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Generating set R44 - User manual - SDMO

1. SPN CID SID PID PPID 2 olx Description Commentary gt o S 110 110 110 Coolant temperature sensor 0 Coolant temperature extremely high 3 Coolant temperature sensor input voltage high 4 Coolant temperature sensor input voltage low 5 Coolant temperature sensor open circuit 15 Coolant temperature high least severe 16 Coolant temperature moderately high 31 Coolant temperature high 111 111 Coolant level sensor 0 Engine coolant level low 1 Engine coolant level low 3 Coolant level sensor input voltage high 4 Coolant level sensor input voltage low 153 153 Crankcase pressure sensor 0 Value above normal 3 Crankcase pressure sensor input voltage high 5 Crankcase pressure sensor open circuit 158 158 Battery voltage sensor 1 Voltage above normal 17 ECU power down error 160 Wheel speed sensor 2 Wheel speed input noise 164 164 Injection Control Pressure 168 168 Electrical system voltage 2 EJ Electrical system voltage low r i Inlet air temperature 172 172 172 Ambiant air temperature sensor sensor for PERKINS 3 Ambiant air temperature sensor input Inlet air temperature sensor voltage high input voltage high 4 Ambiant air temperature sensor input Inlet air temperature sensor voltage low input voltage low 5 Ambiant air temperature sensor open circuit 15 High Inlet air temperature alarm warning 16 High Inlet air temperature alarm action alert 174 174 Fuel temper
2. 50 3 Clean or replace 50 4 F Air intake system CHECKING scott med aule 35 1 Fuel Diesel iiem aii ine ies 10 1 B Handling and 10 1 Fuel filter Belt Replacement enaa e 30 4 Check automatic 1 35 2 Fuel pump model 03 5 Check tension ot entra eines eee tes 30 5 Fuel system Replace 4045 and 6068 engines 50 5 ces 50 5 Bolt and screw torque values ain 65 9 H WMO GCMs LE 65 8 Break in engine oil sssssssssesse 10 2 Hardware torque values MOIO dece RH I D 65 9 Unified inch 65 8 Configuration data viewing 15 3 Coolant Diesel engine 2 10 Instrument panel Drain and flush cooling system 45 1 Adjust 15 10 Pressure testing cooling system 35 5 Adjust contrast aaier e E 15 12 Warm temperature climates 10 4 Changing units of
3. esee 53 6 3 2 Stanting nn URGERE REESE IE OE HUE Dp Dee ee ee 57 6 9 3 Switching n ee OE RE eL Ub ed d tede e RC ERO LE GERE o Leere te 58 6 3 4 ice ee e EROR dete een RE een 58 6 9 4 1 Viewinrig alarms S obe dct tette Wie De srt teet tee ttd 58 6 9 4 2 Activation ot an alarm or fault asuna UE dee ens Der eed e ect e ER v Dee eee Ce ed 59 6 3 4 3 Activation of an alarm and a fault isitin nennen nnne nnn nennen nnne nennen nennen nnne 60 6 944 Engine fault codes display nit ome a EEUU LU HEU D Rio eil atte t aaia 61 6 39345 etu t a leg MEM 62 7 Maintenance schedule opener e e OC REB RUE ERI 63 7 1 Reminder of use noun ORDERED UN ESRB NE 63 7 2 Eriglrie x eiae popolo eb HD 63 7 3 E ERERO DI Een E s m RID BREMEN 63 8 udo Hetero toi ee ac eee am RO utei T 64 8 1 Storage and transport s d eoe HIM mien e 64 8 2 Battery setting INTO Service o cate p be a nA tat ere Bes Pen te atte a ioo td da 65 8 3 ee e 65 8 4 loadipreconiZatior ete d neo atc ee d d Miete RB uites e sue at 66 8 5 FaultS and remedies cid arr ett td tote pecie
4. PMG option N Nbr Description N Nbr Description 1 1 Stator assembly 90 1 Exciter field 4 1 Rotor assembly 91 4 Exciter field fixing screw 15 1 Fan 100 1 Exciter armature 16 6 Fixing screws 44 2 only 107 1 Diode crescent support 28 1 Earth terminal 120 1 Terminal block support AREP 30 1 DE shield 124 1 Terminal block 33 1 Air outlet grille 198 1 Voltage regulator AVR 36 1 Shield on exciter end 207 1 AVR damper seal 37 4 Tie rod 217 1 Terminal block 41 1 Cover front panel 290 1 PMG housing 47 1 Cover rear panel 291 1 Adaptation shaft 48 1 Cover top panel 292 1 Magnetic rotor 49 34 Fixing screws 293 1 Stator 51 1 Air intake grille 294 2 Fixing screws 59 3 Inspection door 295 1 Tie rod 60 1 DE bearing 296 1 Cable gland washer nut 62 2 4 Bearing retainer fixing screw 297 1 End plate 63 1 Cable gland washer 43 2 only 320 1 Hub 44 2 only 67 1 Circlips 343 1 Diode bridge assembly 68 1 Inner bearing retainer 347 1 Surge suppressor 70 1 NDE bearing 349 1 O ring 79 1 Preloading wavy washer 410 1 End shield LEROY 18 SOMER 214 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS LEROY SOMER Electric Power Generation DECLARATION of COMPLIANCE related to CE marking This Declaration applies to the generators designed to be incorporated into machines complying with the Machine Directive Nr 2006 42 CE dated 17 May 2006
5. 02 9 Engine operation D 8500 Hours of 02 10 Standby power units senne 25 9000 Hours of 02 10 Stopping the 15 29 9500 Hours of 02 11 Changing Generator Frequency 15 29 10000 Hours of 02 11 Maintenance rial Number Observe service intervals 20 1 Jod 03 1 Use correct fuels lubricants and coolant 20 1 Engine serial number 03 1 Maintenance interval chart 20 1 Record engine serial number 03 2 Engine option 03 3 Maintenance Daily or every 10 hours Record fuel injection pump model number 03 4 Daily prestarting checks 25 1 Record Engine Control Unit ECU Serial Number A E E uera 03 5 Maintenance 500 hours Record High Pressure Fuel Pump Changing engine oil and filter 30 1 Model N mlber 2 iino 03 5 Replacing fuel filter element s POSEE WES ROT nt 30 4 Checking belt 3029 and 4039 Engines 30 5 Safety oec ten ad m
6. gt t L p 4 1 1 Lg fo Ve 1 amp t oy O O 0 NF C15 100 ai EARTHING SYSTEM y L E 2 EDF earth ai p MAX CONNECTION CABLE CROSS SECTION 185MM M10 BOLT M10 NUT 17 260 EN M126 M127 50Hz FR A RRRRARARAA 1 1 2 lel 1 3 4 DIFFERENTIAL SWITCH Q10 4x63A 30 mA X03 16A 400V SOCKET 16A CIRCUIT BREAKER Q08 X08 16A 230V SOCKET 4x32A CIRCUIT BREAKER Q02 4x16A CIRCUIT BREAKER Q03 X02 32A 400V SOCKET 16A DIRUPTOR CIRCUIT BREAKER Q05 X05 16A 230V SOCKET 18 260 N M126 M127 50Hz EU gt DIFFERENTIAL SWITCH Q10 4x40A 30 mA X03 16A 400V SOCKET 16A CIRCUIT BREAKER Q09 X09 16A 230V SOCKET 4x16A CIRCUIT BREAKER Q03 X01 63A 400V SOCKET 16A DIRUPTOR CIRCUIT BREAKER Q05 X05 16A 230V SOCKET 19 260 N M127 50Hz UK DIFFERENTIAL SWITCH Q03 4 40 30 mA 1X32A DIRUPTOR CIRCUIT BREAKER 004 Q05 006 X04 X05 X06 32A 230V SOCKET 4x63A CIRCUIT BREAKER Q02 X02 63A 400V 3P N T SOCKET 20 260 2 2 Technical specifications N Range Generating set type RENTAL POWER R44
7. 15 13 Crankcase vent tube Main menu 15 1 Cleaning etr erede 35 1 Setup 1 up 15 15 Setup 4 up display 15 21 D Shutdown codes sse 15 9 Using diagnostic 15 1 Daimpot 2 pot tbi 40 4 Viewing active service 15 7 Diagnostic procedure nettes 55 10 Viewing configuration 19 3 Using diagnostic 15 1 Viewing stored service codes 15 5 Diagnostic trouble codes DTCs Intermittent fault 55 13 Active engine service codes viewing 15 7 Stored service codes viewing 15 5 L Diagnostic Trouble Codes DTCOs 55 11 Diagnostic gauge 55 10 Listing of DTOS i 55 11 Diesel engine oil sess 10 2 Lubricant Diesel fUela auto ahi hon NECK UA turi e HAC 10 1 UE ET 10 3 DTCs Diagnostic Trouble Codes OSIOLage ERRARE 10 3 View active service
8. 16 3 3 Terminal connection diagrams 5 4 Exploded view parts list 17 3 4 Commissioning esee 3 5 Settings a nil aaia renes EC DECLARATION OF INCORPORATION 19 AVRO SOMER 3 199 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE 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 able to claim on their insurance and after a visual check tum the machine by hand to detect any malfunction 1 3 Identification The alternator is identified by means of a nameplate glued to the frame Make sure that the nameplate on the alternator conforms to your order The alternator name is defined according to various criteria see below Example of description LSA 43 2 M45 J6 4 LSA Name used in the PARTNER range eM Marine C Cogeneration eT Telecommunications 43 2 Machine type e M45 Model oJ Excitation system C AREP J SHUNT or PMG E COMPOUND 6 4 Winding number number of poles 1 3 1 Nameplate So that you can identify your alternator quickly a
9. Listing of Diagnostic Trouble Codes DTCs Intermittent Fault Diagnostics With Electronic Storage Engine storage guidelines Preparing engine for long term storage Removing engine from long term storage Specifications General engine pack specifications Non Emission Certified Engines General engine pack specifications Stage Il Emission Certified Engines a T AUN N an 1 gt General engine pack specifications EPA Tier 2 Emission Certified Engines 65 6 General engine pack specifications EPA Tier 3 Emission Certified Engines 65 7 Unified Inch Bolt and Screw Torque Values 65 8 Metric Bolt and Screw Torque Values 65 9 78 260 072209 PN 2 Identification Views Identification views 2 lt z 8 CD30840 B 3029DF128 Continued on next page DPSG CD03523 3 19 22JAN07 1 3 072209 01 1 PN 7 79 260 Identification Views co z z CD30841 3 8 4045HF158 Continued on next page DPSG CD03523 3 19 22JAN07 2 3 072209 01 2 PN 8 80 260 Identification Views CD30842 CD30842 UN 10JANO3 6068HF258 DPSG CD03523 3 19 22JANO7 3 3 01 3 072209 8
10. according voltage 140 mm 4 x holes 5 8 x 175 x 115 mm Quad K P1 droop M AREP ST9 ST4 Option External potentiometer for adjusting the voltage Response fM normal ST2 time fast ST1 m Single Stabili n amp 3 stability detection Option R731 3 ph A Ai in 3 ph detection ST1 open Poen 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 Sys EROY SOMER 5 233 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 2 R438 A V R 2 1 2 Setting potentiometers 2 1 Characteristics Storage 55 C 85 C Operation 40 C 70 C Standard power supply AREP or PMG Rated overload current 8 10 s Electronic protection overload short cir cuit 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 0 110 V terminals 95 to 140 V 0 220 V terminals 170 to 260 V 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
11. indicator Drain the water and sediment from the fuel filter s Drain the engine oil and replace E the filter b Replace the fuel filter element s e Check the tension of the belts E A and the automatic tensioner c Check the valve clearances and A 5 adjust if necessary d Clean the breather e Check the air inlet circuit with hoses and unions Check the cooling circuit pressure Check the damper 6 cyl e e Check the engine speed and the regulator droop Drain and flush the cooling circuit f Clean the air filter element a e Check the thermostat and the injectors g a Clean the air filter when the clogging indicator is red Replace the filter element after it has been cleaned 6 times or once a year b Drain the oil and change the filter after the first 100 hours of operation c Check the tension of the belt every 500 hours on 3029 and 4039 engines and on 4045 and 6068 engines fitted with a manual tensioner Check the automatic tensioner every 1000 hours once a year on 4045 and 6068 engines d This operation should be carried out by one of our agents After the first 500 hours of operation then every 1000 hours for 3029 and 4039 engines Every 2000 hours for 3029 and 4039 engines e Operation to be carried out by one of our agents The Damper must be changed every 4500 hours every 5 years f Using John Deere COOL GARD coolant drain and flush the cooling circuit every 2500 hours eve
