil pressure Cause Remedies Check amount of engine oil and lubrication system Insufficient amount of engine oil Refer to P3 2 Faulty engine oil property viscos Analyze oil property Use appropriate engine oil ity Refer to P5 1 Lubricating l Check coolant system system Oil temperature too high o Consult a dealer of Mitsubishi Heavy Industries Ltd Oil filter clogged Inspect and replace oil filter Refer to P8 7 Faulty oil pump operation Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty relief valve operation Consult a dealer of Mitsubishi Heavy Industries Ltd Control Check control system and wire Faulty pressure unit operation system Consult a dealer of Mitsubishi Heavy Industries Ltd Check control system Increase in load l Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine l Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Increase clearance of sliding part Consult a dealer of Mitsubishi Heavy Industries Ltd 11 8 183 242 Chapter 11 TROUBLESHOOTING When fuel has run out When fuel runs out while engine is running and the engine has stopped restart the engine as described below 1 Return the starter switch to the OFF position 2 Add fuel to the fuel tank For filling fuel tank refer to Fuel tank oil level Check 3 2 3 Bleed air from the fuel system For bleeding
133. in a clear space with free access Example of equipment to be used v Crane slings lifting beam safety hook shackles Forklift truck Se Fe TK ON ON 4 1 3 Unloading the generating set Before unloading or moving generating set check that the handling equipment used is able to bear the weight of the generating set Shown on the generating set s identification plate IMPORTANT 4 1 3 1 Slings 1 Attach the sling on the lifting equipment to the ring on the generating set no 1 provided for this purpose Tension the slings slightly Check that the sling is correctly attached and the equipment is steady Lift the generating set carefully Direct the generating set towards the chosen location and stabilise it Carefully set down the equipment while continuing to position it Oy OL ax ote IY Release the sling then detach it 36 242 EN 4 1 3 2 Fork lift truck 1 Position the arms of the forklift truck in the forklift pockets no 2 2 Lift the equipment handling it gently 3 Set down the generating set in its unloading position Figure 14 Points used for lifting and moving 4 1 4 Moving the generating set Whenever moving the generating set ensure suitable equipment is used e g sling forklift etc and identify those parts on the generating set which can be used to move it lifting eye no 1 forklift grooves no 2 tow bar no 3 37 242 EN 4 2 Connect
134. ing immediately wash it away with lots of water Use soap to thoroughly clean The battery electrolyte can cause the loss of sight if splashing into the eyes If it gets into the eyes imme diately flush it away with plenty of clean water and seek immediate medical attention lf the battery electrolyte is accidentally consumed gargle with plenty of water then drink lots of water and seek immediate medical attention 1 6 119 242 Chapter 1 BASIC SAFETY PRECAUTIONS Other cautions Never modify engine Unauthorized modification of the engine will void our warranty Modification of the engine may not only cause engine damage but also produce personal injuries If there is a need to modify the engine contact a dealer of Mitsubishi Heavy Industries Ltd Observe safety rules at work site Observe the safety rules established at your work place when operating and maintaining the engine Do not operate the engine if you are feeling ill inform your supervisor of your condition Operation of the engine with reduced awareness may cause improper operation that could result in accidents When working in a team for two or more people use specified hand signals to communicate among work ers Work clothing and protective gear Wear a hardhat face shield safety shoes dust mask gloves and other protective gear as needed When handling compressed air wear safety goggles a hard hat gloves and other necessary protec
135. ing short circuit capacity 2 R220A V R 2 1 Characteristics Storage 55 C 85 C Operation 40 C 65 C Voltage regulation 0 5 Voltage supply sensing range 85 to 139 V 50 60 Hz Rapid response time 500 ms for a transient voltage variation amplitude of 20 Voltage setting P1 Stability setting P2 MAIN FIELD SHUNT SYSTEM ST4 Option Potentiometer for remote voltage adjustment ST3 Frequency 50 Hz 60 Hz VOLT POT 1K Power supply protected by 8 A fuse slow blow action tolerates 10 Afor 10 s The fuse is impregnated in the resin therefore it can not be replaced Frequency 50 Hz with ST3 jumper 60 Hz without ST3 jumper The size of the screwdriver tip used to adjust the potentiometer is 2 5 mm 2 2 R220 AVR option Potentiometer for remote voltage adjustment 1000 O 0 5 W min adjustment range 5 Remove the ST4 jumper For wiring up the external potentiometer the earth wires must be isolated as well as the potentiometer terminals wires at the same voltage as the power STATOR 12 wires marked T1 to T12 13 T9 T6 12 D O gt x 9 LO Q YN D O lt x N ZH 09 YO4 NJdO LEROY SOMER 222 242 LEROY SOMER R220 A V R 3 INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wiring diagram Check
136. ing the generating set 4 2 1 Connection summary This diagram can be used to retrace the different steps enabling the generating set to be correctly connected TT earthing system EDF application option France only Identify the type of differential protection fitted on the generating set Fixed differential protection Adjustable differential protection Set the differential protection of the generating set No operation required Add differential protection No operation required Add differential protection terminal circuits protected set to 30 mA to the terminal terminal circuits protected set to 30 mA to the terminal circuit output s circuit output s Earth the generating set Connect the generating set to the installation 38 242 4 2 2 Protecting people and equipment 4 2 2 1 Earthing system principle The Earthing system or SLT formerly Neutral system of the electrical installation defines the situation of the generating set neutral in relation to earth and the grounds of the electrical installation at the user end Our generating sets are designed to operate with the TT system or EDF application depending on the option for France only 4 2 2 2 TT system In the TT earthing system automatic power cut off via a Residual Current Device RCD is obligatory at the upstream part of the installation to ensure that personnel are protected additionally a maximum 30 mA device must be installed on outlet circuits
137. ing warm UpP 3 5 ODS KAO I cnc e 3 6 Cautions when Operating ccccccoccncccconnnnonnnoo 3 6 Inspection during operation 0 ceeeeeeeeees 3 6 RODIN ita ete 3 7 Inspection after STOPPING ccccseeeeeseeeeeeeees 3 7 Chapter 4 FUEL Recommended fuel o c oo 4 1 Handling eliana vdd 4 1 Chapter 5 ENGINE OIL Recommended engine oil 9 1 Selection of oil viSCOSItY 5 1 Handling engine Ol ooo ooo 5 1 Engine oil performance requirements 5 2 Engine oil deterioration mechanisms 5 2 Definition of properties of engine oil 5 3 VISCOS Vado 5 3 Total base NUMER siii is 5 3 Total acid NUM ais 5 3 Water COnten clad teen tion duces il diudiea deh ioet 5 3 A aaa E 5 3 IISOINDIC e ei 5 3 Service Limits of engine 0il 5 4 CONTENTS 2 109 242 Chapter 6 COOLANT Recommended water for coolant 6 1 Long life coolant LLC 6 1 Genuine LLC scsi ote iciisda 6 1 Other brand BEC Stcserat das 6 2 Standard for other brand LLC 6 2 General demands of LLC neccen 6 2 LECFSpociica lO Naci rs 6 3 Maintenance of LLC accenn 6 5 Replacement intervals of LLC ee 6 5 LEC CONCONtT Alec 6 5 Importance of LLC cooccccconcccccnncnnnnnn os 6 6 Characteristics of LLC additive and Important notes ccccoccnccnccncnnoninnnns 6 6 Examples of abnormalities cau
138. ion products etc even if LLC is kept in 20 to 25 C 4 to 13 F The validity term of the quality that provides with this specification is 2 years after it delivers with the indoor normal temperature keeping Chapter 6 COOLANT LLC specification LLC shall examine according to JIS K2234 section 7 examination methods and satisfy this specification General matters and the sample to the examination is shown in JIS K2234 Table 6 2 LLC specification Property Standard External Not precipitation Densit Minimum 1 112 g cm 69 4199 lb ft y 20 20 C 68 68 F Stock solution Water content Maximum 5 0 weight Stock solution 30 vol Maximum 14 5 C 6 F Frozen temperature l 50 vol Maximum 34 0 C 29 F Boiling temperature Minimum 155 C 311 F Stock solution pH 7 0 to 11 0 30 vol 30 vol Maximum 4 0 ml Bubbling character T e ane ASTM D 3306 01 5 aximum ml Disappearance of bubble l SPE VOL within 5 sec Hard water adaptability Maximum 1 0 50 vol Test piece Brass 0 15 mg cm Metallic causticit 1 Ar El External of test piece after the Not corrosion on surface excluding between 33642 Hr examination test piece and spacer Discoloration is OK 30 vol E G 50 vol P G Bubbling while examination Not bubbling overflow Properties of pH change 1 0 liquid after the precipitation Maximum 0 5 vol examination a Not remarkable discoloration separation External of liquid and g
139. ions 5 4 1 amp 5 4 2 WARNING During the warranty period this operation should only be carried out in an LEROY SOMER approved workshop or in our factory otherwise the warranty may be invalidated Whilst being handled the machine should remain horizontal rotor not locked in position Check how much the alternator weighs see section 4 7 before choosing the lifting method E JN l 4 6 1 Tools required To fully dismantle the machine we recommend using the tools listed below 1 ratchet spanner extension 1 torque wrench 1 setof flat spanners 8 mm 10 mm 12 mm 1 socket set 8 10 13 mm 1 socket TORX bit T20 T30 1 puller eg Facom U35 U32 350 4 6 2 Screw tightening torque See section 5 4 A The screws for fixing the feet on the 4 6 3 Access to connections and the regulation system The terminals and AVR are accessed directly by removing the terminal box lid 41 4 6 4 Accessing checking and replacing the diode bridge 4 6 4 1 Dismantling Remove the terminal box lid 41 Cut the fixing clamps of the exciter cables disconnect E E from the exciter Remove the 4 nuts on the tie rods Remove the NDE shield 36 using a puller eg U 32 350 Facom Unsolder the connections Check the bridge using an ohmmeter or a battery lamp see section 4 5 1 4 6 4 2 Reassembly Replace the bridges respecting the polarity see section 4 5 1
140. ious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Note Indicates important information or information which is useful for engine operation 106 242 FOREWORD Units of measurement Measurements are based on the International System of Units SI and they are converted to the metric system units in this manual using the following conversion rates Pressure 1 MPa 10 197 kgf cm Torque 1 N m 0 10197 kgf m Force 1 N 0 10197 kgf Horsepower 1 kW 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 75 cmHg Meter of water 1 kPa 10 197 cmH20 cmAg Engine speed 1 min 1 rom Kinetic viscosity 1 mm s 1 cSt Abbreviations standards and others API American Petroleum Institute ASTM American Society for Testing and Materials ISO International Organization for Standardization JIS Japanese Industrial Standards LLC Long Life Coolant MIL Military Specifications and Standards MSDS Material Safety Data Sheet SAE Society of Automotive Engineers 107 242 Chapter 1 BASIC SAFETY PRECAUTIONS Fire and explosions c ccceeeeeeeeees 1 1 Keep flames AWAY ccccscccssseece
141. isplayed If the motor is not fitted with an air preheating system or once the om o preheating delay has elapsed P the engine starts up start of a cycle comprising 3 attempts to El Coolant temperature start up the engine rom m P il pressure Oil Temperature 76 242 6 3 3 Switching off Open the circuit breaker gt manually OR gt by selecting menu 12 CONTROL LOAD Ls The following display will disappear supply stopped ny E pp P F O Press the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24 08 2005 Switch TELYS 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 O Alarms All alarms will cause gt the yellow LED to flash General alarm In conjunction with this LED gt a flashing pictogram appears on the LCD screen gt message on graphic display example representing the circuit affected by the alarm and the associated indicator if present FAULT example ALARM Low Fuel Level 25 12 05 15 30 OK HELP 77 242 EN 2 Faults All faults will cause gt the generating set to stop immediate or gradual stop coolant temperature and overload or short circuit gt the red LED to flash General fault In conjunction with this LED gt a flashing pictogram appears on
142. it of fuel property ooccccccocccccconccoccncncnnnnnnnnnnnos 4 2 Engine oil properties eee 5 4 Water quality standards 6 1 LLC specificatiON occccnncnccnnnnmmmmmmo 6 3 Recommended LLC concentration 6 5 Maintenance schedule eee 7 2 Specific gravity of electrolyte 8 17 Recommended rust preventive oil and corrosion Inhibitor 9 1 The starter does not crank or cranks slowly resulting in start failure 11 2 The starter cranks but the engine does MOS cios 11 2 Output decrease ccccccccocccccnnccococonnnnnss 11 3 Exhaust smoke is white or blue 11 4 Exhaust smoke is black or charcoal 11 5 Fuel consumption is high 11 6 Engine oil consumption is high 11 7 Overheating riei 11 8 Low engine oil pressure 11 8 Main specifications 0 cccccceeeee 12 1 112 242 CONTENTS 5 113 242 Chapter 1 BASIC SAFETY PRECAUTIONS Fire and explosions Keep flames away Do not use flames near the engine in the engine room Fuel vapor or other gas can catch fire and produce dan gerous situations Wipe off spilled fuel oil and LLC immediately and thoroughly Spilled fuel oil and LLC may ignite and cause a fire Store fuel and engine oil in a well ventilated area Make sure that the caps of fuel and engine oil contain ers are tightly
143. itsubishi Heavy Industries Ltd 4 Thoroughly wipe off oil on the mounting surface of oil filter with a waste cloth 5 Check the new oil filter for proper seating of gasket 6 Apply clean engine oil to gasket 7 Install the oil filter When the filter gasket contacts the mounting surface of filter tighten the filter with specified torque Fig 8 14 Oil filter 8 9 162 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system Coolant Change Remove the radiator filler cap only after the engine Turn the cap about Stand the lever to half a turn the upright position has cooled to room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it Coolant containing LLC drained from the engine is toxic Never dispose of coolant into regular sewage For disposal of used coolant consult a dealer of Mit subishi Heavy Industries Ltd or a industrial waste disposer Fig 8 15 Radiator filler cap The service life of LLC is 2 years Be sure to change coolant at least once every 2 years Coolant Drain 1 When draining coolant immediately after engine operation idle the engine in low gear for 5 to 6 min o ao alee cap utes until the coolant temperature drops t