12. POWERIECH AS liter RG8041 UN 15JAN99 DPSG CD03523 11 19 10JUL09 1 1 Engine serial number plate RG8007 UN 15JAN99 CD30746 UN 24SEP99 4045 and 6068 Engines 3029 and 4039 Engines Each engine has a 13 digit John Deere serial number The first two digits identify the factory that produced the engine Your engine s serial number plate A is located on the right hand side of cylinder block behind the fuel filter for 4045 and 6068 engines and near the fuel supply pump CD indicates the engine was built in Saran France on 3029 and 4039 engines DPSG CD03523 12 19 22JANO07 1 1 0 3 1 072209 PN 21 93 260 Serial Numbers Record engine serial number Record all of the numbers and letters found on your engine serial number plate in the spaces provided below JOHN DEERE B This information is very important for repair parts or ENGINE SERIAL NUMBER warranty information 2 CDA4039D123 56 D Engine Serial Number B NU 4039D F008 coo 8 c 1 Engine Model Number C 5 D P S G SARAN IN FRANCE E Coefficient of Absorption Value D 8 3029 and 4039 engine plate JOHN DEERE E o 1 DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE x a 4045 6068 engine plate DPSG CD03523 13 19 22JAN07 1 1 072209 03 2 PN 22 94 260 Serial Numbers Engine option codes JOHN DEERE NUMBER CD6068H123456 6068
13. 10 4 2 Technical support service eeeseeseesseseese esent nnne 10 Any maintenance or breakdown operations on the A V R are to be done by personnel trained on commisioning servicing and maintenance for the electrical and mechanical elements The R250 is an IP00 product It must be installed inside a unit so that this unit s cover can provide IP20 minimum total protection it must only be installed on LS alternators in the appropriate location so that when viewed externally it has a 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 3 219 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 1 SUPPLY The regulator controls the excitation current 2 Hah according to the alternator s output voltage T T SHUNT excitation system With a very simple conception the SHUNT The SHUNT excitation alternator is auto excitation alternator does not have a short excited with a R 250 voltage regulator circuit capacity MAIN FIELD STATOR 12 wires marking T1 to T12 SHUNT SYSTEM e e I7 T2r 4T8 5 eM _ 5 Induced s
14. Weights and Dimensions Dimensions with standard tank Dimensions with high autonomy tank Dimensions x w x h 2080mm x 960mm x 1415 mm Weight 1095kg dry weight 1215kg in operating configuration Hood M127 63 dB 7 m 90 Lwa Dimensions x w x h 2160mm x 966mm x 1582mm Weight 1227kg dry weight 1457kg in operating configuration Hood M127 DW Noise level ea3dBQo7m 90 Lwa Output Voltage Hz Phase Load factor Emergency Prime Prime power s kW kVA Emergency power kW kVA Max current 400 230 50 3 0 8 64 58 35 44 32 40 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 1096 one hour every 12 hours is available as per ISO 3046 1 Engine data Manufacturer model JOHN DEERE 3029TF120 Type 4 cycles Turbo Cylinder configuration 3 XL Cubic capacity 29L Rotation speed 1500 Rpm Max emergency prime power at nominal speed 40 36 4 kW Adjustment type Mechanical Fuel consumption 110 96 emergency power 10 8 L h 100 main power 9 8 L h 75 96 main power 7 5 L h 50 main po
15. 6 2 1 1 Introduction to pictograms The pictograms are as follows Operating temperature Symbols for electric and mechanical sizes Overspeed Non starting fault Starting on external command Battery Preheating Air intake EY e Delay Oil pressure Diagram 6 3 View of pictograms The fuel level pictogram is used to display the fault the alarm and the fuel level The operating temperature and oil pressure pictograms are used to display the fault and analog value The overspeed and non starting fault pictograms are used to display the fault The battery pictogram is used to display the alternator charge fault and to indicate the battery voltage VVVV 41 260 EN 6 2 2 Manual starting A Check that the generating set circuit breaker has triggered Danger Connect the generating set battery Turnthe key switch to the ON position without forcing it All of the LEDs light up for 2 seconds to confirm that they are operating correctly If the LEDs do not light up check the protection fuse and replace it if necessary All the items on the screen are displayed for 2 seconds Only the ON LED remains lit to indicate that the module is powered up The following screen appears nnn rt RPI The first line displays the motor speed in RPM The second line displays the battery voltage in volts V Y Check the battery voltage min 12 V Press
16. 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 59 260 N 6 3 4 3 Activation of an alarm and a fault The appearance of an alarm and a fault causes gt 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 RESEF OK LIST The faults list can be accessed by pressing OK of the scrolling and selection wheel examples 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 th I d select heel t ll through ALARM 25H 2 05 15 30 eee selection wheel to scro roug Low Fuel Level GS OK HELP Esc Check Emerg Stop Pos C
17. byselecting menu 12 CONTROL LOAD T The following display will disappear supply stopped gt gt gt gt 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 Alarms All alarms will cause the yellow LED to flash General alarm In conjunction with this LED a flashing pictogram appears on the LCD screen 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 58 260 N Faults All faults will cause the generating set to stop immediate or gradual stop coolant temperature and overload or short circuit the red LED to flash General fault In conjunction with this LED a flashing pictogram appears on the LCD screen 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
18. 03 4 system i dde 40 Specifications Damper 40 4 Engine Pack 2500 hours 3 years EPA Tier 2 Emission Certified Engines 65 6 Drain and flush cooling system 45 1 EPA Tier 3 Emission Certified Engines 65 7 500 hours Non Emission Certified Engines 65 1 Changing engine oil and filter 30 1 Stage 1 Emission Certified Engines 65 4 Checking belt occid 30 5 Storage Replace fuel 30 4 ENGINE tn ed 60 1 As required Storing fuel ci ri ef Lettere 10 1 Additional service information 50 1 Storing lubricants eosar OFE 10 3 Clean or replace air filter one piece 50 3 Clean or replace air filter element 50 4 T Do not modify fuel system 50 1 Replace fan and alternator belts 4045 Torque charts and 6068 50 5 Mele c ete torn nde de aah eae ee 65 9 Daily or every 10 25 1 Unified INCH iowa nda uso RN cte bo 65 8 Observe service 20 1 Trouble COdES sane cis nds Ee EE e 55 11 Use correct fuel lubricant
19. PN 107 179 260 Storage Engine storage guidelines 1 John Deere engines can be stored outside for up to three 3 months with no long term preparation IF COVERED BY WATERPROOF COVERING 2 John Deere engines can be stored in a standard overseas shipping container for up to three 3 months with no long term preparation 3 John Deere engines can be stored inside warehoused for up to six 6 months with no long term preparation John Deere engines expected to be stored more than six 6 months long term storage preparation MUST BE taken See PREPARING ENGINE FOR LONG TERM STORAGE DPSG CD03523 51 19 22JAN07 1 1 Preparing engine for long term storage The following storage preparations are good for long term engine storage up to one year After that the engine should be started warmed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration 1 Change engine oil and replace filter Used oil will not give adequate protection See CHANGING ENGINE OIL AND FILTER 2 Service air cleaner See CLEAN OR REPLACE AIR FILTER 3 Draining and flushing of cooling system is not necessary if engine is to be stored only for several months However for extended storage periods of a year or longer it is recommended
20. seconds at a time Wait at least 2 minutes for starter to cool before trying again Crank engine for 20 seconds with starter do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated Start engine and run at no load for several minutes Warm up carefully and check all gauges before placing engine under load On the first day of operation after storage check overall engine for leaks and check all gauges for correct operation DPSG CD03523 54 19 22JAN07 1 1 60 1 072209 PN 108 180 260 Specifications General engine pack specifications Non Emission Certified Engines 181 260 ITEM UNIT OF 3029DF120 3029DF128 3029TF120 3029TF158 MEASURE Number of 3 3 3 3 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 110 110 110 Displacement L 2 9 2 9 2 9 2 9 Compression Ratio 17 2 1 17 2 1 17 2 1 17 2 1 POWER 1500 kW hp 27 36 26 35 38 51 36 49 rpm Prime POWER 1500 kW hp 30 41 30 41 42 56 40 54 rpm Standby POWER 1800 kW hp 30 41 30 41 43 58 40 54 rpm Prime POWER 1800 kW hp 35 47 34 46 48 64 45 61 rpm Standby Width overall mm 519 582 519 582 Length overall mm 716 888 716 888 Height overall mm 819 931 819 979 Weight dry kg 316 345 316 350 Engine oil quantity 6 6 8 8 Engine coolant 14 5 14 5 14 5 14 5 quantity
21. DOE 33522039401 4 1 06 07 2009 71 260 72 260 Engines amp Power Units for Generator Sets Saran Built OPERATOR S MANUAL Engines amp Power Units for Generator Sets Saran Built OMCD16564 ISSUE G9 ANGLAIS CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The State of California requires the above two warnings John Deere Usine De Saran This manual replaces OMCD16564 F8 European Version PRINTED IN GERMANY 73 260 Introduction Foreword THIS MANUAL COVERS the following engines for generator sets Non Emission Certified Engines Mechanical Fuel System CD3029DF 120 CD3029DF 128 CD3029TF 120 CD3029TF158 CD4039DF008 CD4039TF008 CD4045DF 158 CD4045HF 120 CD4045HF 158 CD4045TF120 CD4045TF158 CD4045TF220 CD4045TF258 CD6068HF 120 CD6068HF 158 CD6068HF258 CD6068TF158 CD6068TF220 CD6068TF258 Emission Certified Engines Stage Il according to Directive 97 68 EC CD3029HFS70 Mechanical Fuel System CD3029HFU70 Mechanical Fuel System CD3029TFS70 Mechanical Fuel System CD3029TFU70 Mechanical Fuel System
22. Inserta clamp ammeter to monitor the current passing through the short circuit connections Connect a 48 Volt battery in series with a rheostat of approximately 10 ohms 50 W to the exciter field terminals respecting the polarity Open all the alternator openings fully Run the alternator at its rated speed and adjust the exciter field current using the rheostat to obtain the rated output current in the short circuit connections 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 CAUTION Ensure that the alternator has the degree of protection matching the defined environmental conditions LEROY SOMER 202 260 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3434 en 2010 10 i 3 2 2 Mechanical checks 3 3 Terminal connection diagrams Before starting the machine for the first time check that the fixing bolts on the feet are tight the cooling air is drawn in freely the protective grilles and housing are correctly in place the standard direction of rotation is clockwise as seen from the shaftend phase rotation in order 1 2 3 Foranti clockwise rotation swap 2 and 3 the winding connection corresponds to the site operating voltage see sect
23. PN 12 84 260 Maintenance Records 2500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series n Cooling system drain and flush if COOL GARD is used Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 60 19 22JAN07 1 1 3000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Air intake system check Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 61 19 22JAN07 1 1 02 4 072209 PN 13 85 260 Maintenance Records 3500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 62 19 22JAN07 1 1 4000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean
24. 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 3 ph Open for module pr installation tri detection Response time 50 ou 60 Hz Frequency selection Potentiometer LAM Supply LAM voltage drop amplitude U f function bend position 13 or 25 function Delivrery position Quadrature droop operation with C T Voltage Stability Excitation current ceiling 2 2 Frequency compared with voltage without LAM Voltage i Bend 57 5 Hz 48Hz 4 PT 100 U UN 50Hz a 60 Hz Frequency 60 Hz Hz ee 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 eitherto reduce the speed variation frequency and i
25. 19 Oil pan 59 Oil Cooler 20 Coolant pump 60 Add on Auxiliary Drive Pulley 21 Thermostat Cover 62 Alternator Mounting 22 Thermostat 63 Low Pressure Fuel Line Continued on next page DPSG CD03523 14 19 22JAN07 1 2 03 3 072209 PN 23 95 260 Serial Numbers Option Description Option Codes Codes 23 Fan Drive 64 24 Fan Belt 65 X 25 Fan 66 X 20 Engine Coolant Heater 67 27 Radiator 68 X 28 Exhaust Manifold 69 29 Ventilator System 72 Starting Motor 74 31 Alternator 75 32 Instrument Panel 76 __ 35 __ Fuel Filter 81 36 X Front Plate 83 37 Fuel Transfer Pump 84 X 39 Thermostat Housing 86 40 Oil Dipstick 87 X 41 Belt Driven Front Auxiliary Drive 88 43 __ Starting Aid 91 44 Timing Gear Cover with Gears 94 J 45 Balancer Shaft 95 46 Cylinder Block With Liners and Camshaft 97 X 47 Crankshaft and Bearings 98 48 Connecting Rods and Pistons 49 Valve Actuating Mechanisms Description Exhaust Elbow Turbocharger Temperature Switch Electronic Tachometer Sensor Damper Engine Serial Number Plate ECU Electronic Software Option Air conditioner Compressor Mounting Air Restriction Indicator Oil Pressure Switch Primary Fuel Filter Electronic Software Electrical Wiring Harness Fan Pulley Automatic Belt Tensioner Oil Filter Special Equipment Factory Installed Vehicle Timing Identificatio
26. 44 2 4 POLE ALTERNATORS 3 INSTALLATION Personnel undertaking the various operations discussed in this section must wear the appropriate personal protective equipment for mechanical and electrical hazards 3 1 Assembly All mechanical handling operations must be undertaken using approved equipment and the machine must be horizontal Check how much the alternator weight see 4 9 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 lifting hooks or handles should be determined by the shape of these rings Choose a lifting system that has regard for the integrity and environment of the alternator 3 1 2 Coupling 3 1 2 1 Single bearing alternator Before coupling the alternator and the heat engine check they are compatible by undertaking a torsional analysis of the transmission on both units checking the dimensions of the flywheel and its housing the flange coupling discs and offset CAUTION When coupling the alternator to the prime mover the holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Do not use the alternator fan to turn the rotor Make sure the alternator is securely bedded in position during coupling Tighten the coupling disc screws to the recommended t
27. 5 balancing error mechanical failure Cylinder 5 unknown error mechanical failure Cylinder 6 status injector Short circuit high side to B Short circuit high side to low side or low side to B 676 39 Short circuit high or low side to ground Cylinder 6 circuit open Cylinder 6 circuit shorted Cylinder 6 balancing error mechanical failure Cylinder 6 unknown error mechanical failure Glow plug relay status Glow plug relay voltage high Glow plug relay voltage low 677 Start relay status Start relay control short circuit to high Start relay control short circuit low Start relay control open circuit 253 260 SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Commentary 678 41 8 Volt power supply ACM 8 Volt DC supply open short to B ACM 8 Volt DC supply open short to ground 679 42 Injection control pressure regulator pressure release valve 723 342 Secondary speed sensor Secondary engine speed sensor data intermittent 11 Secondary engine speed sensor loss of signal 12 Loss of signal sensor failure 729 70 Inlet air heater signal Preheat sense Inlet air heater signal high Inlet air heater signal
28. 89 260 072209 PN 17 Maintenance Records 7500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series n Cooling system drain and flush if COOL GARD is used Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 70 19 22JAN07 1 1 8000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Cooling system drain and flush if COOL GARD is not used n Valve clearance adjust POWERTech n Air intake system check n Vibration damper check Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 71 19 22JAN07 1 1 02 9 072209 PN 18 90 260 Maintenance Records 8500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 72 19 22JAN07 1 1 9000 Hours of operation a Engine oi
29. Lights signallin only for on road trailers Warning lights are obligatory for on road driving Signalling must comply with regulations in force in the country of use Red rear lights Front reflective devices white direction indicators stop lights Rear reflective devices triangle red Side reflective devices orange Figure 4 2 Example of French signalling 4 4 Unhitching the trailer This operation should be carried out on horizontal flat stable ground 000000 Lock the wheels Lower the front wheel Disconnect the road signals wire Refit the hitch using the wheel to release the hook ring from the tow vehicle Engage the handbrake Release the tow vehicle 32 260 N 4 5 Implementation for installation Operations to be carried out Ensure that the ground is strong enough for the assembly not to sink into it Unhitch the trailer Immobilise the trailer by placing chocks under the wheels Fully engage the parking brake if fitted Using the front wheel position the generating set as close to horizontal as possible Lower the stands if fitted and lock them lt lt 4 lt lt 5 4 6 Break transmission adjustment A The handbrake is used only as a parking brake Setting is carried out starting with the brakes moving to the brake control Important After fitting the wheels on the axle turn the wheels in the FORWARD direction on all RA 2 type brak
30. MOTEURS LEROY SOMER Boulevard Marcellin Leroy 16015 ANGOULEME France Declares hereby that the electric generators of the ranges PARTNER Industrial and Professional as well as their derivatives manufactured by Leroy Somer or on Leroy Somer s behalf comply with the following International Standards and Directives EN et CEI 60034 1 et 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets The Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with the Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the following International Standards and Directives The Machine Directive Nr 2006 42 CE dated 17 May 2006 The 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 Technical Managers P Betge O Cadel uj 4152 en 12 2009 c LEROY SOMER 19 215 260 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOULEIME CEDEX FRANCE RCSANGOUL ME N 671820223 S A aucapita
31. Oil filter on 4045 and 6068 engines 4 Replace oil filter 3029 and 4039 engines a b Remove and discard oil filter element B using a suitable filter wrench Oil new packing C and install new filter element Hand tighten element according to values printed on filter element If values are not provided tighten element approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element 4045 and 6068 engines a b C Remove and discard oil filter element A using a suitable filter wrench Apply clean engine oil to inner B and outer C seals and to filter threads Wipe both sealing surfaces of the header D E with a clean rag Ensure notches in dust seal F are properly installed in the slots in the housing Replace dust seal if damaged Install and tighten oil filter by hand until firmly against dust seal F DO NOT overtighten CD30759A UN 29JANO7 P E CD30760 UN 26AUG99 CD30926 UN 30JANO7 RG11617 UN 240CT01 Oil filter seals RG11618 UN 240CT01 Filter and mounting header A Oil filter element B Inner seal C Outer seal 5 Close oil pan drain valve Continued on next page D Sealing surface E Sealing surface F Dust seal DPSG CD03523 29 19 01JUL09 2 3 30 2 144 260 072209 PN 72 Maintenance 500 hours 6 Oil filler cap on rocker arm
32. USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF Engine Parameters RG13199 UN 26SEP03 OURGP11 00000B1 19 03SEP03 9 18 10 Use the Arrow keys to scroll to and highlight a selected parameter parameter with a number to right PERCENT LOAD AT CURRENT RPM of it ENGINE OIL PRESSURE This number indicates ENGINE COOLANT TEMPERATURE te order of display tor 2 the parameters and amp that the parameter is D selected for display 1 2 1 8 D a Select Parameters Continued on next page OURGP11 00000B1 19 03SEP03 10 18 072209 15 18 PN 55 127 260 Operating the Engine 11 Press the Enter key to deselect the selected parameter removing it from the list of parameters ENGINE SPEED being displayed on the 1 Up Display PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE OG Deselect Parameters RG13219 UN 26SEP03 OURGP11 00000B1 19 03SEP03 11 18 12 Use the Arrow keys to scroll and highlight the desired ENGINE SPEED parameter that has not been selected for display PERCENT LOAD AT CURRENT RPM 2 parameter without a number to right of it ENGINE OIL PRESSURE 1 Note that the numbers ENGINE COOLANT TEMP now indicate the new order ol display for S i the parameters Select Desired Parameters RG13151 UN 24SEP03 OURGP11 00000B1 19 03SEP03 12 18 13 Press the Enter key to select the parameter