144. k to O open position start the en gine and let it idle for several minutes 9 Check the water sedimenter for fuel leakage If leakage Is found loosen ring nut and check O ring for damage Fuel filter cartridge type Replace When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Clean the area around the fuel filters Place a fuel tray under the fuel filter Put a stopper on fuel pipe and stop fuel flow Change the fule filter for a new one aS SY Bleed air from the fuel filter Refer to Fuel system Bleed air 8 3 Start the engine and let it idle for several minutes gt 7 Check the fuel filter for fuel leakage If fuel leakage is found retighten the fixing clamp of the fuel pipe Fig 8 8 Fuel filter cartridge type Replace 8 5 158 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter element switching cock type Replace When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Clean the area around the fuel filters Place a fuel tray under the fuel filter Turn the cock to C close position stop fuel flow Se NS Remove ring nut and cup chang the filter elemet for a new one and then fix the ring nut 5 Bleed air from th
145. lectrolyte is spilled on your skin or clothes flush immediately with plenty of water If battery electrolyte get into your eyes flush them immediately with plenty of water and then get medical attention Do not use open flames or other fire hazards near the battery When handling the battery be careful of soarks gen erated by accidental shorting For other cautions in handling the battery refer to Service battery 1 6 Battery electrolyte evaporates during use and the electrolyte level gradually decreases Proper electro lyte surface level is between the LOWER LEVEL IIA and UPPER LEVEL lines le l 394 to 0 591 in For the battery without level lines proper electrolyte Proper surface level is about 10 to 15 mm 0 394 to 0 591 in re ies MA LO above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water pour in carefully Fig 3 1 Battery electrolyte level Inspect 3 1 130 242 Chapter 3 OPERATION Fuel tank oil level Check When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not remove the strainer when filling the fuel tank For fuel to be used refer to FUEL 4 1 Make sure the fuel tank is full If the fuel level is low refill the tank to the FULL level line Fig
146. ler of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Insufficient amount of air Refer to P8 16 shes and Check intake air pressure and leakage of intake air e Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Control Check control system Increase in load o system Consult a dealer of Mitsubishi Heavy Industries Ltd 11 5 180 242 Chapter 11 TROUBLESHOOTING Fuel consumption is high Table 11 6 Fuel consumption is high Cause Remedies Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Improper fuel property Use appropriate fuel Refer to P4 1 Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes injection pipes Consult a dealer of Mitsubishi Heavy Ind
147. load bearing capacity and securing devices 2 For control boxes packing in an SEI 4 C case solid case with waterproof cover is obligatory 34 242 4 Installation Connections 4 1 Unloading the generating set 4 1 1 Choosing the location When choosing where to site the generating set bear in mind the proximity to the electrical distribution panel nuisance caused by the noise fuel supply burnt gas evacuation direction of these gases and the noise generated Incorrect ventilation and exhaust Building or terrain too rough Generating set incorrectly seated es Mental fay So Eomae Impossible to open enclosure doors Impossible to fill with fuel Figure 13 Examples of problems that may be encountered 35 242 4 1 2 Safety during unloading Always follow the safety instructions before unloading IMPORTANT The lifting machinery or equipment is suitable for the work required and the weight of the generating set This is indicated on the generating set s identification plate The sling is correctly positioned in the central lifting eye or the lifting arms are correctly positioned in the fork lift pockets intended for this purpose The ground is able to bear the load of the generating set and its lifting machinery without stress otherwise lay down stabilising beams of sufficient strength The generating set is put down as close as possible to its place of use or transport
148. ltage is still correct when the battery is removed Lack of residual magnetism The alternator builds up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to the AVR Faulty diodes Armature short circuit The alternator builds up but its voltage disappears when the battery is removed Faulty AVR Field windings disconnected Main field winding open circuit check the resistance Voltage too low Check the drive speed Correct speed Check the AVR connections AVR may be faulty Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the AVR voltage pot P2 before running at the correct speed Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Voltage oscillations Adjust AVR stability potentiometer If no effect try normal fast recovery modes ST2 Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F bend set too high Voltage correct at no load and too low when on load Run at no load and check the voltage between E and E on the AVR Voltage between E and E SHUNT lt 20 V AREP PMG lt 10V Check the speed or U F bend set too h
149. ly T 2 5 R438 A V R Options rro ninas M 3 INSTALLATION COMMISSIONING c0occcoooccocconcccccnncnnccononnconnnanoronnnnnnrrnnnnnrrrrnannnrrrnananennanas 8 3 1 Electrical checks on the AV Parranda dieta ne dd A 8 gA EEUN eere A 8 du 010 62 aU ea E roce 11 TA SPARE PARES sitiada iii taa 12 4 1 Designation A e E ON specs 12 4 2 Technical support service ra 12 All such operations performed on the A V R should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components The R438 is an IPOO product It must be installed inside a unit so that this units cover can provide IP20 minimum total protection it must only be installed on LS alternators in the ap propriate location so that when viewed externally it has a higher degree of protection than IP20 Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 3 229 242 LEROY SOMER R438 A V R 1 SUPPLY 1 1 AREP excitation system For both AREP 8 PMG excitation systems the alternator voltage regulator is the R438 With AREP excitation the R438 electronic AVR is powered by two auxiliary windings which are independent of the voltage match circuit The first winding has a voltage in proportion A
150. m Engine oil and Oil filter Replace CAUTION When draining oil or changing the oil filter wear gloves Hot engine oil and parts may cause burns Do not dump waste oil It is forbidden by law For disposal of waste oil consult a dealer of Mitsubishi Heavy Indus tries Ltd Change engine oil and the oil filter at the same time Also checking and analyzing the oil properties is recommended when changing the engine oil Do not reuse the oil filter element as it is a paper type When replacing filters always replace gasket with new ones Engine oil Drain After the engine has stopped drain engine oil from the engine oil drain port Note Draining by suction should be avoided d Engine oil drain plug Fig 8 11 Engine oil drain plug 8 160 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine oil Refill 1 Make sure that the oil drain plug is tightened 2 Remove the oil filler cap 3 Fill the engine oil pan with specified engine oil to the specified level Note For engine oil refer to ENGINE OIL 5 1 For engine oil capacity refer to MAIN SPECIFICA TIONS 12 1 4 Check the oil level in the oil pan as follows 5 Pull out the oil level gauge and wipe it with a waste cloth 6 Insert the oil level gauge fully into the oil level gauge gu
151. ment ineffective Faulty AVR Voltage oscillations Adjust AVR stability potentiometer Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F bend set too high Voltage correct at no load and too low when on load Run at no load and check the voltage between E and E on the AVR Check the speed or U F bend set too high Faulty rotating diodes Short circuit in the main field Check the resistance Faulty exciter armature Caution For single phase operation check that the sensing wires coming from the AVR are correctly connected to the operating terminals Voltage disappears during operation Check the AVR the surge suppressor the rotating diodes and replace any defective components The voltage does not return to the rated value Exciter winding open circuit Faulty exciter armature Faulty AVR Main field open circuit or short circuited Warning after operational testing replace all access panels or covers LEROY SOMER 224 242 LEROY SOMER R220 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 028 4 2 Technical support service Our technical support service will be happy to provide any information you require When ordering spare parts you should in dicate the complete machine type its serial number and t
152. merchantability fitness for a particular purpose or use or against infringement of any patent Mitsubishi Heavy Industries Ltd will not be liable for any damages or consequential damages including but not limited to damages or other costs resulting from any abuse misuse misapplication of the engine and devices supplied from us Mitsubishi Heavy Industries Ltd will not be liable for any damages or personal injuries resulting from any modification without our written permission of the engine and devices supplied from us Mitsubishi Heavy Industries Ltd will not be liable for any damages or production losses caused by the use of fuel engine oil and or long life coolant LLC that we are not recom mended The owner of the engine is responsible for the performance of the required maintenance listed in this operation manual Mitsubishi Heavy Industries Ltd may deny the warranty coverage if the engine or part has failed due to inadequate or improper maintenance 99 242 FOREWORD Emission warranty IMPORTANT The following warranty applies to the engines that are approved of the emission regulation of the U S Environ mental Protection Agency Warranty coverage Mitsubishi Heavy Industries Ltd warrants to the first owner and each subsequent purchaser of a new non road die sel engine that the emission control system of your engine vis designed built and equipped so as to conform at the time of sales with all a
153. meter configuration for display display of the engine configuration parameters etc depending on the type of engine B Use The Murphy module MDDM offers simple menu navigation 1 To browse the list of parameters press the Up and Down buttons A 2 To enter or exit a sub menu press both arrows simultaneously 58 242 EN The Parameter menu to navigate in this menu simply use the arrow buttons separately The sub menus The sub menus are available at the end of the parameter menu To go to these sub menus scroll through the parameters using the A and Y buttons until you reach the required sub menu C The Sub menus The sub menus enable certain aspects of the fault finding module display to be modified Changing the unit of measurement There are two display modes available for units English or metric To change your units of measurement use the A and Y scroll buttons until you get to the sub menu Press the A and Y arrows simultaneously if you want to retain the current designation Press one of the scroll buttons to show the second mode for displaying units If you want to retain the second display mode confirm this by pressing the A and Y buttons simultaneously 60 242 D Displaying the active service codes The fault finding module enables the machine faults and alarms to be displayed in real time When a fault appears the display shows the message SrvcCode every five seconds between displaying the
154. n 4 6 6 4 7 Table of characteristics Table of average values Alternator 4 pole 50 Hz 60 Hz Winding no 6 and M or M1 connected in dedicated single phase 400 V for the excitation values The voltage and current values are given for no load operation and operation at rated load with separate field excitation All values are given to 10 for exact values consult the test report and are subject to change without prior warning For 60 Hz operation the resistance values are the same and the excitation current i exc is approximately 5 to 10 weaker 4 7 1 Three phase 4 pole SHUNT excitation Resistances at 20 C Q LSA 40 L N stator Rotor Field coil Armature Field excitation current i exc A 400V 50 Hz i exc excitation current of the exciter field LSA 40 No load At rated load 2 1 VS1 0 9 l 8 2 2 8 8 S2 0 S3 0 S4 0 2 2 M5 0 2 1 L7 0 8 2 1 4 7 2 Three phase 4 pole AREP excitation Resistances at 20 C Q LSA 40 L N stator Rotor Field coil Armature Resistance of auxiliary windings at 20 C Q LSA 40 X1 X2 auxil wdgs Z1 Z2 auxil wdgs LEROY 16 SOMER 210 242 LEROY SOMER Installation and maintenance LSA 40 4 POLES ALTERNATORS Field excitation current i exc A 4 7 4 Table of weights 400V 50 Hz ies E ee values given for information o
155. n the equipment are supplied only by the dealer Handle the equipment according to best practices using techniques which do not risk damaging the equipment Replace any safety pictograms that are missing or illegible on the equipment Note the mounting bolts on the protective devices of the rotating parts are captive bolts equipped with retaining washers Also in order to ensure the integrity of this assembly it is prohibited to use electric or pneumatic screwdrivers to undo these mounting bolts Cleaning the equipment gt gt gt Clean off any trace of oil fuel or coolant using a clean cloth Use only approved cleaning solvents Cleaning products and methods that are strictly prohibited e petrol or other flammable substances e soapy solution containing chlorine or ammonia e high pressure cleaner Additional instruction gt If necessary contact the dealer for the following reasons e answers to any questions relating to the equipment e training requests for personnel e supplying the relevant documentation for maintenance operations e supplying spare parts e corrective or preventive maintenance operations 9 242 Operating site Maintenance gt Clean the entire operating site regularly with suitable cleaning materials gt The presence of dangerous or combustible materials inside premises must be limited to the operating requirements Access gt Prohibit free access to persons who are not par