33. Ul 25 V s 30 mA 500 500 100 mA 500 250 300 mA 167 83 500 mA 100 50 1A 50 25 3A 17 8 5A 10 5 10A 5 2 5 The UI value 25 V is required for work site installations and livestock buildings etc For a default voltage of 25 V and a default current of 30 mA this rod must be of a minimum length of see table below Length of Nature of ground rod in metres 1 Thick arable land moist compact ballast Lean arable land 1 Gravel coarse ballast To obtain an equivalent length you can use several earthing rods 3 6 connected in parallel and set apart by at least their length Example 4 interconnected 1 metre rods separated by 1 metre Bare stony soils dry sand impermeable rock Note For the United States National Electrical Code reference NFPA 70 The generating set must be earthed To do this use a copper wire with a minimum cross section of 13 3 mm or AWG 6 at most connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically This earthing rod embedded fully in the ground must have a minimum length of 2 5 m 3 5 Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be install
34. 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 genset nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field supply current by adjusting the rheostat or the Variac and measure the output voltages on L1 L2 L3 checking the excitation voltage at no load see machine nameplate or ask for the factory test report When the output voltage is at its rated value and balanced within 196 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 Variac 6 Exciterfield 5 Diode 1A DC 12V 220 V Assembly B 4 6 Dismantling reassembly see sections 5 4 1 5 4 2 amp 5 4 3 During the warranty period this operation should only be carried out inan LEROY SOMER approved workshop or in our factory otherwise the warranty may be invalidated Whilst being handled the alternator should remain horizontal translational movement of rotor not locked Check how much the alternator weighs see section 4 9 before choosing the lifting method The choice of lifting hooks or handles should be determined by the shape of the lifting rings 12 LEROY SOMER 208 260 LEROY SOMER INSTALLATION
35. Water dirt or air in fuel system Dirty or faulty injection nozzles Defective thermostat Defective temperature gauge or sender Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Turbocharger not functioning Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oil level Continued on next page Solution Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Have authorized servicing dealer or engine distributor check injectors Remove and check thermostat Check gauge sender and connections Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing dealer or engine distributor check injectors See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Clean or replace fuel hose See your authorized servicing dealer or engine distributor Add oil
36. c T4 5 11 Te T12 Field e 6 e BOR R 250 4 x holes 5 8 x 50 x 115 mm 140 mm Slow fuse F1 250V 8A P1 6 Voltage Frequency selector 50 Hz 60 Hz for U F fonction and LAM adjustement P2 G Stability D ST4 Option External potentiometrer for voltage adjusting LEROY 2 SOMER 220 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 2 R250 A V R 2 1 Characteristics Storage 55 C 85 C Operation 40 C 70 C Voltage regulation around x 0 5 96 Supply range voltage detection 85 to 139 V 50 60 2 Rapid response time 500 ms for a transient voltage variation amplitude of 20 96 Voltage setting P1 Stability setting P2 Power supply protected by 8 A fuse replacement product Ferraz Shawmut T084013T fast blow fuse 8 A FA 250 V breaking capacity 30 kA 2 2 U F Fonction and LAM The threshold position 50 Hz 60 Hz to action the U F fonction as well as the LAM setting type is selected using the potentionmeter WARNING The jumper settings must correspond to the rated operating The threshhold position and LAM fonction settings are done with the jumper Operating at 50 Hz U F gradient 0 threshold at 48 Hz without LAM for impacts between 30 and 40 of the rated lo
37. dirty side NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi Mark air filter to keep track of each cleaning operation 6 Fully depress air restriction indicator reset button and release to reset indicator 7 Check air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM DPSG CD03523 58 19 22JAN07 1 1 50 4 072209 PN 91 163 260 Maintenance As required Replacing fan and alternator belt 4045 and 6068 Engines NOTE Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR for additional information on the belt tensioner 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary 2 On engines with automatic belt tensioner release tension on belt using a breaker bar and socket on tension arm On engines with manual tensioner loosen cap screws holding the alternator Remove poly V belt from pulleys and discard belt 4 Install new belt making sure belt is correctly seated in all pulley grooves Refer to belt routing at right for your application 5 Apply tension to belt See CHECKING BELT 6 Start engine and check belt alignment ALT Alternator CP Crank Pulley FD Fan Drive I Idler Pulley T Tensioner WP Water Pump CD30769 UN 01SEP99 Installation on 4045 engines 9 CD30770 UN 01SEP99 Installation on 6068 engines DPSG CD03523 45 19 31JAN07 1 1 Bleeding the fuel syst
38. such as alternators The last two digits of each code identify one specific option provided on your engine such as a 12 volt 55 amp alternator NOTE These option codes are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice If an engine is ordered without a particular component the last two digits of that functional group option code will be 99 00 or XX The list on the next page shows only the first two digits of the code numbers For future reference such as ordering repair parts it is important to have these code numbers available To ensure this availability enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page NOTE NOTE Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory If option code label is lost or destroyed consult your servicing dealer or engine distributor selling the engine for a replacement Option Description Option Description Codes Codes Engine Base Code 11 Rocker Arm Cover 50 Oil Pump 12 Oil Filler Neck 51 Cylinder Head With Valves 13 Crankshaft Pulley 52 Auxiliary Gear Drive 14 Flywheel Housing 53 Fuel Heater 15 Flywheel 54 Oil heater 16 Fuel Injection Pump 55 Shipping stand 17 Air inlet 56 Paint Option 18 Air cleaner 57 Coolant Inlet
39. the ECU will flash each code in numerical order If there are no active DTCs the Fault Lamp will flash a code 88 4 Following the active codes the Fault Lamp will flash a code 33 This indicates the start of blinking stored codes If there are any stored DTCs the Fault Lamp will flash its 2 digit number If there is more than one stored DTC the ECU will flash each code in numerical order If there are no stored DTCs the Fault Lamp will flash a code 88 5 Once complete this sequence will repeat 6 When complete turn ignition OFF As an example if an engine had an active DTC 18 and stored DTC 53 the flashing sequence would be flash three times short pause flash two times long pause flash one time short pause flash eight times long pause flash three times short pause flash three times long pause flash five times short pause flash three times CD03523 0000191 19 02FEBO7 1 1 072209 PN 103 55 9 175 260 Troubleshooting Using diagnostic gauge for retrieving Diagnostic Trouble Codes DTC s NOTE The method below applies on applications having the optional diagnostic gauge shown refer to the generator documentation for more information 1 Make sure all engine mechanical and other systems not related to the electronic control system are operating properly See ENGINE TROUBLESHOOTING in this section NOTE Diagnostic gauge A uses the menu key B to acce
40. 070CT03 OURGP11 00000B2 19 03SEP03 14 14 Break in period Within first 100 hours of operation During the first 100 hours of operation avoid overloading excessive idling and no load operation If oil has to be added during this time see ENGINE BREAK IN OIL NOTE During the break in period a higher than usual oil consumption should be considered as normal After first 100 hours of operation After the first 100 hours drain the crankcase and change the oil filter see CHANGING ENGINE OIL AND FILTER Fill crankcase with seasonal viscosity grade oil see DIESEL ENGINE OIL Check tension of alternator belt Check connections of air intake hoses Check for proper tightening of cap screws all around the engine DPSG CD03523 17 19 22JAN07 1 1 Starting the engine A oM Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aids See COLD WEATHER OPERATION 1 Perform all prestarting checks outlined in Maintenance Daily Section Open the fuel supply shut off valve if equipped 3 Activate the starter motor switch to crank the engine and release it as soon as engine starts NOTE Do not operate the starter motor more than 20 seconds at a time DPSG CD03523 18 19 22JAN07 1 1 15 25 072209 PN 6
41. 1 27 100 Above 12 60 V 1 25 80 12 54 V 1 20 60 12 36 V From 50 recharge 1 19 40 12 18 V Risk of sulphation 1 13 20 Under 11 88 V Unusable 65 260 N 8 4 Load preconization Y Very discharged or sulphated batteries can no longer regenerate or charge in a generating set Note Sulphation is the formation of whitish lead sulphate deposit on the plates which becomes hard and insoluble in acid This deposit reduces the active surface of the plates and increases their internal resistance A A discharged battery may become irreparably damaged Recharge it immediately Important Battery charge When several batteries are connected together the following points should be checked Are the batteries connected in series Is the voltage chosen exact 1 x 12 V battery 3 x 36V batteries Adjust the charge current to the lowest battery The power difference between the batteries must be as low as possible lt lt 4 lt Example of charge 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery should be recharged to 30Ah Charge factor 1 2 Ah x 1 2 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required lt lt lt lt 54 lt Recharging is complete when the battery voltage and the acid density stop increasing The charging current must always be 1 10 of the nominal capacity of the batter
42. 15 7 View stored service codes 15 5 M E Maintenance 1000 hours 1 year Engine Check and adjust valve clearance 3029 Operations n tro ai 15 29 and 4039 35 3 Engine Control Unit ECU serial number 03 5 Checking air intake system 35 1 Engine oil Checking automatic belt tensioner e rre tree 10 2 4045 and 6068 35 2 Diesel ein ed e i 10 2 Cleaning crankcase vent tube 35 1 Dfaihlfig iiid deat ets 30 1 Pressure testing cooling system 35 5 Engine speed Mechanical fuel system 40 3 Continued on next page Index 1 BN 191 260 Index Page Page 2000 hours 2 years Engine option codes 03 3 Adjust speed droop governor Engine serial number plate 03 1 Mechanical fuel system 40 3 Fuel pump model 03 5 Adjust valve clearance 4045 and 6068 POWERTech 03 1 cine ay 40 1 Record engine serial 03 2 Check engine speed Mechanical fuel Record fuel injection pump model number
43. 2 Manual Starting ces ccm ede cepe cm et e rend deen rri re le eae n ds 42 6 2 3 Switching Off cohetes eee t ht ipei S rede e neers 43 6 2 4 Alarms and fa lts uiuat me Alva haa Ee Ue e Rn Lor qu Re READER HERE Re eve 43 6 2 5 Faults and alarms Detalls 1 rente tee egere dee viet e pe dise Lt nd gain ovens re Rec ep tad 43 6 3 Generator set with TELYS control panel nennen nnne nnn entrent nnne nnne tns entere nns enne 46 6 9 1 Control panelipresentallon 3 ett pe UU ates te Eid eb gk eie ti e See at 46 6 3 1 1 View of the front panel eet gae eee Here apt et ete RE RR besoin edie eed shee tae ac v esate 46 6 3 1 2 Description of the screen Ete deep coegi re gister PERRA cen a ege ea Lote be papier iota eed 48 6 3 1 3 Description of the pictograms in zone 1 ssssseeeeneenen nenne ener nnne nennen nennen nennen nennen 49 6 3 1 4 Description of the pictograms in zone 2 ssssssseeenenneeen nennen nennen nere 50 6 3 1 5 Description of the pictograms in zone 3 ssssssssseeeneeeeen eee eene nennen nennen 51 6 3 1 6 Display of messages in zone 4
44. 6 5 Press the Menu key to return to the main menu ADJUST CONTRAST ON lt lt gt QOO Return To Main Menu RG13187 UN 26SEP03 OURGP11 00000AF 19 03SEP03 5 6 6 Press the Menu key to exit the main menu and return to the engine parameter display aoe 1009 REM 1800 RPM 57 PSI VOLT OAL PRES RG13159 UN 26SEP03 Exit Main Menu OURGP11 00000AF 19 03SEP03 6 6 Selecting Units Of Measurement 98 TOO REM LOADAPM ENG RPM 1 Turn the key switch to the ON position Starting at 1800 RPM 8 the single or four engine parameter display press the 57 PSI p Menu key BAT VOLT OIL PRES 1 5 a c Menu Key Continued on next page OURGP11 00000B0 19 03SEP03 1 7 15 13 m 122 260 Operating the Engine 2 The main menu will be displayed Use the Arrow GO TO 1 UP DISPLAY dtu through the menu until Select Units is STORED CODES ignigntea ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT OGO Select Units RG13188 UN 020CT03 OURGP11 00000B0 19 03SEP03 2 7 3 Once the Select Units menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to access the Select lsTORED CODES Units function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Press Enter Key RG13189 UN 020CT03 OURGP
45. AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 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 set of flat spanners 7 mm 8 mm 10 mm 12 mm 1 socket set 8 mm 10 mm 13 mm 16 mm 18 mm 21 mm 22 mm 24 mm 1 size 5 Allen key eg Facom ET5 1 size 6 Allen key eg Facom ET6 1 size 10 Allen key eg Facom ET10 1 size 14 Allen key eg Facom ET14 1 T20 and T30 TORX bit 1 puller eg Facom U35 1 puller eg Facom U32 350 4 6 2 Screw tightening torque IDENTIFICATION screw Torque N m Field terminal block screw M4 4 N m Field screw M6 10 N m Diode bridge RP M6 5N m Diode nut M5 4N m 43 2 tie rod M12 57 N m 44 2 tie rod M14 90 N m Earth screw M8 26 N m 43 2 disc shaft screw M12 110 N m 44 2 disc shaft screw M16 250 N m 44 2 turbine screw M6 5 Grille screws M6 5 Cover screws M6 5 Terminal block nut M10 20 N m 4 6 3 Access to connections and the regulation system The terminals are accessed directly by removing the terminal box lid 48 To access the AVR adjustment potentiometers the side plate 367 should be removed 4 6 4 Accessing checking and replacing diodes 4 6 4 1 Dismantling Remove the air intake grille 51 Remove the surge suppressor 347
46. AREP amp 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 MAIN FIELD AREPSYSTEM 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 a STATOR 12 wires marked T1 to T12 Aux windings T1 T7 T2 T8 T3 T9 m po mx 5 2 EE Armature QD T4 T10 T5 T11 T6 T12 Field oe o 10 Yellow 11 Red 12 Black 9 Green uu according voltage 140 Sou _ 4x holes 5 8 x F1 250V 8A 175 x 115 mm ST5 with LAM without LAM 4 P1 need ST3 ET Ln M AREP Frequency 50Hz 60Hz r3 PMG ST10 LAM 13 25 Excitation 5 Option STA External potentiometer for adjusting the voltage ceiling open STI 1 knee point 65 Hz Resp
47. AVR Main field open circuit or short circuited Caution Internal protection may be activated overload open circuit short circuit LEROY SOMER 207 260 11 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE 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 CAUTION Damage caused to the AVR in such conditions is not covered by our warranty 4 5 2 Checking the diode bridge Anode e 9 C e Cathode LSA 43 2 44 2 diode bridge 2 C C A A X TI C CC A diode in good working condition allows the current to flow in only one direction from anode to cathode 4 5 3 Checking the windings and rotating diodes using separate excitation During this procedure make sure 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 Exciterfield 5 Rh 50 9 300 W Diode 1A 12 V battery Assembly B Connect a
48. Disconnectthe 6 diodes using an ohmmeter or a battery lamp see section 4 5 2 4 6 4 2 Reassembly Replace the bridges respecting the polarity see section 4 5 1 Replace the surge suppressor 347 Refit the air intake grille 51 Replace the terminal box lid 48 4 6 5 Replacing the NDE bearing on single bearing machines 4 6 5 1 Dismantling Remove the terminal box lid 48 Remove the air intake grille 51 Unscrew the fixing clamps on the power output cables remove the connector from the exciter and the R 791 module Remove the 4 nuts on the tie rods Remove the NDE shield 36 using a puller eg U 32 350 FACOM 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 machine Place the preloading wavy washer 79 in the shield and fit a new O ring seal 349 Refitthe NDE shield and pass the bundle of wires between the top bars of the shield Refit the fixing clamps on the cables the R 791 module and the exciter connector Refit the air intake grille 51 Replace the terminal box lid 48 B ZZ NDE shield Screw rod d lt 4 6 6 Replacing the bearings on two bearing machines 4 6 6 1 Dismantling Uncouple the alternator from the prime mover Remove the 8 assembly screws Remove the DE shield 30 Remove t
49. OIL LEVEL lt NEXT gt HIDE ET Hide Trouble Code RG13239 UN 29SEP03 OURGP11 00000AE 19 03SEP03 3 6 4 The display will return to the single or four parameter f f 1000 RPM display but the display will contain the Shutdown 8 icon Pressing the Enter key will redisplay the hidden 1800 RPM H trouble code 14 2 57PSI 9 COOL TEMP d a i IMPORTANT Ignoring the shutdown message can pm 7 Nri ACER result severe engine damage fea E MS PUT SN OOO GOco Flashing Shutdown Icon Continued on next page OURGP11 00000AE 19 03SEP03 4 6 15 9 PN 46 118 260 Operating the Engine 5 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four tex SHUTDOWN parameter display SPN 100 FMI 1 FAULT ENGINE OIL PRESSURE LOW CORRECTIVE ACTION CHECK OIL LEVEL lt NEXT gt HIDE Redisplay Trouble Code RG13239 UN 29SEP03 OURGP11 00000AE 19 03SEP03 5 6 6 The single or four parameter screen will display the shutdown icon until the trouble code condition is corrected IMPORTANT Ignoring the shutdown message can result in severe engine damage RG13180 UN 26SEP03 Shutdown Icon OURGP11 00000AE 19 03SEP03 6 6 Adjusting Backlighting 98 1000 RPM LOADARPM ENG RPM 1 Turn the key switch to the ON position Starting at
50. Y The operating and safety instructions must be made known to operating personnel They will be regularly updated Y Read and understand the manuals provided with the generating set pump unit or lighting column properly The manufacturer s instructions must remain at the disposal of technicians if possible in situ Y facility must be operated under the direct or indirect supervision of a person appointed by the operator who is familiar with the operation of the facility and the dangers and drawbacks of the products used or stored in the facility Y Do not wear loose clothing or get close to machines in operation Note that the fans are not clearly visible when the engine is running Y Warn personnel present to keep their distance during operation Y Donotrun the generating set pump unit or lighting column without refitting the protective covers and closing all the access doors Y Never let a child touch the generating set pump unit or lighting column even when shut down Y Avoid operating the generating set pump unit or lighting tower in the presence of animals disturbance scares etc Y Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site When chocking the trailer on a slope ensure that there is nobody in the path of the trailer Y Never start the engine without an air filter or exhaust Y Engine with turbocharger never start the engine without fitting the air fi
51. 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 comin operating terminals g from the AVR are correctly connected to the Voltage disappears during operation components Check the AVR the surge suppressor the rotating diodes and replace any defective 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 Warning after operational testing replace all access panels or covers 12 LEROY SOMER 240 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f 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 Partnumbers should be identified from the exploded views and their description in the parts list Our extensive network of service stations can dispatch the neces
52. and flush cooling system every 2500 hours 3 years when John Deere COOL GARD coolant is used Otherwise every 2000 hours 2 years Contact your dealer when thermostat or injection nozzles are suspected to be defective Replace injection nozzles every 5000 hours and thermostat every 10000 hours DPSG CD03523 26 19 25JANO07 1 1 2 0 z 1 072209 PN 67 139 260 Maintenance Daily or every 10 hours Daily prestarting checks CD30753 UN 26AUG99 o o n o N z 2 Q i N o e a o FD000047 Do the following BEFORE STARTING THE ENGINE for the first time each day Py a 5 CD30754 UN 26AUG99 3029 and 4039 engines FD000047 UN 13MAR96 IMPORTANT DO NOT fill above the crosshatch area Oil levels anywhere within crosshatch are IMPORTANT DO NOT add makeup oil until the oil considered in the acceptable operating range level is BELOW the add mark 1 Check engine oil level on dipstick A Add as required using seasonal viscosity grade oil See DIESEL ENGINE OIL Add oil at rocker arm cover filler cap B Continued on next page DPSG CD03523 27 19 07FEBO07 1 4 25 1 140 260 072209 PN 68 Maintenance Daily or every 10 hours CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Only remove filler cap when engine is cold or when cool enough to touch with bare hands Slowly loosen cap
53. b duet 32 4 5 Implementation for installations toda ier ote f c t cet ah 33 4 6 Break transmission adjUstiTient Dea e t te tenter e p ob e Su aes 33 4 7 s ciae co ae ice to decani cet est rp redimendi ote o ces 35 4 8 Electrical Connection diagrams 5 re eel a ee eit tienda ese aee iretur duet 36 4 9 Complete wheels technical information enne nnnm nennen nnns terns nnns enne etse enn sentent enn nes 36 5 Preparation betore operating the Set iei eto da i ot oe MeL Ende eee en aded ete P dro dee 37 5 1 Installation checks eee Rom eie e ed e dice tocan et Pane needs 37 5 2 Checks after starting the generating set essessessessesesseseseeseeeeee nennen nnne nnns ennt rennen nnns 37 1 260 6 Using the generator Set db tetto bU de Dt ete ve Siete qe leto ues tds dates e bd me Pete lese aes 37 6 1 Pr Start InspectiOri uoi reto ce aed ebat eim a Pt io es rece et ee ate iet ae a dec ec rrt 37 6 2 Generator set with NEXYS control panel sessssssssseseseseeeeee nennen nnne nnn nennen entre inns innen eere s entes nnne s tenen nenne nnne 40 6 2 1 Control panelipresentation dsi hiri Anes erede p cote en et d fr d i de n c A c rrt d ied 40 6 2 1 1 Introduction to pIClOGraMS E e i a va PO dedecus eme eee a ie 41 6 2