156. ncountered problems on the CAN Bus and it tries to automatically re establish the network connection 63 242 6 3 Generator set with TELYS control panel 6 3 1 Control panel presentation 6 3 1 1 View of the front panel 1 O O JO O a WO N Wits TLLYS aa J j ial i j i l ES i 3 A Ti l Pe i Cy eo z E eaco i ee a Li Pid r i Pi mi Figure 19 View of the front panel Emergency stop button AU for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for switching the module on off Electronic board protection fuse Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel STOP button press to switch off the generating set START button press to switch on the generating set Power ON LEDs and alarm fault warning LEDs Location of USB ports Mounting bolt LCD for displaying alarms and faults operating statuses electrical and mechanical quantities ESC button for returning to the previous selection and for default RESET function MENU button for accessing the menus Lighting for the emergency stop button 64 242 Figure 20 Description of the LEDs A lit LED indicates 1 2 3 oma Alarm activated flashing yellow Fault found flashing red Module on green on continuously Figure 21 Close up of US
157. nd coolant Check the operating record of the engine to determine the most appropriate service intervals Feel free to consult a dealer of Mitsubishi Heavy Industries Ltd regarding service intervals Service the items at multiples of the original requirement For example at 1000 service hours also service those items listed under every 250 service hours and every 50 service hours ltems marked with in the maintenance schedule require special tools or large equipment For the servicing of those items contact a dealer of Mitsubishi Heavy Industries Ltd 7 1 152 242 Chapter 7 MAINTENANCE SCHEDULE Maintenance schedule Table 7 1 Maintenance schedule Interval and Service item Fuel tank Drain water If water sedimenter is installed drain water every 500 service hours or 1 Every 50 service hours year Air cleaner Check 153 242 Page 8 2 8 14 8 2 8 7 8 18 8 18 8 14 8 10 8 15 8 16 8 3 8 5 8 17 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic engine Belt and belt tension Inspect and Adjust If defects such as cuts or surface separations are found during inspection replace the belt Keep oil and grease away from the belt They may cause the belt to slip and shorten the service life Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt Adjust the belt tension accurately by following the procedures below Belt
158. neral description of the generating set Protective grille Lifting ring Air filtration Forklift grooves 6 Oil drainage pump 15 242 Figure 8 General description of the generating set Charging alternator External fuel supply combined tap Amato optional Starter battery 6 Battery isolating switch 16 242 EN Control a ll el r e Figure 9 General description of the generating set Control unit Working hours counter Emergency stop Power circuit breaker Socket control panel 6 Connection terminal block Note Photo presented with the Nexys control unit 17 242 N 2 2 Technical specifications Range Generating set type RENTAL POWER R16CC Weights and Dimensions Dimensions with high autonomy tank Dimensions x wxh 1850 mm x 901 mm x 1355 mm Weight 794 kg dry weight 937 kg in operating configuration Hood M3126 Sound pressure level at 1 m 73 dB A measurement uncertainty 0 55 Emergency 2 Voltage Hz Phase Load factor es EE power EE ee mergency KW kVA kW kVA 4007230 50 3 08 2 128 16 116 145 1 ESP Stand by output available for emergency use under variable charge up to 200hrs per year as per ISO 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 1
159. neutral between the alternator output terminals and the generator set control cabinet part of the circuit not protected by circuitbreakers or relays in the cabinet The machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram 3 4 Commissioning A The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The machine is tested and set up at the factory When first used with no load make sure that the drive speed is correct and stable see the nameplate With the regreasable bearing option we recommend greasing the bearings at the time of commissioning see 4 2 2 On application of the load the machine should achieve its rated speed and voltage however in the event of abnormal operation the machine setting can be altered follow the adjustment procedure in section 3 5 If the machine still operates incorrectly the cause of the malfunction must be located see section 4 4 3 5 Setting up LN The various adjustments during tests must be made by a qualified engineer Ensure that the drive speed specified on the nameplate is reached before commencing adjustment After operational testing replace all access panels or covers The AVR is used to make any adjustments to the machine LEROY 10 SOMER 204 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 4 S
160. ng Turning off the battery switch during operation not only stops the instrument opera tions but also may deteriorate the alternator diode and regulator Never turn the key to the START position during operation The starter may be damaged When operating the engine with a 30 of rated load or lower limit each operation to an hour Prolonged warm up operation causes carbon build up in the cyl inders that leads to incomplete combustion Operate the engine with a 30 of rated load or more for over 5 minutes after continuous operation for an hour to prevent causing carbon build up 3 6 135 242 Inspection during operation Carefully check the exterior of engine such as piping joints for leaks Check for abnormal engine noises or vibrations such as knocking Check the color of exhaust gas from the exhaust muf fler Check the instruments and gauges for proper opera tion and make sure they indicates normal values Table 3 3 Standard values at rated speed Item Standard 0 29 to 0 49 MPa 3 to 5 kgf cm 43 to 71 psi 70 to 90 C 158 to 194 F Engine oil pressure Coolant temperature Note a When the oil pressure drops below 0 15 MPa 1 5 kgf cm 21 psi in normal operation or below 0 05 MPa 0 5 kgf cm 7 psi at low idling stop the engine immediately Be sure to locate the cause of problem and correct it before restarting the engine b When the thermo switch is activated in nor mal run idle the
161. ng securely close the filler cap Never mix different brands of engine oil Mixing different brands of engine oil may cause a chemical reaction of additives in the engine oil that could degrade the engine oil quality When handling oil in greater than the legally specified quantities be sure to have the work performed by a service station in compliance with the law When removing oil from the engine or oil can use an oil pump Do not suck oil with the mouth to siphon it Be sure to close the cap on the oil can after use Keep oil in a well ventilated area and out of direct sunlight Be sure to obtain the MSDS of the engine oil used and follow the instructions of the MSDS 5 1 142 242 Chapter 5 ENGINE OIL Engine oil performance requirements Engine oil requires the following performances Excellent dispersion performance the ability of oil to disperse sludge in the oil at high temperature that prevents engine oil deterioration due to sludge accu mulation and soot contamination Excellent acid neutralizing performance that prevents oxidative degradation due to fuel sulfur content Excellent high temperature oxidation stability that en dures continuous operation under prolonged high load Sufficient viscosity concentration to maintain the cold start performance and lubrication performance at high temperature Good rust and corrosion resistance to water Good foam resistance to prevent the lubricating qual
162. ng and bearing scuffing Sulfur content in fuel is burned and transformed into sulfurous acid gas and sulfuric gas that cause corro sive wear of cylinders and piston rings A detergent additive in the engine oil neutralizes them into harm less substances As the detergent additive is con sumed in its role of neutralizing the engine oil total base value decreases A decrease in the total base value indicates a corresponding decrease in soot dis persion ability As a result deposits on the pistons in crease Due to oxygen in the air oil temperature rise under high load continuous operation causes oxidation deg radation As oxidation degradation accelerates oxi dative products are polymerized The polymerized oxidative products cause the oil viscosity to increase which leads to the generation of sludge and varnish As a result problems such as lubrication failure and piston ring sticking occur Also acid substances gen erated by oxidation can cause problems like main bearing corrosion Chapter 5 ENGINE OIL Definition of properties of engine oil Viscosity Viscosity is a basic physical property of engine oil and is considered as the most important aspect when eval uating oil Contamination of oil by blow by gas and deterioration of oil by its natural aging in crease the viscosity and degrade the performance of viscosity which will cause the deposition of sludge inside the engine and oil filter clogging Contamination
163. nl i exc excitation current of the exciter field 9 y LSA 40 No load At rated load ESA 40 Total weight kg Rotor kg VS1 VS2 S3 S4 M5 4 7 3 Dedicated single phase 4 pole SHUNT excitation Resistances at 20 C Q After operational testing itis essential to replace all access panels or covers LSA 40 L N stator Rotor Field coil Armature Field excitation current i exc A 230V 50 Hz i exc excitation current of the exciter field At rated load LEROY SOMER 17 211 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 5 SPARE PARTS 5 1 First maintenance parts Emergency repair kits are available as an option They contain the following items ALT 040 KS 001 ALT 040 KS 002 Emergency kit SHUNT AVR R 220 Diode bridge assembly Surge suppressor Emergency kit AREP AVR R 438 Diode bridge assembly Surge suppressor AVR fuse Single bearing kit ALT 422 KB 002 Non drive end bearing O ring Preloading wavy washer Double bearing kit Non drive end bearing Drive end bearing O ring Preloading wavy washer ALT 422 KB 001 5 2 Technical support service Our technical support service will be pleased to provide any additional information you may require When ordering spare parts you should indicate the complete machine type its s
164. nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnninnaness 191 2 242 TABLE OF ILLUSTRATIONS FOUE 1 Warning pico dans a secretin a add eet ee pac oS uae a dd ern ee ees 5 Figure 2 Pictograms indicating prohibited activities ccccseeeccccceeseceecceeeeeeeccueeeeeeeseeuseeessaeueeeeesaeseaeeeeeseaseeeesseaaeeeesseaeeesssaaeeeeessaeeeeeeaas 5 Figure 3 Pictograms Indicating compulsory operations cccccseeceeceeeecneeeecaeeeeecseeeessueeeesueeeesseeeeeaeseueeesaeeeessaeeeeseueeesseeeeseaeeeeseeeeessaes 6 Foure ad INTORMALION DICLOOlaInS e o o tel ba ball ital all cai o o oO 6 Figure S opece DICIOCKAIIS oa 7 Figure G Pictograms relating tO DAME a i a a ah tate ties a a dad tard 7 Figure 7 General description of the generating SCt cccccssssccccceeeececceeeeeceeecseuseeeesueceeeseeeeeeessaeseceeeseeaeceesseaeeceessaaeeeesseageeeessaegeeeseaas 15 Figure 8 General description of the generating Slide 16 Figure 9 General description of the Generating SCt cccccssssecccceseeccecceeseeeeeceeeeeeeeaueeeesaeaeeeessaaeeceeseuaaeeeesseaeeeeeeseaeceeeseageeeessagaeeeseaas 17 Figure 10 Example of a generating set identification plate oooccccccconncnncccnnncnnnnnnnnnnnononcnnnnononnnnnnnnnonnncnnnnnnnnrnnnnnnnnnnnnnrnnnrnnnnnnanens 20 KOUSTE RUTENIO conan td lo dd do e de 21 Figure AZ Example of French signalling said ri dd dit 33 Figure 13 Examples of problems that may be encountered
165. nnnnononncononanonnnnnonnnaronnnnrenananenanannn 5 3 1 Electrical checks ON the AVR nani rencia 5 ao A E E E sete p eae cee seme tig aueaeatsapnctio eas AT 5 3 3 Electrical faults en ee ee eet ee ene ee een a ee eee neers 6 SPARE PAR unan tai 7 A te DES ION ALO asi Ec oda T 4 2 Technical support service cccccescccscccceeeceseecacecccecsaeecusecsuessaeecsueeseueessueessaeeaaaeeaas T All such operations performed on the A V R should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components The R220 is an IPOO product It must be installed inside a unit so that this units cover can provide IP20 minimum total protection it must only be installed on LS alternators in the appropriate location so that when viewed externally it has a higher degree of protection than IP20 Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 3 221 242 LEROY SOMER R220 A V R 1 SUPPLY 1 1 SHUNT excitation system The alternator with Shunt excitation is self excited with an R 220 voltage regulator The regulator monitors the exciter excitation current as a function of the alternator output voltage Very simple in design the alternator with shunt excitation has no sustain
166. not only engine damage but also personal injuries Changing the engine speed set ting is prohibited Never change engine speed setting Tampering with the setting can cause the engine and its coupled machine to operate at excessive speeds and result in accidents Chapter 1 BASIC SAFETY PRECAUTIONS Be careful of exhaust fume poisoning Operate engine in a well venti lated area enclosed area and the exhaust gas amp If the engine is installed in an is ducted outside ensure that there is no exhaust gas leakage from duct joints When using the engine as portable generator set do not run it in doors such as a warehouse or tunnel or in an poorly ventilated area near the shielding When running it indoors by necessity discharge the exhaust gas to outside and thoroughly ventilate the room Make sure the exhaust gas is not discharged directly to surrounding buildings plants or living passersby Exhaust gas from the engine contains carbon monox ide and other harmful substances Operating the engine in an poorly ventilated area can produce gas poisoning Be careful of falling down A During lifting process keep the engine in a well bal Lift engine carefully To lift the engine use slings capable of supporting the weight of the engine Attach the wire rope to the hangers provided on the engine using a cor rect sling anced position by taking the center of gravity of the engine into considera
167. nset starting Genset stabilised voltage and Flashing AUTO mode Fixed frequency Flashing impression of constant movement from left to right The genset is generating and in use Fixed Usage supplied Fixed Synchronisation Flashing oo 67 242 EN 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 TELYS is initialised Data displayed Fuel level indicator Alarm Fault L Alarm Fault low fuel level high fuel level Coolant level temperature indicator Aam A cae 4 No preheating Low level f level fault temperature Gx fault fault MA alarm fault alarm Battery Min battery Max battery Battery charge voltage ON f indicator flashing Vonage MlasnIng AQ flashing bars Oil pressure temperature indicator High or low oil Oil pressure level Alarm Fault Alarm Fault Emergency stop High or low oil temperature Alarm Fault Emergency stop fault Overload or short circuit Tripping of circuit breaker following an overload B or short circuit a Engine speed Underspeed fault iy Y 7o Non starting fault 68 242 6 3 1 5 Description of the pictograms in zone 3 Zone 3 pictograms All the pictograms for these zones are activated when the TELYS is initialised The pictograms below are shown for information only Generating set stopped m H t J Fuel Level
168. nspection in the written instructions required by Sub section e shall be warranted for the warranty period defined in Subsection b 2 A statement in such writ ten instructions to the effect of repair or repla ce as necessary shall not reduce the period of warranty coverage Any such part repaired or replaced under the warranty shall be warranted for the remaining war ranty period 3 Any warranted part which is scheduled for replacement as required maintenance in the written instructions required in Subsection e shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or re placed by Mitsubishi Heavy Industries Ltd accordi ng to Subsection 4 below Any s uch part repaired or replaced under warranty shall be warranted for the remainder of the period prior to the first scheduled re placement point for the part 4 Repair or replacement of any warranted part under the warranty provisions shall be performed at no charge to the owner at a warranty station 5 Notwithstanding the provisions of Subsection 4 above warranty services or repairs shall be provided at all Mitsubishi Heavy Industries Ltd distribution centers that are franchised to service the subject engines 6 The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provide
169. nt and fuel used petrol diesel and gas Periodically examine the burnt gas exhaust Pipes must be replaced as soon as their condition demands it Note the carbon monoxide present in the exhaust gas may lead to death by inhalation if the concentration levels in the atmosphere are too high Corrosion inhibitor in the coolant contains alkali Read the instructions on the packaging Keep the product out of the reach of children Do not swallow it Avoid prolonged or repeated contact with the skin Never allow contact with the eyes In the event of contact with the eyes 1 Rinse immediately with plenty of water for at least 15 minutes 2 Consult a doctor immediately In the event of contact with the skin 1 Wash thoroughly with water and soap 2 Consult a doctor immediately Fuels and oils Do not swallow it Ensure proper ventilation Use a suitable protective mask 13 242 Battery electrolyte Avoid all contact with the skin and eyes Wear suitable protective goggles and clothing and strong alkali resistant gloves for handling the electrolyte If solashes get into the eyes 1 Rinse immediately with running water and or a 10 diluted boric acid solution 2 Consult a doctor immediately 1 4 6 Precautions for risks relating to handling phases DANGER HANDLING PHASES RISK OF DROPPING 1 Select the appropriate handling equipment and apparatus according to
170. ntenance Operate the engine for maintenance at least once a month as described below 1 Run the engine with starter for approx 10 seconds while pulling the stop lever Stop the operation for approx 1 minute then repeat the operation two or three times 2 Make sure the engine oil pressure rises 3 Operate the engine about 5 to 10 minutes under no load as the maintenance operation Note For starting the engine refer to Starting 3 4 9 2 173 242 Chapter 10 TRANSPORTATION Lifting the engine o q3Oo 4h WARNING Front hanger Rear hanger To lift the engine use wire ropes shackles and slings capable of supporting the weight of the engine Attach the wire rope to the hangers provided on the engine using a correct sling Keep the engine balanced during lifting by consider ing the engine s center of gravity Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident Attach wire ropes to the hangers after removing the pipe cover and the insulator near the hangers To prevent wire ropes from contacting the engine use a cloth or other soft padding Fig 10 1 Hangers _ Engine center N Engine center Crankshaft center The center of gravity Z The center S3L S3L2 40 of gravity SAL S4L2 90 mm Fig 10 2 Engin
171. o 70 to 80 C 158 to 176 F 2 Open the radiator filler cap 3 Place coolant receiving can under the drain cocks and plugs and open the coolant drain cocks and plugs to drain the coolant Coolant drain cock Fig 8 16 Coolant drain cock radiator 8 10 163 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system Clean Clean the cooling system when operating the engine first time or restarting the engine after storage with coolant drained 1 Close coolant drain cocks and plugs 2 Pour in a cleaning solution a solution that is non corrosive to rubber and metals in the cooling sys tem and operate the engine at 800 to 900 min for about 15 minutes then drain the cleaning solution Close coolant drain cocks and plugs Pour in fresh water and operate the engine at 800 e ai to 900 min for about 10 minutes Repeat rinsing until the draining water becomes clear and clean Water drain plug Fig 8 17 Coolant drain plug engine 8 11 164 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES C
172. o avatar a trai von ales 1 8 Use of tools optimum for each work 1 8 Avoidance of prolonged time of starter OOS NOM siete A 1 8 Do not turn off the battery switch during OPA MON aan ER E a santa 1 8 Cautionary instructions for transporting the 21016 go uri ferent ee a eee 1 8 Chapter 2 NAME OF PARTS Engine external diagrams 2 1 Equipment and instrument 2 4 Starr Willi aa 2 4 PrENGAINGICAION caceria ita oli Ll 2 4 Water temperature meter and thermo unit 2 5 AMM caia 2 5 HOU Mr leed nales des 2 5 SION SOlENOIG siria ado 2 6 Engine protection devices 2 7 Oil pressure SWitCh ooocccccccoccnncnooncncncnnnnnnonnns 2 7 TREMO SWITO A cunda A 2 7 Air cleaner indicator ccc ccccssseeesseeeeseeeeeees 2 7 CONTENTS 1 CONTENTS Chapter 3 OPERATION Preparations for operation 3 1 Engine external Inspect oooccccccccnnccccccccnncccns 3 1 Battery electrolyte level Inspect 3 1 Fuel tank oil level GhecCk oooooncccinncnncccncccccnccs 3 2 Engine oil level Check cccoooccccccconoconononnns 3 2 Coolant level Check ccccceeeeeessseeeeeeees 3 3 SLANG ss 3 4 Automatic glow plUYQ cccoocncccconnccoccncnnncnnnnoo 3 4 Manual glow Plis calead 3 4 Warm Up OperatiON ccoocccoccccccnccnonccno 3 0 Checking engine oil presSure ooococccccnnnncccnn 3 5 External inspection dur
173. ob to confirm 34 50Hz lt gt 60Hz 36 PARAMETERS 37 INSTALLER ACCESS GS OK ESC NOMINAL VOLTAGE e Set the desired voltage then confirm using the scroll RY vac a and confirm knob o Min 380 s Max 480 G5 OK Esc 89 242 N e Select the desired configuration using the configuration option selector located next to the TELYS 2 control unit e Start up the generating set by pressing the START button e Adjust the voltage after starting up the generating set using the 2003R08 potentiometer Configuration selector ULM y p Ir LS MENU Potentiometer Warning when switching to 60Hz do not use sockets if fitted to the generating set IMPORTANT 90 242 9 2 Neutral system Turn the switch to the desired neutral system Select the neutral system with the generating set switched off 9 3 Fuel supply valve The 3 way valve is used to select between the generating set fuel tank and an external fuel supply Valve in vertical position no 1 generating set supplied by the daily service tank Valve in horizontal position no 2 generating set supplied by the external tank 91 242 92 242 10 Appendix 10 1 Appendix A Engine user and maintenance manual 93 242 94 242 User guide and maintenance manual MITSUBISHI Engine SERIE SL 99610 31120 01 07 2009 339022049401_3_1 95 242 96 242 OPERATION amp MAINTENANCE MANUAL MITSUB
174. of moving parts while engine is running Do not approach rotating or sliding ty CF If any part of the clothing or outfitting is caught by a parts of the engine while the engine is running Keep objects likely to be caught by rotating parts away from such parts rotating part serious bodily injuries could result 1 2 115 242 Lockout and tagout Be sure to lockout and tagout before starting inspec tion and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to OFF position and attach a Do Not Run or similar caution tag to the starter switch The starter switch key must be kept by the person who performs inspection and maintenance during the work Keep engine stopped during servicing Be sure to stop the engine before proceeding to inspection and service procedure Never attempt to make adjustments on the engine parts while the engine is running Rotating parts such as belt can entangle your body and cause serious injuries Always restore engine turning tools after use Be sure to remove all turning tools used during main tenance and inspection work Remember also that the turning gear must be returned to the operating condi tion before starting the engine Starting the engine with the turning tools inserted or with the turning gear in engagement can lead to
175. of oil by fuel and sheared molecules of viscosity index improver in oil decrease the viscosity and degrade the performance of viscos ity which will cause insufficient lubrication and friction wear of engine parts Total base number Total base number TBN shows the ability to neutral ize acids such as organic acid due to engine oil oxida tion or sulfurous or sulfuric acid due to the sulfur content of fuel Because TBN indicates the amount of dispersant detergent in oil it can be used to estimate consump tion of basic dispersant detergent The ability to dis perse sludge declines as dispersant detergent is used Up Total acid number The total acid number in oil increases as the organic acid is being derived by the engine oil oxidation or sulfurous acid or sulfuric acid derived by the combus tion of sulfur content of fuel or the oil becomes con taminated with imperfect combustion products An increase in the total acid number will result in cor rosion or wear of the inner parts of the engine such as cylinder liners or metal due to sulfur content and piston ring seizure due to sludge 144 242 Water content Water in oil promotes corrosion wear and decreases lubricity in sliding parts Flash point The flash point is lowered by contamination with fuels Flash point is measured to check the dilution of fuel The dilution of fuel reduces oil film and causes insuffi cient lubrication that will cause friction or w
176. of the generating set 3 Feed the power connection cables through the cable router flap Power cables 46 242 4 Connect the power connection cables onto the bars i ri N LO L1 L2 L3 or N2 R2 S2 T2 using the terminals no 4 paa oy At Sic wi 3 x Bea le 5 Slide the cable router flap towards the inside of the generating set until it makes contact with the power connection cables then retighten the two knobs close the access door to the power section back up again 6 Connect the power connection cables to the installation to be powered ensuring the live and neutral wires are correctly connected Our generating sets are factory set with a conventional direction of phase rotation A phase converter not supplied can be used to ensure correspondence of phases between IMPORTANT the generating set and the installation N LO ou ou ou ou N2 R2 S2 T2 Installation to be powered e g cabinet distribution box installation etc To limit the risk of falls caused by obstacles on the floor it is recommended to suspend cables and ventilation ducts As necessary ensure that cables which remain on the floor are protected by burying or covering them IMPORTANT 47 242 EN 4 2 3 4 Connecting the battery or batteries to the generating set Always ensure that the polarities of the battery and starter motor correspond Never swap the positive and negative battery terminals when connecting them This could cause sever
177. off road engine but Mitsubishi Heavy Industries Ltd cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the heavy duty off road engine owner you should however be aware that Mitsubishi Heavy Industries Ltd may deny you warranty coverage if your heavy dutyoff road engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with California s emissions requirements You are responsible for initiating the warranty process The Air Rexources Board suggests that you present your heavy duty off road engine to a Mitsubishi Heavy Industries Ltd dealer or distributor dealer as soon as problem exists The warranty repairs should be completed by the dealer or distributor as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact Mitsubishi Engine North America at 1 630 268 0750 101 242 FOREWORD Warranty coverage a The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser b Mitsubishi Heavy Industries Ltd warrants to the ultimate purchaser and each subsequent purchaser of the en gine registered in the state of California that the engine is 1 Designed built and e
178. ommended fuel _ WARNINGS Use a fuel specified in this manual only Do not refill a the fuel tank more than the specified level as it may Diesel fuel result in a fire gt equivalent Use a diesel fuel equivalent for JIS K 2204 diasel for fuel 2 It is necessary to use a fuel that has a pour point suit JIS K2204 able for the ambient temperature Fig 4 1 Recommended fuel Handling fuel When using fuel stored in a storage tank leave it to sit for more than 24 hours so that dust and water can settle at the bottom Then use the upper clean fuel Fill up the fuel tank or service tank after each operation This prevents water from mixing with fuel in the tank and also gives time for dust and water to separate and settle at the bottom of the tank Before refilling clean the areas around the caps thoroughly and remove the caps from the drum and tank Also clean your hands and the hose before refueling When using a hand operated pump be careful not to pump water or sediment accumulated at the bottom of the storage tank Be sure to use a Strainer when filling fuel tank For a complete filtration it is recommended to use a clean lint free cloth together with the strainer 4 1 138 242 Chapter 4 FUEL Table 4 1 Recommended limit and use limit of fuel property Properties Recommended limits Test method JIS K 2265 2007 Flash point 50 C 122 F or higher 45 C 113 F ISO 3769 ISO 2719 Initial boiling point
179. on 50Hz 60Hz Field 5 ohms R 438 gt ST4 Voltage Static adjustment of the current limit potentiometer P5 factory setting 7 5 A fuse rating 8 A 10 seconds The maximum factory setting corresponds to that of the excitation current required to obtain a 3 phase short circuit current of approximately 3 IN at 50 Hz for industrial power unless otherwise specified A static method can be used to reduce this value oradaptthe Isc to the actual operating power derated machine which is safer for the alternator and the installation Disconnect power supply wires X1 X2 and Z1 Z2 and the voltage reference 0 110V 220V 380V on the alternator Connect the mains power supply using a transformer 200 240V as indicated X1 X2 48V Install a 10A D C ammeter in series with the exciter field Turn P5 fully anti clockwise and activate the power supply If there is no output current from the AVR turn potentiometer P2 voltage clockwise until the ammeter indicates a stable current Switch the power supply off then on again turn P5 clockwise until the required max current is obtained no more than 8 A LEROY 10 SOMER 236 242 LEROY SOMER R438 A V R Checking the internal protection Open switch D the excitation current should increase to its preset ceiling remain at that level for 10 seconds and then drop to lt 1A To reset switch off the power supply by ope ning switch A
180. oncentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICA TIONS 12 1 3 Ifa reserve tank is equipped fill the reserve tank with coolant up to the FULL level line Fig 3 6 Reserve tank coolant level 3 3 132 242 Chapter 3 OPERATION Starting The starting method changes based on the application and specifications Start the engine according to the specified procedure WARNING Before starting the engine check to make sure no one Is near the engine and that tools are not left on or near the engine In a loud voice notify people in the area when starting the engine CAUTION Do not apply a load to the engine at starting Disengage the clutch if installed Continuous operation of the starter will drain the battery power and cause the starter to seize Do not use the starter for more than 10 seconds at a time When the engine does not start wait for more than 1 minute before cranking again When preheating do not heat over 30 seconds at a time For manual glow plug Otherwise the battery capacity reduce in a short time or decrease glow plug life Automatic glow plug 1 Turn the starter key to ON position Confirm the oil pressure lamp water temperature lamp battery charge lamp and preheat lamps turn on at the time The preheat lamp lighting duration is as follows Note When the engine is cold move the speed control lever to FULL position and turn the
181. ontained in the appendices of this manual 6 I2 10 2 1 fi TT E 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 3 14 16 LLG kN 7 i PRESS ACIU TOL EHD PPE ed aw ama Rs eso C 4 PLS ANCE ai ee ATATA i AAA HD Lwa 91 dB 15 18 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 arking e g GOSSTANDART 17 Sound pressure 18 Sound power Figure 10 Example of a generating set identification plate 20 242 2 4 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 The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Figure 11 Fluid retention container The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached In all cases the retention containers must be regularly checked to ensu
182. oolant Refill 1 Tighten the coolant drain cocks and plugs 2 Remove the radiator filler cap and pour in undilut ed LLC Note Determine the amounts of LLC and water to be added by using the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICA TIONS 12 1 3 Pour in water soft water with minimal impurities Ee ae ae such as tap water slowly to FULL level line 4 Check the radiator and other parts for coolant leak age If any coolant leakage is found repair it 5 When coolant reaches FULL level line close the radiator filler cap securely 6 Run the engine with starter for approx 10 seconds while pulling the stop lever Stop the operation for 1 minute then repeat the operation two or three times to bleed the cooling system 7 Check the coolant level in the radiator If the engine is equipped with a reserve tank fill the Fig 8 19 Reserve tank reserve tank with coolant to FULL level line as well Always use the coolant with the same LLC concen tration 8 12 165 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Radiator fins Check and Clean When handling compressed air wear safety goggles a hardhat gloves and other necessary protective gear Works without wearing proper protective gear could result in serious injuries Check the radiator fins for holes and cracks To clean the radiator fins
183. osion improves the effectiveness and service life of the cooling system High temperature feature promotes heat exchange Long term protection against overheating and corrosion under extreme conditions of use Compatible with the original fluid however it is recommended to drain the entire cooling system when replacing the fluid Specifications Specifications Characteristics Alkalinity reserve ML Freezing temperature Typical values given for information purposes 26 242 3 Transporting the equipment 3 1 Warnings concerning transport It is prohibited to operate generating sets whilst they are being transported IMPORTANT 3 2 Preparing for transport Before the equipment is transported perform the following operations 1 Close the tap on the oil top up tank outlet 2 Fill up the oil top up tank with oil 3 Fill up the crankcase with oil 4 Fill up the on board tank with fuel 5 Check that the batteries are fitted and filled with electrolyte 3 3 Road transport 3 3 1 Generating sets with and without an enclosure Generating sets must be transported by road in accordance with the regulations of the countries concerned When transporting generating sets in containers by road the following steps must be observed 1 Puta plastic cover over non enclosed generating sets during transportation 2 Select transport equipment trailer semi trailer etc suitable for this usage and having all
184. portions as to produce chemical reactions that suppress corro sion ionization of engine parts in contact with the coolant LLC loses its effectiveness by hours of use as well as lapse of time Moreover if the chemicals in LLC are not maintained certain chemicals in the LLC become rapidly used up and result in dissolution of metals instead of protecting metals from corrosion Consequently other corrosion preventing chemicals react with dissolving metals and accelerate corrosion This condition generates more severe corrosion than when plain soft water is used This is a typical problem caused by the use of inap propriate LLC 6 6 151 242 Examples of abnormali ties caused by LLC amine type Pitting of iron parts Amines are generally effective in suppressing the rust ing of ferrous metals but they are said to cause prob lems for copper parts Dissolved copper copper corrosion in the cooling system deposits on iron parts and the copper deposits cause corrosion and then pitting on iron parts that have a high ionization characteristics due to galvanic or local cell action Corrosion of aluminum parts Silicate is highly effective in protecting aluminum against rusting However it is unstable in a solution in which the pH is 9 or lower and can turn to gel and pre cipitate in the solution For this reason the pH is usu ally specified to be about 10 to ensure a high alkaline level This means after silicate is use
185. pplicable regulation of the U S Envi ronmental Protection Agency If the vehicle in which the engine is installed is registered in the state of California a separate California emission regulation also applies vis free from the defects in material and workmanship which will cause the engine to fail to meet these regulations within the warranty period Then its warranty period is The emission warranty period is shown below However if your engine warranty period is longer than the emission warranty period the emission warranty period extends to same as the engine warranty period Below warranty period shall begin on the date the engine is delivered to the first owner If your engine is certified as Then its warranty period is er speed or constant E or 2 years whichever Constant speed la or 2 years whichever Constant speed Seda ee or 5 years whichever Variable speed sited a or 5 years whichever ae speed or constant 3000 hours or 5 years whichever Warranted parts Mitsubishi Heavy Industries Ltd warrants the parts which will increase the emission of pollutants when they become defective The followings are examples Inlet Exhaust manifold Crankcase ventilation system Fuel system Fuel injection nozzle LIMITED WARRANTY Refer to LIMITED WARRANYT 100 242 FOREWORD California emission control warranty statement your warranty rights and obligations IMPORTANT The following warranty applies to the engines tha
186. quipped so as to conform with all applicable regulations adopted by the Air Resources Board 2 Free from defects in materials and workmanship which cause the failure of a warranted part to be identical in all material respects to the parts as described in Mitsubishi Heavy Industries Ltd s application for certifi cation for a period of 5 years or 3 000 hours of operation whichever occurs first In the absence of a device to measure hours of use the engine shall be warranted for a period of 5 years For all engines rated less than 19kW and for constant speed engines rated under 37 kW with rated speeds higher than or equal to 3 000 min the period of 2 years or 1 500 hours of operation whichever occurs first shall apply In the ab sence of a device to measure hours of use the engine shall be warranted for a period of 2 years c The warranty on emission related parts shall be interpreted as follows 1 Any warranted part which is not scheduled for replacement as required maintenance in the written instruc tions required by Subsection e shall be warranted for the warranty period defined in Subsection b 2 If any such part fails during the period of warranty cove rage it shall be repaired or replaced by Mitsubishi Heavy Industries Ltd according to Subsection 4 bebw Any such part repaired or replaced under the war ranty shall be warranted for the remaining warranty period 2 Any warranted part which is scheduled only for regular i
187. r switch to MAN mode if STOP is pressed or if a fault occurs OK Esc The 51 Hz offset must be applied to Operating phase genset operating stable voltage all of the power plant s and frequency gensets Warning message for setting offset on all of the power plant s generating sets G 13 1 Esc 75 242 6 3 2 Starting A Check that the generating set circuit breaker has triggered Connect the generating set battery O 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 lt gt AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS GS OK Esc O Press Esc several times to return to the following home menu OPERATION MANUAL Press START to start 24 08 2005 O Check the battery voltage pi L O Press START O E A AVAILABLE POWER AIR PREHEATING START UP 100 0 IN PROGRESS 10 seconds 24 08 2005 24 08 2005 24 08 2005 The following pictogram is displayed If the engine is equipped with an Warning the number of successive air preheating system there is a and automatic starting attempts is delay adjustable before the limited to 3 engine starts preheating Oo activation period The following pictogram will flash The following information is d
188. r the battery to be charged and the charging time available Note if several batteries connected together are being recharged the following points must be checked Are the batteries connected in series Is the voltage chosen exact 1 battery x 12 V 3 x 36V batteries Adjust the charge current to the lowest battery The power difference between the batteries must be as low as possible 8 4 Cleaning the battery oa Keep the batteries clean and dry The presence of impurities and rust on the battery and A terminals may cause the current jumps voltage drops and the battery to discharge particularly i oe in humid weather W La a i 1 Clean any signs of oxidation on the battery terminals and the cable terminals using a brass brush 2 Fully tighten the cable terminals and lubricate them with grease for battery terminals or vaseline A terminal which is not secured correctly may cause sparks and therefore lead to an explosion 86 242 8 5 Fault finding Fault observed Probable origin Measures or observations Th dh h and Incorrect composition Cool ie ME MENOS Incorrect storage Charge the battery Prolonged storage in a damp place Check the acid density The acid escapes through the filler holes The battery is too full Reduce the battery fluid level Battery tray not leaktight Replace the battery Acid level too low Considerable formation of gas due to a Check the charger and repair if very high charging voltage ne
189. railers M3128 M3129 type trailers Disengage the jockey wheel from the notches in the Remove the safety pin from the position lock 8 on the tube 6 with its handle 5 jockey wheel Loosen the jaw of the tube 7 with its lever Remove the position lock 8 Lower the tube until the jockey wheel touches the Place the jockey wheel in the bottom position ground Fit the position lock 8 Tighten the jaw of the tube 7 with its lever Fit the position lock pin Lower the jockey wheel to the ground with its handle Support the load on the jockey wheel gt Lower the jockey wheel with its handle gt When you are sure that the wheel can bear the load the towbar rises unhitch the trailer from the vehicle 5 Fit the stabiliser 1 Loosen the jaw of the stabiliser 2 with its lever Place the stabiliser in contact with the ground Tighten the jaw of the stabiliser 2 with its lever 31 242 3 3 2 2 Check before towing Before first use it is essential to check the tightness of the wheel bolts o IMPORTANT Before towing check the following Wheel tightness Hitching hook locked Tyre pressure Signalling lights working Enclosure doors closed Parking brake released for on road trailers Guide wheels jockey wheels and stands lifted Safety cable fitted for on road trailers INFLATION PRESSURE BAR 145R13 185R14C 155 70R13 195
190. re feed by oil pump Lubrication oil Class CF or CH 4 oil API service classification Whole engine Approx 4 5 L Sandara 1 2 U S gal Whole engine Approx 6 0 L 1 6 U S gal Oil oan Oil pan Max Min Approx 3 7 L Oil pan Max Min Approx 5 5 L 1 5 U S gal P 1 0 U S gal Approx 2 2 L Approx 3 7 L 1 0 U S gal Engine oil 0 6 U S gal capacity Whole engine Approx 6 2 L 1 6 U S gal Whole engine Approx 8 2 L o 2 U S gal Oil pan Max Min Approx 5 7 L Oil pan Max Min Approx 7 7 L 2 0 U S gal 1 5 U S gal Approx 3 1 L Approx 4 2 L 1 1 U S gal 0 8 U S gal Oil filter Cartridge type paper element Water cooled Cooling method Forced water cooling by centrifugal pump Approx 1 8 L 0 5 U S gal Approx 2 5 L 0 7 U S gal Coolant capacity basic engine only basic engine only Starting system Electric motor starting Starter DC 12 V 1 7 kW DC 12 V 2 0 kW 12 1 186 242 Chapter 12 MAIN SPECIFICATIONS Table 12 1 Main specifications ltem Specifications Alternator DC 12 V 50A Note a The specifications above are subject to change without prior notice b The specifications above are described for the standard model The special model specifications may differ from those of standard model 12 2 187 242 July 2009 J CRTNSMNEWEMLA SL SERIES Pub No 99610 31120 188 242 Printed in Japan Pub No 99610 31120 189 242 190 242 10 2 Appendix B Altern