54. bad condition punched dented S allowing no filtered air to enter the engine 8 3 Clean air filter with compressed air working from clean to dirty side NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi 4 Mark air filter to keep track of each cleaning operation 8 Fully depress air restriction indicator reset button and S release to reset indicator i 6 Check air system entirely for proper condition see S CHECKING AIR INTAKE SYSTEM DPSG CD03523 44 19 22 7 1 1 50 3 PN 90 162 260 Maintenance As required Clean or replace air filter element A Primary element B Secondary safety element Clean air filter when restriction indicator C is red Replace both primary A and secondary B filter elements after primary element has been cleaned six times or at least once a year Proceed as follows 1 Thoroughly clean all dirt around air filter area 2 Remove wing nut D and remove primary element A from canister IMPORTANT Do not attempt to clean the secondary safety element B It must be only replaced as recommended 3 Thoroughly clean all dirt from inside canister CD30772 UN 27AUG99 C Air restriction indicator D Wing nut IMPORTANT If primary element shows evidence of bad condition punched dented replace both the primary and the secondary elements 4 Clean primary element with compressed air working from clean to
55. bicarbonate of soda diluted in 4 litres of water The bicarbonate of soda solution should be added until the reaction has finished lather The remaining liquid should be rinsed off with water and left to dry Y Dry batteries do not require any servicing Y Batteries ready for use must be recharged at the latest when the acid density drops below 1 20 8 1 Storage and transport Y Batteries ready for use must be stored in a cool and dry place frost free protected from the sun self discharge Y Batteries must be transported and stored vertically risk of acid spillage Y Leave the terminal cover on the positive terminal 64 260 N 8 2 Battery setting into service Batteries filled with acid have a density of 1 28 g ml and are charged n the case of dry batteries fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates Let the battery rest for 20 minutes Before fitting the battery stop the engine and any power consumer clean the terminals and give them a light coating of grease When connecting connect the positive terminal first and then the negative terminal Temperature when activated 10 C Fill with acid to the mark or about 1 cm above the edge of the plates battery becomes hot No wait 5 to 20 mins Voltage check charge 10 mins 12 5 V Fit on the set 8 3 Check Acid density Charge status Voltage when idle
56. case of damage LEROY 10 SOMER 226 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R LEROY SOMER 227 260 11 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOULEME CEDEX FRANCE 338 567 258 RCS ANGOUL ME S A au capital de 62 779 000 www leroy somer com 228 260 LEROY SOMER 3971 2010 11 f T4 T7 T4 T10 z ize ov 220 320 Installation and maintenance 229 260 140 LEROY SOMER Installation and maintenance 3971 en 2010 11 f 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 this manual are accompanied by recommen da tions or symbol
57. cover o o n o N z 23 i o e a o 2 Fill engine with correct John Deere engine oil through opening on rocker arm cover C or on the side of the engine D See DIESEL ENGINE OIL Section for determining correct engine oil To determine the correct oil fill quantity for your engine see the Specifications Section dipstick whichever is present DO NOT overfill o m i z 2 e o e a o Oil filler neck on engine side 9 NOTE Crankcase oil capacity may vary slightly ALWAYS 3 fill crankcase to full mark or within crosshatch on W 7 Start engine and run to check for possible leaks FD000047 8 Stop engine and check oil level after 10 minutes If necessary top up Oil dipstick FD000047 UN 13MAR96 DPSG CD03523 29 19 01JUL09 3 3 30 3 145 260 072209 PN 73 Maintenance 500 hours Replacing fuel filter element s A Retaining ring C Drain plug B Final fuel filter element D Bleed plug Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand If any fluid is injected into the skin it
58. dry kg 451 505 Engine oil quantity 12 12 Engine coolant quantity 25 25 with Fan PApproximate ITEM UNIT OF MEASURE 6068HFS72 6068HFS73 6068HFS76 6068HFS77 Number of Cylinders 6 6 6 6 Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 127 127 127 127 Displacement L 6 8 6 8 6 8 6 8 Compression Ratio 17 0 1 19 0 1 17 0 1 17 0 1 POWER 1500 rpm kW hp 112 150 139 186 167 224 189 253 Prime POWER 1500 rpm kW hp 123 165 153 205 184 247 207 277 Standby POWER 1800 rpm kW hp Prime POWER 21800 rpm kW hp Standby Width overall mm 784 784 960 960 Length overall mm 1500 1500 1509 1509 Height overall mm 1137 1137 1381 1381 Weight dry kg 764 764 764 764 Engine oil quantity 32 32 32 32 Engine coolant quantity 32 32 35 35 with Fan PApproximate ITEM UNIT OF MEASURE 6068HFU72 6068HFU74 6068HFU79 Number of Cylinders 6 6 6 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 127 Continued on next page CD03523 0000194 19 08JUL09 2 3 65 5 d 185 260 PN 113 Specifications ITEM UNIT OF MEASURE 6068HFU72 6068HFU74 6068HFU79 Displacement L 6 8 6 8 6 8 Compression Ratio 17 0 1 17 0 1 19 0 1 POWER 1500 rpm kW hp 111 149 166 223 188 252 139 186 Prime POWER g 1500 rpm kW hp 123 165 184 247 207 277 153 205 Standby POWER 1800 rpm kW hp 191 256 Prime POWER 1800 rpm kW hp 201 2
59. for inclusion in the Single Engine Parameter Display ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 14 Continue to scroll through and select additional ENGINE OIL PRESSURE 1 parameters for the custom 1 Up Display Press the Menu key at any time to return to the Custom Setup ENGINE COOLANT TEMP menu 8 n 3 z CNC A N N e c Select Parameters For Display Continued on next page OURGP11 00000B1 19 03SEP03 13 18 1 5 1 9 072209 PN 56 128 260 Operating the Engine 15 Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected set of parameters one at a time Use the Arrow keys to scroll to the Automatic Scan function USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13221 UN 26SEP03 Automatic Scan Off OURGP11 00000B1 19 03SEP03 14 18 16 Press the Enter key to toggle the Automatic Scan function on USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN ON RG13222 UN 26SEP03 Automatic Scan On OURGP11 00000B1 19 03SEP03 15 18 17 Press the Enter key again to toggle the Automatic Scan function off Continued on next page USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF Automatic Scan Off RG13223 UN 26SEP03 OURGP11 00000B1 19 03SEP03 16 18 072209 PN 57 15 20 129 260 Operating the Engine 18 Once the Use Defaults Cust
60. for loose dirty or disconnected connectors Inspect the wiring routing looking for possible shorts caused by contact with external parts for example rubbing against sharp sheet metal edges Inspect the connector vicinity looking for wires that have pulled out of connectors poorly positioned terminals damaged connectors and corroded or damaged splices and terminals Look for broken wires damaged splices and wire to wire shorts Use good judgement if component replacement is thought to be required NOTE The engine control unit ECU is the component LEAST likely to fail Suggestions for diagnosing intermittent faults If the problem is intermittent try to reproduce the operating conditions that were present when the diagnostic trouble code DTC set f a faulty connection or wire is suspected to be the cause of the intermittent problem clear DTCs then check the connection or wire by wiggling it while watching the diagnostic gauge to see if the fault resets Possible causes of intermittent faults Faulty connection between sensor or actuator harness Faulty contact between terminals in connector Faulty terminal wire connection Electromagnetic interference EMI from an improperly installed 2 way radio etc can cause faulty signals to be sent to the ECU NOTE Refer also to generator documents for more information about connections and wirings CD03523 0000193 19 05FEBO7 1 1 55 13 072209
61. generating set in Manual Mode G3 ready to start Date and time depending on settings 53 260 N t Screen Data displayed OPERATION AUTO WARNING Operating mode generating set in Auto Mode Sm depending on settings IMMEDIATELY 24 08 2005 13 12 WARNING Operating mode generating set in Auto Mode with AUTOMATIC Start programmed start G5 19 min 30 sec Countdown to micro disconnection delay or EJP notice delay for France only Date and time depending on settings 24 08 2005 Generating set start up ie Screen Data displayed G6 START UP Operating phase generating set in starting phase IN PROGRESS Date and time depending on settings 24 08 2005 AIR PREHEATING Operating phase air preheating prior to starting G7 generating set Countdown for air preheating delay 10 seconds Date and time depending on settings 24 08 2005 54 260 Generating set started EN d Screen Data displayed AVAILABLE POWER Operating phase generating set in operation 75 stable voltage and frequency den tC Available power eS Date and time depending on settings 24 08 2005 AUTOMATIC STOP Operating mode operation in Auto Mode IN PROGRESS Opening of power supply device motorised circuit breaker or source changeover switch controlled by G9 TELYS ne m n Countdown for the mains return delay OR the load mn sec
62. have little meaning Therefore FMI 14 Special Instructions is usually used The goal is to refer the service personnel to the manufacturer s troubleshooting manual for more information on the particular diagnostic code This failure mode does not relate to the signal range definition as do many of the FMls This type of fault may or may not be directly associated with the value of general broadcast information FMI 15 DATA VALID BUT ABOVE NORMAL OPERATING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region i of the signal range definition Broadcast of data values is continued as normal FMl 16 DATA VALID BUT ABOVE NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region k of the signal range definition Broadcast of data values is continued as normal 258 260 EN FMl 17 DATA VALID BUT BELOW NORMAL OPERATING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid ra
63. kVA and kW according to the ISO 13 Rated current A 8528 1 standard 14 Weight kg PRP main power 15 CE marking ESP emergency power 16 Non CE standard marking 7 Rated power factor e g GOSSTANDART 8 Maximum altitude of the site above sea level m 17 Sound pressure for the rated power 18 Sound power Figure 1 3 Example of generating set identification plate mtu Dieselmotor J O H N D E R E ea 12V 4000 660 Engine Serial Num iber _ CD4045T123456 MotorNr 526 100 950 D Baujahr 2002 2 o Masse Kg MTU Motoren und Turbinen Union Friedrichshafen GmbH o VOLVO PE NTA ENGINE MODEL m FRIEDRICHSHAFEN Dieselmotor Leistung 1330 kW Nis dently ech ROWER XXX XXX with fan kW hp XXX XXX Drehzal 1500 l min SPEED AT RATED POWER MTU Motoren und Turbinen Union Friedrichshafen GmbH PRELIFT IT XXX X XXxX X o MADE IN SWEDEN 3826077 Figure 1 4 Examples of engine identification plates 12 260 rmm Maem CREAIIO VICENZA ITAL 29 Jat be aig DER e ee 787 Cows E pe ava 22 25 22 fs 22 ao 23 2s 22 29 ss uz id ii ud d on d a o pisepre ope eeepc jefes sf Figure 1 5 Examples of alternator identification plates il Designation ARMOIRE DE 400KVA A0217010 Cde AVP31650 01C Reference SOREEL 371562
64. low 810 Vehicle speed Calculated vehicle speed input noise Not possible with Genset application 861 861 Diagnostic output status Diagnostic output open short to B Diagnostic output short to ground 898 CAN throttle status Speed value invalid or missing 970 Auxiliary engine shutdown switch status EMS Auxiliary engine shutdown switch signal invalid Not used 31 Auxiliary engine shutdown switch active 971 External engine de rate switch status 31 External engine de rate switch active Not used 1069 Tire size status Tire size error Tire size invalid Tire size error Not possible with Genset application 1076 Fuel Injection pump status Pump control valve closure too long Injection DE10 Pump control valve closure too short Injection DE10 Pump detected defect Injection VP44 Pump solenoid current high Injection DE10 Pump solenoid circuit open Injection DE10 Pump solenoid circuit severely shorted Injection DE10 Oo oO hm oO Pump control valve closure not detected Injection DE10 Pump solenoid circuit moderately shorted Injection DE10 E Pump current decay time invalid Injection DE10 1077 Fuel injection pump controller stat
65. maintenance is governed by standard NFC 15 100 France or by the standards in the relevant country based on international standard IEC 60364 6 61 They must also adhere to the regulations in the NFC 15 401 application guide France or to the regulations and standards in the relevant country b Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose The cable cross section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation The choice of conductors must comply with international standard IEC 30364 5 52 Three phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors or single conductor joined when precision 4X 1 Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C Circuit breaker Cable sizes calibre 0 50m 51 100m 101 150m A mm2 AWG mm2 AWG mm2 AWG 10 1 5 14 2 5112 4110 16 25 12 4 10 6 9 20 25 12 4110 6 9 25 4110 6 9 10 7 32 6 9 6 9 10 7 40 10 7 10 7 16 5 50 10 7 10 7 16 5 63 16 5 16 5 25 3 80 25 3 25 3 35 2 100 35 2 35 2 4X 1X50 0 125 1 4X 1X50 0 4X 1X50 0 4X 1X70 2 0 160 1 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 250 1 4X
66. must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source NOTE Engines with mechanical fuel system have a single fuel filter while electronically controlled engines DE10 HPCR have two fuel filters primary and final Both the primary and the final filters have to be replaced together at the same time 1 Thoroughly clean fuel filter assembly and surrounding area 2 Loosen drain plug C and drain fuel into a suitable container NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators X9811 UN 23AUG88 o pompe somnos FF CD30930 UN 07FEB07 Fuel filters E Water separator bowl F Primary fuel filter element 3 Firmly grasp the retaining ring A and rotate it clockwise 1 4 turn Remove ring with filter element B IMPORTANT Do not dump the old fuel into the new filter element This could cause fuel injection problem A plug is provided with the new element for plugging the used element 4 Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation 5 Install new filter element dry onto mounting base Be sure el
67. n Cooling system drain and flush if COOL GARD is not used Valve clearance adjust POWERTech n Air intake system check n Vibration damper check Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 63 19 22JAN07 1 1 02 5 072209 PN 14 86 260 Maintenance Records 4500 Hours of operation a Engine oil drain o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner a Valve clearance adjust 300 Series n Vibration damper replace 6 cyl Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 64 19 22JAN07 1 1 5000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Injection nozzles replace n Air intake system check n Cooling system drain and flush if COOL GARD is used Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 65 19 22JAN07 1 1 02 6 87 260 072209 PN 15 Maintenance Records 5500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve cle
68. 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 or adapt the Isc to the actual operating power derated machine which is safer for the alternator and the installation Disconnect power supply wires X1 X2 and 21 22 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 10 LEROY SOMER 238 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f 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 1A Toreset switch off the power supply by ope ning switch A 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 sh
69. or engine distributor Use proper viscosity oil Clean and tighten loose connections Clean and tighten connections DPSG CD03523 50 19 22JAN07 1 2 55 8 174 260 072209 PN 102 Troubleshooting Symptom Problem Sulfated or worn out batteries Blown fuse Solution See your authorized servicing dealer or engine distributor Replace fuse DPSG CD03523 50 19 22JAN07 2 2 Displaying Of Diagnostic Trouble Codes DTCs There are several different methods for displaying both stored and active DTCs from the ECU via a fault lamp or a diagnostic gauge on the electronic instrument panel 2 DIGIT CODES Some engines display Service Codes or DTCs as 2 digit codes read from a fault lamp which gives blink codes SPN FMI CODES Stored and active diagnostic trouble codes are output on the diagnostic gauge on the Deere electronic instrument panel according to the J1939 standard as a two part code as shown on the tables on the following pages The first part is a six digit Suspect Parameter Number SPN followed by a two digit Failure Mode Identifier FMI code In order to determine the exact failure both parts SPN and FMI of the code are needed The SPN identifies the system or the component that has the failure for example SPN 000110 indicates a failure in the engine coolant temperature circuit The FMI identifies the type of failure that has occurred for example FMI 03 indicates value ab
70. other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating TS220 UN 23AUG88 Do all work in an area that is well ventilated to carry toxic fumes and dust away Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly will take place DX PAINT 19 24JULO02 1 1 072209 05 7 PN 32 104 260 Safety Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 DX RCAP 19 04JUN90 1 1 Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer Components in products that may contain asbestos fibers are brake pads brake band and lining assemblies clutch plates and some gaskets The asbestos used in these components is usually found in a resin or sealed in some way Normal handling is not hazardous as long as airborne dust containing asbestos is not generated TS220 UN 23AUG88 Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding material containing asbestos When servicing wear an approved respirator A special va
71. pressure above normal 1 Manifold air pressure below normal 3 Manifold air pressure sensor input Short to V voltage high 4 Manifold air pressure sensor input Short to V voltage low 15 Manifold air pressure moderately low 16 Manifold air pressure low 105 105 Manifold air temperature sensor 0 Manifold air temperature extremely high 3 Manifold air temperature sensor input voltage high 4 Manifold air temperature sensor input voltage low 5 Manifold air temperature sensor open circuit 16 Manifold air temperature moderately high 106 106 Air inlet pressure sensor 0 Air inlet pressure above normal 3 Air inlet pressure sensor input voltage high 5 Air inlet pressure sensor open circuit 107 107 Air filter differential pressure sensor 0 Air filter restriction high 3 Air filter differential pressure sensor input voltage high 4 Air filter differential pressure sensor input voltage low 5 Air filter differential pressure sensor open circuit 31 Air filter restriction high 108 274 108 Barometric pressure sensor Deo with EDC Mand 3 High barometric pressure sensor short to high 4 High barometric pressure sensor short to low option sensor 17 High barometric pressure 248 260 N
72. screen B LI to be displayed one or more pictograms or a fault code along with mar the SOS message are displayed e F3 1 hl AUT nni 7O 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 message Low coolant level fault indicates that the level of coolant is low in the radiator linked to a two second time delay LS n 3 Or Overload or short circuit fault optional with the circuit breaker SD unn contact closing overload or short circuit the generating set switches off immediately also causing the main circuit breaker to Ful be triggered LILILI Additional fault linked to message opposite is displayed in the following two cases Associated message gt Differential fault 1 E gt insulation fault 2 n 1 Differential fault optional with a differential fault causing the SS activation of the differential relay the g
73. that the cooling system be drained flushed and refilled Refill with appropriate coolant See DIESEL ENGINE COOLANT Fill the fuel tank Remove fan alternator belt if desired Remove and clean batteries Store them in a cool dry place and keep them fully charged Clean the exterior of the engine with salt free water and touchup any scratched or chipped painted surfaces with a good quality paint Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint Seal all openings on engine with plastic bags and tape Store the engine in a dry protected place If engine must be stored outside cover it with a waterproof canvas or other suitable protective material and use a strong waterproof tape DPSG CD03523 53 19 22JAN07 1 1 Removing engine from long term storage Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with 1 Remove all protective coverings from engine Unseal all openings in engine and remove covering from electrical systems 2 Remove the batteries from storage Install batteries fully charged and connect the terminals Install fan alternator belt if removed 4 Check for filled fuel tank Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS IMPORTANT DO NOT operate starter more than 30 6