191. re they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers via the drain port v Note Never allow these fluids to drain onto the ground ensure they are collected in a designated container 21 242 EN 2 5 Fuels lubricants and coolants All specifications product features are given in the engine and alternator maintenance manuals attached to this manual In addition to these we recommend the fuels lubricants and coolants mentioned in the Specifications section 2 5 1 Fuel specifications General quality requirements The quality of the fuel is essential for engine performance lt affects the technical performances such as the service life power supplied and fuel consumption as well as the ability to respect the requirements issued by authorities relating to pollutant emissions Only fuels which conform to the current legal requirements and national and international standards should be used Consult the local fuel distributor to find out the characteristics of the diesel fuel available in the area Examples of standards and requirements European standard CEN for vehicle fuel fuels for diesel engines diesel fuel requirements and test methods American Society for Testing and Materials basic requirement in the United States and Canada JIS KK 2204 Japanese Industrial Standards Japanese industrial standards Respecting pollutant emissions ASTM D 975 1 D and 2 D
192. rentheses are the standard value In addition to the items specified above turbidity is specified to be below 15 mg liter Long life coolant LLC Should coolant or LLC be accidentally consumed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention Be sure to use Mitsubishi Heavy Industries Ltd genuine long life coolant LLC GLASSY long life coolant Ethyl ene glycol type or PG GLASSY long life coolant Non amine type as coolant When using other brand LLCs by necessity be sure to use the LLC that meets the specification in Mitsubishi Heavy Industries Ltd Mitsubishi heavy industries Ltd disclaim the warranty claim concerning malfunctions caused by the use of LLC that does not meet the following specification Genuine LLC Mitsubishi Heavy Industries Ltd recommends the use of our genuine long life coolant GLASSY long life coolant Ethylene glycol type and Eco friendly prod uct PG GLASSY long life coolant Non amine type which are most appropriate coolant for diesel engine from Mitsubishi Heavy Industries Ltd Fig 6 1 GLASSY LLC 6 1 146 242 Chapter 6 COOLANT Other brand LLCs CAUTION Never mix Mitsubishi Heavy Industries Ltd genuine LLC with other brand LLCs Mixing with other brand LLCs degrades the performance of Mitsubishi Heavy Industries Ltd genuine LLC When using LLC other than Mit
193. rning rail transport When transporting generating sets in containers by rail the following steps must be observed 1 Puta plastic cover over non enclosed generating sets during transportation 2 Choose transport equipment appropriate for this usage and having all the safety guarantees both in terms of load bearing capacity and securing devices 33 242 3 5 Shipping 3 5 1 Generating sets with and without an enclosure Transportation must be carried out in accordance with the rules of shipping Generating sets must be transported in a shipping container When shipping generating sets in containers the following steps must be observed 1 Choose transport equipment appropriate for this usage and having all the safety guarantees both in terms of load bearing capacity and securing devices 2 Inthe case of a grouped load container SEI cases must be used for packing 3 6 Air transport Containers must be transported by air in accordance with the specific rules governing air transport The UN has classified generating sets as dangerous goods listed under UN code 3166 class 9 Engine internal combustion flammable liquid powered Any air shipment of generating sets must be subject to prior declaration to the air freight company in accordance with form MOD3909 For air transport observe the following steps 1 Choose transport equipment appropriate for this usage and having all the safety guarantees both in terms of
194. roduct in this manual may differ from those of product you have Please note that depending on specifications items described in this manual may differ from those on your engine in shape or may not beinstalled on your engine Please contact a dealer of Mitsubishi Heavy Indus tries Ltd if you need more information or if you have any questions elf you lost or damaged this manual obtain a new copy at a dealer of Mitsubishi Heavy Industries Ltd as soon as possible Mitsubishi Heavy Industries Ltd recommends the engine owner to install an hour meter on the engine due to monitor correct running intervals and to per form the maintenance at the appropriate timing 105 242 FOREWORD Warning indication The following means are used to call the attention of the operators and maintenance personnel to potential dangers of the engine Warning statements in the manual Warning labels affixed on the engine Warning statements The warning statements in this manual describe potential danger in operating inspecting or maintaining the engine using the following 5 classifications to indicate the degree of potential hazard Failure to follow these directions could lead to serious accidents which could result in personal injury or death in the worst case Understand the directions well and handle engines with following directions Indicates an immediately hazardous situation which if not avoided will result in death or ser
195. rrect operation and the safety of our machines we recommend the use of original manufacture spare parts In the event of failure to comply with this ad vice the manufacturer cannot be held res ponsible for any damage LEROY SOMER 239 242 13 LEROY SOMER R438 NOTES LEROY 14 SOMER 240 242 LEROY SOMER R438 NOTES LEROY SOMER 15 241 242 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOUL ME CEDEX FRANCE 338 567 258 RCS ANGOULEME S A au Capital de 62 779 000 www leroy somer com 242 242
196. rrect when the battery is Lack of residual magnetism Connect a new battery of moved No voltage 4 to 12 volts to terminals The alternator builds up but its voltage Check the connection of the voltage reference to the AVR at no load on E and E respecting does not reach the rated value when Faulty diode start up the polarity for 2 to 3 the battery is removed Armature short circuit seconds The alternator builds up but its Faulty AVR voltage disappears when the battery Field windings open circuit check winding is removed Main field winding open circuit check the resistance Check the AVR connections possible AVR failure Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Correct speed Voltage too low Check the drive speed Increase the drive speed do not touch the AVR voltage pot P2 Speed foo low before running at the correct speed Voltage too Adjust AVR voltage high potentiometer Adjustment ineffective Faulty AVR Check the speed possibility of cyclic irregularity Voltage Adjust AVR stability If no effect try normal fast recovery Loose connections oscillations potentiometer modes ST2 Faulty AVR Speed too low when on load or LAM set too high Voltage Voltage between E and E Check the speed or LAM set too high lice aa Run at no load and check SHUNT lt 6V AREP lt 10V the vol
197. ry sand or impermeable backfill IMPORTANT Oe Bare stony soils dry sand ee impermeable rock 4 Plant the earthing rod in the ground and connect it to the earth cable ground 1 metre Note For the United States National Electrical Code ref NFPA 70 use a copper wire with a minimum cross section of 13 3 mm or AWG 6 at most connected to the generating set s earth connection and a galvanised steel earthing rod completely buried in the ground in an upright position This earthing rod must be at least 2 5 m long of which at least 1 m must be in the ground 4 2 3 Making the connections 4 2 3 1 Connections general information When connecting always comply with standard NFC 15 100 and the application guide NFC 15 401 in France or follow standards based on the international standard IEC 60364 countries outside France The cable cross section and number of connection cables should be determined according to the type of connection cable and the current standards to be observed in the country of installation The choice of connection cables must comply with international standard IEC 60364 5 52 44 242 EN 4 2 3 2 Selecting the power cables The calculation rules used to choose the power connection cable size are defined below Identify the current shown on the generating set s identification plate From the table below select the circuit breaker rating directly above the current shown on the generating set s identific
198. s and idlers E Emission control information labels F Any other part with the primary purpose of reducingemissions or that can increase emission during fail ure without significantly degrading engine performance e Mitsubishi Heavy Industries Ltd shall furnish with each new engine written instructions for the maintenance and use of the engine by the owner LIMITED WARRANTY Refer to LIMITED WARRANTY VII 104 242 FOREWORD Important information To avoid the potential hazard accident prevention activities must be planned methodically and con ducted continually by considering all aspect of engine operation maintenance and inspection All related personnel including managers and supervi sors should actively participate recognize their roles and organize themselves and their work to ensure a safe environment The foremost safety objective is to prevent accidents which may result in injury or death or equipment damage Always observe laws or regulations of the local or federal national government Mitsubishi Heavy Industries Ltd cannot foresee all potential dangers of the engine potential danger resulting from human error and other causes or dan ger caused by a specific environment in which the engine is used Since there are many actions that cannot be performed or must not be performed it is impossible to indicate every caution in this manual or on warning labels As such it is extremely important
199. s below FAULTS Press Esc to return to the previous screen FAULT 25 12 05 15 30 Press OK to go to the HELP screen help on the highlighted fault Emergency Stop Use the scrolling and selection wheel to scroll through ALARM 25 12 05 15 30 the list of faults Low Fuel Level GS OK HELP Esc 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 79 242 EN 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 Terminology used by the SAE CAN J1939 standard SPN Suspect Parameter This represents the system or component at fault for example SPN 100 Number indicates an oil pressure problem or a problem with the oil pressure sensor This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by VOLVO FMI Failure Mode 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 SID System Identifier This term used in the J1587 standard
200. 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 ERANS DP The first line displays the motor speed in RPM an Y The second line displays the battery voltage in volts V Y Check the battery voltage min 12 V Press once briefly the green START button v Ifthe motor is equipped with an air preheating system there is a 10 second delay before the motor starts preheating activation period v The following screen appears Mu Y The third line displays the air preheating time Jul i remaining with pictograms representing a wy Ht s resistor and an hourglass v Ifthe 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 v The following screen appears 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 55 24
201. sed by LLC amine tye oreren aa 6 6 Pitting Of iron parts oooocccccnncccncnnnnconconancnnnonaness 6 6 Corrosion of aluminum Parts cccceeeeeeeees 6 6 Pitting and clogging of the radiator 6 6 Chapter 7 MAINTENANCE SCHEDULE How to use the maintenance A 7 1 Maintenance schedule 7 2 CONTENTS Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic engine iiitvecie des eenidaeieuaaweeeacenk 8 1 Belt and belt tension Inspect and Adjust 8 1 FUCL SS 8 2 Fuel tank Drain watter ccccseccceeeeseeeeeeees 8 2 Solenoid fuel pump filter Inspect and clean 8 2 Fuel system Bleed air cccoooonnnccccoccnccconcnnnos 8 3 Water sedimenter Drain water 00 8 5 Fuel filter cartridge type Replace 8 5 Fuel filter element Switching cock type A A 8 6 solenoid fuel pump filter Replace 8 6 Lubricating SySteM ccooccnccccccccncnconnnnns 8 7 Engine oil and Oil filter Replace 8 7 Cooling SySteM ccccoonccncccccncoconcnnnnnns 8 10 Coolant Change ccccccoccnnccconcnnconancnnnonannnnnnnns 8 10 Radiator fins Check and Clean 8 13 Inlet and exhaust systems 8 14 Ar cleaner Checa 8 14 Turbocharger InSpect ooccccccconcnccccoccnnnononos 8 14 Pre cleaner Clean Inspect and Replace 8 15 Air cleaner element Clean Che
202. sence of leaks Check the electrical parameters gt voltage frequency current gt rotating field On load tests Check the mechanical parameters gt engine parameters oil pressure coolant temperature gt absence of abnormal vibrations gt absence of abnormal noises gt absence of leaks Check the electrical parameters gt voltage frequency current gt rotating field 49 242 6 Using the generator set 6 1 Pre Start Inspection Inspecting the engine compartment gt Make sure there is no combustible material near the engine or battery Also check to make sure that the engine and battery are clean lf combustible materials or dust are found near the engine or battery remove them gt Check the electrical wiring for such components as the starter and alternator for looseness gt Check the entire engine for fuel leakage engine oil or coolant If leakages are found repair gt Make sure the following valves plugs and cocks are open or closed tightened properly v Fuel feed valve Open Y Coolant drain cock plug Closed Tightened v Oil drain valve Closed Checking the engine oil level A Do not top up the oil if the oil level is not below the low level marker Do not exceed the hatched area The oil level is correct if it is within the hatched area O Pull out the oil level gauge and wipe it clean using a waste cloth 9 insert the oil level gauge fully into the oil lev
203. speeds for 5 to 10 minutes for warm up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lubricated before they are subjected to heavy loads Warm up operation circulates lubricants in the engine and contributes to a longer service life and economi cal operation Do not conduct warm up operation for prolonged period of time Prolonged warm up operation causes carbon build up in the cylinders that leads to incom plete combustion Never operate the engine in an overloaded condition If the engine shows an overloaded condition such as black exhaust smoke reduce the load immediately to operate the engine at an appropriate output and load Overloading causes not only high fuel consumption but also excessive carbon deposits inside the engine Carbon deposits cause various problems and will shorten the service life of the engine Chapter 1 BASIC SAFETY PRECAUTIONS Conduct cooling operation before stopping the engine Before stopping the engine let it idle in low gear for 5 to 6 minutes to cool down Stopping the engine immediately after high load oper ation will cause engine parts to heat up and shorten the service life of the engine During cooling operation check the engine for abnor malities Protection of the engine against water entry Do not allow rainwater etc to enter the engine through the air inlet or exhau
204. st openings Do not wash the engine while it is operating Cleaning fluid water can be sucked into the engine Starting the engine with water inside the combustion chambers can cause the water hammer action which may result in internal engine damage and serious accidents Properly maintain the air cleaner and pre cleaner Maintain the engine with air cleaner or pre cleaner according to the following instructions Do not maintain the air cleaner or pre cleaner while the engine is running The turbocharger may suck particles of foreign materials into the engine and could result in serious accidents Remove the air cleaner or pre cleaner slowly to pre vent foreign materials accumulated on the element from falling off After removing the air cleaner or pre cleaner immediately cover the opening inlet port of air cleaner port in body for pre cleaner with plastic sheet or similar means to prevent foreign materials from entering the engine Clean the pre cleaner periodically The pre cleaner clogging can cause insufficient intake air or increasing in the exhaust temperature If the engine is equipped with a dust indicator con duct maintenance when the clog warning sign ap pears 1 8 121 242 Use of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace them with new tools Avoidance of prolonged time of s
205. subishi Heavy Indus tries Ltd genuine long life coolant LLC GLASSY long life coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type be sure to use the LLC which meets specification in Mitsubishi Heavy Industries Ltd The quality and performance of commercially avail able LLCs as well as their component variations are the responsibility of LLC suppliers Before purchasing commercial LLC be sure to dis cuss the suitability of LLC with the LLC supplier Use only all season LLC non amine type Do not use antifreeze alone instead of LLC 6 2 147 242 Standard for other brand LLC When using other brand LLCs by necessity be sure to use the LLC that meets following specification Mit subishi heavy industries Ltd disclaim the warranty claim concerning malfunctions caused by the use of LLC that does not meet the following specification General demands of LLC LLC shall be a homogeneous liquid Engine cooling system shall not receive troubles such as corrosions and precipitation products etc by LLC when the LLC is diluted to 30 to 60 density LLC shall be mixed with other LLC that satisfies this specification and shall not separate elements each other and shall not decrease the performance each other LLC shall not allow the container to be corroded and shall not has precipitation products etc even if LLC is left in the container for 6 months LLC shall not has extract
206. t If battery electrolyte is spilled on your skin flush immediately with plenty of water If battery electrolyte enters the eyes flush them immediately with lots of fresh water and seek medical attention at once Do not use open flames or other fire hazards near the battery When handling the battery be careful of sparks gen erated by accidental shorting Battery electrolyte level Inspect Battery electrolyte evaporates during use and the f electrolyte level gradually decreases The proper elec trolyte surface level is between the LOWER LEVEL and UPPER LEVEL lines For the battery without level lines the proper electro lyte surface level is about 10 to 15 mm 0 394 to 0 591 in above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water pour in carefully Specific gravity of battery electrolyte Check If the specific gravity measured at 20 C 68 F is lower than 1 22 then charge the electrolyte a s Electrolyte Table 8 1 Specific gravity of electrolyte surface Specific gravity amp UA Glass tube Less than 1 22 Discharged Charge LZ From 1 26 to 1 28 Fully charged eee 3 From 1 22 to 1 26 Charged Charge 7 Fig 8 28 Specific gravity of battery electrolyte Check 8 17 170 242 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Starter Inspect Visually check the starter for damage
207. t are approved of the emission regulation of the California Air Resources Board CARB The California Air Resources Board CARB is pleased to explain the emission control system warranty on you 2008 or later engine In California new heavy duty off road engines must be designed built and equipped to meet the State s stringent anti smog standards Mitsubishi Heavy Industries Ltd must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mitsubishi Heavy Industries Ltd will repair your heavy duty off road engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2008 and later heavy duty off road engines are warranted for the Warranty Period If any emission related part on your engine is defective the part will be repaired or replaced by Mitsubishi Heavy Industries Ltd OWNER S WARRANTY RESPONSIBILITIES As the heavy duty off road engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Mitsubishi Heavy Industries Ltd recommends that you retain all receipts covering maintenance on your heavy duty
208. t excessive wear the fuel must have satisfactory lubricity refer to the manufacturer s instructions for the engines fitted to our generating sets The ignition behaviour of diesel fuels is described by the cetane index The cetane index is important for emissions the ability to start in cold weather and engine noises The minimum technical requirements are 45 The fuel and tank must not contain any water Water causes the engine parts to corrode and wear more rapidly particularly the injection system parts In addition water promotes the growth of bacteria and fungi in the tank which can clog the fuel filter The fuel must not contain any type of residue Organic contaminants bacteria fungi etc can block the fuel filters inorganic material in the fuel dust sand can cause serious damage to the injection equipment 23 242 EN 2 5 2 Lubricant specifications Essential for the correct operation of the engine The oil should be selected according to its use Besides the lubrication function oil should also cool certain parts protect metal parts against corrosion improve the sealing in particular between pistons piston rings and cylinders remove impurities to the filter It is recommendable to use a top of the range lubricant for diesel engines The table below lists the oils recommended for each engine manufacturer Engine Make Type Make Type John Deere All GenPARTS GENLUB TDX 15W40 Mitsubishi Gen
209. t of the establishment except for those designated by the user Respecting the environment gt Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil gt Burning of waste in the open air is prohibited gt Remove waste water sludge and other waste in a specialised processing centre 1 4 2 Electrical safety precautions ELECTRICAL EQUIPMENT RISK OF ELECTRIC SHOCKS j 7 DANGER i Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the installation being supplied The electrical connections must be made in accordance with current standards and regulations in the country of use and the neutral system sold Ask a qualified electrician to intervene when there are specific cases requiring equipment to be connected to an existing electrical network Disconnect the power to the equipment equipment voltage battery voltage and network voltage before any installation or maintenance operation is performed Connect the equipment wires by respecting the wiring diagram supplied by the manufacturer Always handle the equipment with dry hands and feet Take all the necessary precautions to avoid touching stripped cables or disconnected connectors Use and maintain the cables in good condition well insulated and connected correctly and securely Only r
210. t on opening of voltage sensing circuit excitation overload current for 10 seconds then return to approximately 1A The alter nator must be stopped or the power switched off in order to reset the protection Fuse F1 on X1 X2 8A slow 250V Voltage sensing 5 VA isolated via trans former e 0 110 V terminals 95 to 140 V e 0 220 V terminals 170 to 260 V e 0 380 V terminals 340 to 520 V Voltage regulation 1 Normal or rapid response time via ST2 jumper see below Voltage adjustment via potentiometer P2 other voltages via adapter transformer Current sensing parallel operation C T 2 5 VA cl1 secondary 1 A optional Quadrature droop adjustment via potentio meter P1 Max excitation current adjustment via P5 see below 2 1 1 Configuration jumpers function Delivrery config Open Closed ST1 45h Open for module pn installation tri detection ST2 Fast Response time ST3 50 ou 60 Hz Frequency selection External ST4 potentio meter ST5 Without with LAM Others PMG Uno Potentiometer LAM voltage drop amplitude U f function bend position 13 or 25 2 1 2 Setting potentiometers function Delivrery position NE Quadrature droop operation with C T Voltage S tability xcitation current ceiling 2 2 Frequency compared with voltage without LAM Voltage A Bend 57 5 Hz 48 HZ 4 4 100 U UN 50 Hz
211. tage ac cording to the principle If the speed drops between 46 and 50 Hz the rated voltage follows a fast gradient as it i without is restored Gl If the speed drops below 46 Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value prop N lt 46 Hz Time Load on the shaft kW Drop N gt 46 Hz LEROY SOMER T 233 242 LEROY SOMER R438 A V R 2 5 R438 A V R options Current transformer for parallel operation of 1A 5 VACL 1 Remote voltage adjustment potentiometer 470 Q 0 5 W min adjustment range 5 range limited by internal voltage potentio meter P2 Remove ST4 to connect the po ten tiometer A 1 kQ2 potentiometer can also be used to extend the adjustment range For wiring up the external potentiometer the earth wires must be isolated as well as the potentiometer terminals wires at the same voltage as the power R731 external module sensing of 3 phase voltage 200 to 500 V compatible with parallel operation Disconnect ST1 to connect the module set the voltage via the module po tentiometer R 734 module detection of 3 phase current and voltage for parallel operation on unba lanced installations imbalance gt 15 R 726 module 3 functions mounted exter nally P F regulation 2F and voltage sensing cir cuit before paralleling 3 F Control
212. tage between E Faulty rotating diodes and too low Voltage bet E and E aulty rotating a et E on the AVR oltage between E an g when on load SHUNT gt 10V AREP gt 15V Short circuit in the main field Check the resistance Faulty exciter armature Check the resistance Warning During single phase operation check that the sensing wires from the AVR are connected to the correct output terminals Voltage Check the AVR the surge Exciter winding open circuit disappears suppressor the rotating The voltage does not return to the Faulty exciter armature during diodes and replace any rated value Faulty AVR operation defective components Main field open circuit or short circuited Warning The AVR internal protection may cut in overload lost connection short circuit LEROY 12 SOMER 206 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 4 5 1 Checking the winding You can check the winding insulation by performing a high voltage test In this case you must disconnect all AVR wires WARNING Damage caused to the AVR in such conditions is not covered by our warranty 4 5 2 Checking the diode bridge A diode in good working order should allow the current to flow only in the anode to cathode direction O O Anode e Cathode IN GR 4 5 3 Checking the windings and rotating diodes using separate excitation During this procedure make sure
213. tarter operation Do not use the starter for more than 10 seconds ata time If the engine does not start wait for at least 1 minute before cranking again Continuous operation of the starter will drain the bat tery power and cause the starter to seize Do not turn off the battery switch during operation Do not turn off the battery switch during operation If the battery switch is turned OFF when the engine is running not only various meters will stop working but also the alternator may have its diode and transistor deteriorated Cautionary instructions for transporting the engine When transporting the engine on a truck consider the engine weight width and height to ensure safety Abide by road traffic law road vehicles act vehicle restriction ordinance and other pertinent laws Chapter 2 NAME OF PARTS Engine external diagrams The external diagram is for the standard type of the engine The installed equipment and shapes differ according to the engine type S3L S3L2 left view Oil filler Front a eee Exhaust manifold Ee Alternator Fan Starter ae A Flywheel Fig 2 1 Engine left view S3L S3L2 right view Inlet cover Fuel injection nozzle Fuel injection pump Rear hanger Stop solenoid Y 7 Water pump
214. that the alternator is disconnected from any external load and inspect the terminal box to check that the connections are fully tightened 1 Stop the unit disconnect and isolate the AVR wires 2 There are two ways of creating an assembly with separate excitation Assembly A Connect a 12 V battery in series with a rheostat of approximately 50 ohms 300 W and a diode on both exciter field wires 5 and 6 ASSEMBLY A 6 Exciter field 5 Rh 509 300W 12V battery Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation power of the machine see the nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 L2 L3 checking the excitation voltage and current at no load see the machine nameplate or ask for the factory test report When the output voltage is at its rated value and balanced within 1 for the rated excitation level the machine is in good working order The fault therefore comes from the AVR or its associated wiring ie sensing auxiliary windings ASSEMBLY B 6 Exciter field 5 Diode 1A 12V LEROY SOMER 13 207 242 LEROY SOMER LSA 40 4 POLES ALTERNATORS 4 6 Dismantling reassembly see sect
215. the type of equipment being handled Check that there is sufficient handling capacity 2 Check that the handling equipment and apparatus are in good operating condition 3 Respect the handling instructions described in the present documentation and the pictograms displayed on the equipment to be handled 4 Be sure never to stand under the load being handled Note the lifting rings provided on the equipment are designed to handle the generating set alone If additional equipment is fitted to the generating set a study should be conducted in order to define the centre of gravity of the assembly and to check the correct mechanical performance of the structure and its lifting rings 1 4 7 Precautions for risks relating to noise HIGH SOUND LEVEL RISK OF HEARING LOSS Always use suitable ear defenders when working in close proximity to a generating set which is in operation Note for generating sets used inside for which the ambient noise levels are dependent upon the installation conditions it is not possible to specify these ambient noise levels in the operating instructions As prolonged exposure to high sound pressure levels can cause permanent damage to hearing it is necessary to measure the acoustics after installation in order to determine the sound pressure level and if necessary to implement the appropriate preventive measures 14 242 EN 2 General description 2 1 Description Overview Figure 7 Ge
216. this manual are accompanied by recommen da tions or symbols to alert the user to potential risks of accidents It is vital that you unders tand and take notice of the following warning symbols This A V R can be incorporated in a ma chine marked C E WARNING Warning symbol for an operation ca pable of damaging or destroying the ma chine or surround ing equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest tech nological developments The information contained in this document may therefore be changed without notice LEROY 2 SOMER 228 242 LEROY SOMER Installation and maintenance R438 A V R CONTENTS A PPP e Sy PON UA 4 1 1 AREP excitation system apsaietossineravsmiasusinesladnati onurinscedhimesiiadoiinooliateindahersandesimanniadeaanecs 4 1 2 PMG excitation SSI isso rita 5 1 3 SHUNT or separate excitation SySteM ocoooonccncocccccnncnnoncnnononcononnnnnnnnonnnnnnononrnnnonancennos 5 DISS ANV R ii a ia 6 Ale A nn A 6 2 2 Frequency compared with voltage without LAM ooooccococccnccconcnnconoooconononncncnnonconnonnnons 6 2 3 LAM Load Acceptance Module characteristiCS o occcoooccccnccooncnnonnonononnnanoncnnonons 6 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F on
217. tion Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident If the wire rope contacts the engine directly place a cloth or other soft padding to avoid damage to the engine and wire rope Do not climb onto the engine Do not climb onto the engine nor step on any engine parts located on the lateral sides To work on parts located on the upper section of engine use a ladder stool etc that was firmly secured Climbing on the engine may not only damage engine parts but also cause falling down from the engine and result in personal injuries Always prepare stable scaffold When working on the upper part of the engine and other hard to reach places use a stable work platform Standing on a decrepit stool or parts box may result in personal injury Do not place any unnecessary objects on a work plat form 116 242 Chapter 1 BASIC SAFETY PRECAUTIONS Protect ears from noise A CAUTION Wear ear plugs Always wear ear plugs when entering the machine room engine room Combustion sound and mechanical noise generated by the engine can cause hearing problems Be careful of burns _ OA CAUTION Do not touch the engine during or immediately after operation To avoid burns do not touch the gt tion work wait until the engine has cooled sufficientl
218. tive gear Works without wearing proper protective gear could result in serious injuries Never break seals To ensure proper engine operation the fuel control linkage is sealed to prevent accidental change of the injection volume and rotation speed settings Operat ing the engine without these seals in place can cause problems described below and also invalidates the warranty Rapid wear of sliding and rotating parts Engine damage such as seizing of engine parts Considerably increased consumption of fuel and lu bricating oil Degradation of engine performance due to improper balance between fuel injection volume and governor operation or overrunning of the engine which could result in a serious accident 120 242 Perform all specified pre opera tion inspections and periodic inspections Conduct the pre operation inspections and periodic inspections as described in this manual Failure to conduct the specified inspections may cause various engine problems damage to parts and serious accidents Break in the engine To break in new engines or overhauled engines oper ate the engine at a speed lower than the rated speed in a light load condition during the first 50 hours of operation Operating new engines or overhauled engines in a severe condition during the break in period shortens the service life of the engine Warm up the engine before use After starting the engine run the engine at low idling
219. to follow directions in this manual and also to take general safety measures when operating maintain ing and inspecting the engine When the engine is used by individuals whose native language is not English thecustomer is requested to provide thorough safety guidance to the opera tors Also add safety caution and operating signs that describe the original warning label statements in the native language of the operators The engine must be operated maintained and inspected only by qualified persons who have thor ough knowledge of engines and their dangers and who also have received risk avoidance training viii To prevent an accident do not attempt to carry out any operation other than those described in this man ual and do not use the engine for any unapproved purpose When the ownership of the engine is transferred be sure to provide this manual with the engine to the new owner Also inform Mitsubishi Heavy Industries Ltd of the name and address of the new owner of the engine This manual is copyrighted and all rights are reserved No part of this manual including illustra tions and technical references may be photocopied translated or reproduced in any electronic medium or machine readable form without prior written con sent from Mitsubishi Heavy Industries Ltd The contents in this manual are subject to change at any time without notice for improvement of the engine Pictures or illustrations of the p
220. to the hitching plate on the towing vehicle Examples of how to attach the hitching cable If the hitching ring is not correctly connected to the hitching hook the trailer will become separated from the towing vehicle In this case the unlocking cable actuates the parking brake which then becomes an emergency brake To ensure that the device fulfils its function correctly the unlocking cable MUST NOT be wound around the jockey wheel as this will disable emergency braking IMPORTANT MUST NOT be taut or obstructed as this could activate emergency braking during towing MUST be routed as straight as possible and not be obstructed at any point MUST be sufficiently long to allow cornering 7 Connect the electrical cable plug controlling the lamps indicators etc to the socket on the towing vehicle 8 Remove the parking brake Remove the wheel chocks if necessary and store them Perform the following operations simultaneously on the parking brake gt Press the unlocking button 9 gt Lower the handle 10 fully 30 242 Unhitching a trailer fitted with a hitching ring 1 Immobilise the trailer Chock the wheels Apply the parking brake gt Raise the parking brake lever 10 fully 2 Disconnect the electrical cable plug controlling the lights indicators etc from the socket on the towing vehicle 3 Remove the unlocking cable on the towing vehicle 4 Release the hitching ring M3126 M3127 type t
221. ture from the fuel tank Apply rust preventive oil NP 3 liberally on the exposed sections of the machining Seal the air inlet exhaust outlet breather and other openings with an adhesive cloth tape 2 53 p Cover the entire engine Note a Store the engine in a well ventilated indoor area b It is not necessary to drain coolant since it contains LLC Add LLC to increase the concentration to between 30 to 60 c Post a sign at an easily noticeable place to warn that the rust preventive oil in the engine must be replaced with engine oil and the fuel tank must be filled with fuel before operating the engine for the first time after storage d New engine oil can substitute for rust preventive oil NP 10 2 of lubrication system Recommended rust preventive oil and corrosion inhibitor Table 9 1 Recommended rust preventive oil and corrosion inhibitor JIS No Recommended IES SES Application Prevention of rust on a Nippon Oil Corporation i NP 3 Anti Rust P 1600 oo machine sur K 2246 NP 9 Nippon Oil Corporation Prevention of rust in fuel Anti Rust P 2400 system NP Nippon Oil Corporation Prevention of rust in 10 2 Anti Rust P 230 lubricating system Ryoukou Kagaku Z 1519 VCI Diana ND volatile corrosion Prevention of rust in air intake system inhibitor Maintenance during storage Charge the battery once a month First check the battery electrolyte for proper level and then charge the battery 9 1 17
222. uaeeeesseaeeeesaeaeaeeeessaaeceessueeeesssaeeeeessaas 49 5 5 Checking th generating s et atestado A A aeaa a i Ea 49 1 242 SING INE generator Sel Ai 50 6 1 Presstart INSP CMON rs E a E E a 50 6 2 Generator set with NEXYS Control Panel di is 53 621 CONTO panel ES tl ol oa rod ae EDO 53 6 2 1 1 gigas Mei O ance 54 A A E A ee ee en eee Meee eeeee ene er 55 023 SWIEC TANG Osa ceca 56 624 Ma rims anda TAINS secretes eee Ti E IE A O Rie cease oom eee 56 62 9 EaultS and alatins DelalSucaa acc 56 6 2 0 MURIEELY lag nostic MALAS e sate passat 58 6 3 Generator set with TELYS Control Panel ccccceecccccceccceeeseececeeeeeeeeeeeeeeeeesaeeeeeeeeeeesseeseceeeeseseeeeseeeeeeeeeessseeeaeeeeeeesssaaaeeeeeeees 64 6 51 Control panel presenta ON ivi is 64 6 3 1 1 ME ts A ieee eee eee ie ea ea ewe E 64 6 3 1 2 Description OF the SCI IN ess statics eee O ied ds ete Need A iia 66 6 3 1 3 DESCHDION Ol AE DICTOGFAMS NY ZOMG scarico ti tii tod Ii 67 6 3 1 4 DESCHOLONCOnING pictograms IN ZONE 2 si ii dolio 68 6 3 1 5 Description of the pictograms IN ZONE B ccccseececcesececeeececceuececseueeecsueeeccaueeecsadeeecsuueeeseueeessaueeeesssaeeessaneeessaeeessaaeees 69 6 3 1 6 Display or Messages Mi ZO CA cease cease A el ance cave REE eae eecmteue ena thae unas 71 A PI 76 A Sree ea teen aciee ccd aetna ees ne es eucams ac S 77 A E 77 6 3 4 1 WIG WING Alar NS GMOS als a ici dotados nde lianas 77 6 3 4 2 Activan 81ers Lars 1s 1d 1
223. ult 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 List of alarms associated with a pictogram Associated pictogram A Bar Low fuel level alarm Indicates the need to fill up with fuel Associated pictogram Alternator charging fault alarm indicates a problem affecting the alternator charging rate 57 242 6 2 6 MURPHY diagnostic module The fault finding module MDDM is an indicator for analysis and fault finding designed and manufactured for reading information available on the J1939 CAN Bus The fault finding module is easy to use and will enable you to view the values of the various engine parameters and engine operating status codes It shows two lines each of 8 characters on a backlit LCD display Two scroll buttons enable you to navigate in the menus and parameters Two LEDs one red and one orange indicate the fault or alarm status of the engine or ECU DISPLAY SCROLL BUTTONS A Machine Parameters The following parameters are available on the Murphy fault finding module working hours counter engine speed battery voltage engine speed coolant temperature oll pressure fuel economy air manifold temperature actual consumption active status codes status codes recorded coming from the engine MDDM20 para
224. ume change 0 to 40 ee Hardness change 10 to 0 Tensile strength change O to 10 Ethylene Elongation change 30 to 0 propylene diene monomer Volume change 0 to 10 Hardness change 10 to 0 Storage stability vol 30 vol room temperature 6 Hr Maximum 0 3 6 4 149 242 Chapter 6 COOLANT Maintenance of LLC CAUTION Should coolant or LLC be accidentally consumed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention LLC is toxic Never dispose of coolant containing LLC drained from engine into regular sewage For disposal of used coolant consult LLC distributor Replacement intervals of LLC Be sure to renew LLC at the intervals specified in the maintenance schedule of this manual Failure to renew LLC may cause malfunctions due to performance degradation of preventing rust and cavitation The coolant mixed with LLC which Mitsubishi Heavy Industries Ltd recommended expires in 2 years Be sure to change coolant at least once every 2 years LLC concentration Keep the LLC concentration of 30 GLASSY and 40 PG GLASSY on any temperature conditions LLC of less than 30 concentration does not provide sufficient corrosion protection If the LLC concentration is lower than 10 it may accelerate corrosion When adding coolant do not add plain water Always use coolant with the same LLC concentration Table 6 3
225. ustries Ltd Check radiator Refer to P8 13 Cooling eCheck control system system eueheooNee Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Insufficient amount of air Refer to P8 16 ee and Check intake air pressure and leakage of intake air om Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd 11 6 181 242 Chapter 11 TROUBLESHOOTING Engine oil consumption is high Table 11 7 Engine oil consumption is high Cause Remedies Fuel system Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Check oil leakage Oil leakage to the outside of engine l o l Consult a dealer of Mitsubishi Heavy Industries Ltd Lubricating Engine oil viscosity too low Use appropriate oil viscosity Refer to P5 3 sysiem Check amount of engine oil and lubric
226. y by checking the temperature gauge engine during or immediately after operation A hot engine can cause burns To conduct maintenance and inspec Do not open the radiator filler cap when the engine is hot Never open the radiator filler cap while the engine is running or immediately after the engine is stopped When opening the cap stop the engine and allow the coolant temperature to lower sufficiently When opening the radiator filler cap open slowly to discharge the pressure inside the tank Also to avoid a risk of getting scalded by steam wear thick rubber gloves or wrap a cloth around the cap When closing the cap be sure to tighten securely The coolant is hot while engine is running and immedi ately after the engine stops If the cap is opened when the coolant is at operating temperature steam and hot coolant may blow out and result in burns Do not touch high pressure injection fuel If fuel leaks or sprays out from the high pressure injec tion pipe do not touch the fuel Fuel in the fuel injection pipes is under high pressure and if the fuel contact your skin it goes into deep tis sues and may result gangrene Refill coolant only after the coolant temperature dropped When refilling of coolant perform it after coolant tem perature drops not immediately after the engine is stopped Otherwise you are scalded with hot coolant 117 242 Chapter 1 BASIC SAFETY PRECAUTIONS Be careful when handling

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