74. the appropriate coolant if the level is too low Check for leaks in the cooling circuit Checking the air filter A The maximum authorised vacuum in the air filter is 6 25 kPa 0 06 bar 1 0 psi 25 in water A clogged filter element limits the engine s air intake Important If the air filter is fitted with a dust control valve C press the tip of the valve to evacuate any accumulated dust particles Check the air filter clogging indicator D If the indicator is red clean the air filter 38 260 N Checking the fuel filters A Danger The fuel is highly flammable and its vapours are combustible The fuel filter s must only be bled when the engine is stopped and cold Note Engines with a mechanical supply circuit have a single fuel filter whilst electronically controlled engines DE10 and high pressure common rail fuel circuits have two fuel filters primary and final In addition fuel filters in electronically controlled engines may be fitted with a water presence sensor An indicator on the instrument panel warns the operator that the water must be drained from the filter cup Inspect fuel filters C and D as follows in order to detect any traces of water or debris Undo the drain plug s A at the bottom of the fuel filter s or cup s by two or three turns Loosen the air drain plugs s B by two full turns and drain the water into a suitable
75. the single or four engine parameter display press the 1800 RPM 14 2 57 PSI key BAT VOLT OIL PRES 1 1 Menu Key OURGP11 0000237 19 210CT03 1 6 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Adjust Backlight S ES is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY ADJUST BACKLIGHT 9 2 2 Select Adjust Backlight Continued on next page OURGP11 0000237 19 210CT03 2 6 15 10 m 119 260 Operating the Engine 3 Once the Adjust Backlight menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to activate the STORED CODES Adjust Backlight function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT o Press Enter Key RG13182 UN 020CT03 OURGP11 0000237 19 210CT03 3 6 4 Use the Arrow keys to select the desired backlight intensity ADJUST BACKLIGHT ONE C LON GO Adjust Backlight Intensity RG13183 UN 29SEP03 OURGP11 0000237 19 210CT03 4 6 5 Press the Menu key to return to the main menu ADJUST CONTRAST OM se summ gt a a 1 z 9 ij gt E N o Return To Main Menu Continued on next page OURGP11 0000237 19 210CT03 5 6 1 5 1 1 072209 PN 48 120 260 Operating the Engine 6 Press the Menu key to ex
76. the vent tube Be sure the O ring fits correctly 2 in the rocker arm cover for elbow adapter Tighten z hose clamp securely 1 1 3 DPSG CD03523 32 19 22JAN07 1 1 Checking air intake system 8 z j 5 J IMPORTANT The air intake system must not leak Any leak no matter how small may result in engine failure due to abrasive dirt and dust entering the intake system 2 Check clamps on piping A which connect the air filter engine and if present turbocharger and air to air radiator Tighten clamps as necessary 3 Test air restriction indicator B for proper operation 1 Inspect all intake hoses piping for cracks Replace Replace indicator as necessary as necessary Continued on next page DPSG CD03523 33 19 22JAN07 1 2 35 1 072209 PN 77 149 260 Maintenance 1000 hours 1 year If engine has a rubber dust unloader valve C inspect the valve on bottom of air filter for cracks or plugging Replace as necessary 5 Service air filter as necessary RG4687 UN 20DEC88 DPSG CD03523 33 19 22JAN07 2 2 Checking automatic belt tensioner 4045 and 6068 Engines Belt drive systems equipped with automatic spring belt tensioners cannot be adjusted or repaired The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt If tensioner spring tension is not within specification replace tensioner assembly Checking belt wear The belt tension
77. ub pti o erus aeta eot t lt a et dte 67 9 APPENA 355 EE 68 9 1 Appendix A Engine user and maintenance 69 9 2 Appendix B Alternator user and maintenance manual 193 9 3 Appendix G Commori spare parte or cider ie eed ai ae tes e rore de t e a c te a as 245 9 4 Appendix D List of John Deere Volvo and Perkins fault 247 2 260 N 1 Preface 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to help you operate and maintain your electrical generating set correctly The information contained in this manual is taken from technical data available at the time of print In 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 accidents faults or damage These instructions must always be followed You are likely to encounter several warning symbols in this manual This symbol indicates an immediate danger to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure Danger A This symbol draws attention
78. under load IMMEDIATELY restart it to prevent overheating of turbocharger components Idling engine Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system If an engine will be idling for more than 5 minutes stop and restart later NOTE Generator set applications have the governor locked at a specified speed and do not have a slow idle function These engines idle at no load governed speed fast idle DPSG CD03523 21 19 22JAN07 1 1 Standby power units To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 weeks DO NOT allow engine to run extended period of time with no load DPSG CD03523 22 19 22JAN07 1 1 Stopping the engine 1 Before stopping run engine for at least 2 minutes at fast idle and no load 2 Stop the engine DPSG CD03523 23 19 22JAN07 1 1 Changing Generator Frequency Generator sets powered by 6068HFU74 engine are dual frequency 50 Hz 1500 rpm or 60 Hz 1800 rpm Refer to the generator set documentation for more information CD03523 000018C 19 26JANO0
79. 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 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 videthe rated power ofthe 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 Max excitation 50 60 Hz supply 50Hz 60Hz Field 1 110 220 380 V D 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
80. years Checking engine speed Mechanical fuel system NOTE Most engines for generator set application 1500 rpm for 50 Hz or 1800 rpm for 60 Hz run only at fast idle and therefore they do not have slow idle Specification Fast idle 50 Hz Generator ecrire error PR UP reet 1550 1580 rpm 60 Hz Generator set 1865 1890 rpm NOTE Fast idle is settled by the factory then the idle adjusting screw A is sealed to prevent from tampering Fast idle adjustment can only be done by an authorized fuel system agent A Fast idle adjusting screw CD30763 UN 24SEP99 DPSG CD03523 38 19 31JAN07 1 1 Adjust speed droop governor Mechanical fuel system 1 Warm engine to normal operating temperature 2 Run engine at fast idle 3 Apply full load 4 If specified power cannot be obtained turn screw B to adjust droop until the requested power is reached NOTE If surging exits upon removing the load turn screw B clockwise to eliminate B Speed droop governor adjusting screw CD30764 UN 24SEP99 DPSG CD03523 39 19 31JAN07 1 1 40 3 156 260 072209 PN 84 Maintenance 2000 hours 2 years Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY 1 Remove belts shown removed 2 Grasp vibration damper with both hands and attempt to turn it in both directions If rotation is felt damper is defective and should be replaced IMPORTANT The v
81. 0 minutes then recheck belt tension A JDG529 Tension Gauge D Upper nut B Tension tester E Lower nut C Straightedge 7 1 DPSG CD03523 31 19 30JAN07 1 1 072209 30 5 PN 75 147 260 Maintenance 500 hours Checking belt 4045 and 6068 Engines with manual tensioner Inspect belts for cracks fraying or stretched out areas Replace if necessary NOTE Belt adjustment is measured using a gauge stamped on the top edge of the alternator bracket 1 Loosen cap screws B and C 2 Slide alternator in slot by hand to remove all excess slack in belt Scribe a reference mark D on line with notch E on upper alternator bracket IMPORTANT Do not pry against alternator rear frame 3 Using the gauge A on the alternator bracket stretch belt by prying outward on alternator front frame Stretch the belt 1 gauge unit for a used belt and 1 5 gauge units for a new belt 4 Tighten cap screws B and C A Belt gauge D Reference mark B Cap screw E Alternator upper bracket C Cap screw notch CD30843 Reference marks RG9132 UN 040CT99 CD30843 UN 10JANO03 DPSG CD03523 57 19 30JAN07 1 1 30 6 148 260 072209 PN 76 Maintenance 1000 hours 1 year Cleaning crankcase vent tube If you operate the engine in dusty conditions clean the tube at shorter intervals 1 Remove and clean crankcase vent tube A 2 Install
82. 00 rpm Standby POWER 1800 rpm Prime POWER 21800 rpm Standby Width overall Length overall Height overall Weight dry Engine oil quantity Engine coolant quantity With Fan Approximate ITEM Number of Cylinders UNIT OF MEASURE 4045TF120 4045TF158 4 4 Diesel Diesel mm 106 5 106 5 mm 127 127 L 4 5 4 5 17 0 1 17 0 1 kW hp 63 84 61 83 kW hp 70 94 68 92 kW hp 72 98 kW hp 79 107 mm 598 606 mm 861 1191 mm 980 1027 kg 396 505 12 12 25 25 UNIT OF 6068HF120 115 6068 120 183 6068HF158 MEASURE 6 6 6 Diesel Diesel Diesel mm 106 5 106 5 106 5 mm 127 127 127 L 6 8 6 8 6 8 17 0 1 17 0 1 17 0 1 kW hp 140 188 166 223 134 182 kW hp 155 208 183 245 148 201 kW hp 164 223 kW hp 187 254 mm 623 623 798 mm 1141 1141 1500 mm 1009 1009 1136 kg 569 569 705 20 20 20 32 32 32 UNIT OF MEASURE 6068TF158 6068TF220 6 6 Continued on next page 4045TF220 4045TF258 4 4 Diesel Diesel 106 5 106 5 127 127 4 5 4 5 17 0 1 17 0 1 75 101 72 98 83 111 80 109 90 121 80 109 100 134 88 120 598 652 861 1225 980 1027 396 520 12 12 25 25 6068HF258 6 Diesel 106 5 127 6 8 17 0 1 160 218 177 241 179 243 200 272 798 1500 1204 764 32 32 6068TF258 6 DPSG CD03523 55 19 08JUL09 2 3 65 2 182 260 072209 PN 110 Specifications ITEM UNIT OF MEASURE 6068TF158 6068TF220 6068TF258 Fuel Diesel Die
83. 00 rpm kW hp 67 90 85 114 107 143 Prime POWER 21800 rpm kW hp 74 99 94 126 118 158 Standby Width overall mm 600 765 765 Length overall mm 1230 1365 1365 Height overall mm 1010 1162 1162 Weight dry kg 505 505 505 Engine oil quantity 12 16 16 Engine coolant quantity 25 32 32 with Fan PApproximate ITEM UNIT OF MEASURE 6068HFS82 6068HFS83 6068HFS89 Number of Cylinders 6 6 6 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 127 Displacement L 6 8 6 8 6 8 Compression Ratio 19 0 1 19 0 1 17 0 1 POWER 1500 rpm kW hp Prime POWER 1500 rpm kW hp Standby POWER 1800 rpm kW hp 134 180 161 216 214 287 Prime POWER 31800 rpm kW hp 147 197 177 237 235 315 Standby Width overall mm 784 784 960 Length overall mm 1500 1500 1509 Height overall mm 1137 1137 1381 Weight dry kg 764 764 764 Engine oil quantity 32 32 32 Engine coolant quantity 32 32 35 with Fan PApproximate CD03523 00001D4 19 08JUL09 1 1 65 7 WR 187 260 PN 115 Specifications Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAYOS3 O Bolt or SAE Grade 1 SAE Grade 2 SAE Grade 5 5 1 or 5 2 SAE Grade 8 or 8 2 Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry Size Ib in Ib in
84. 000611 03 Injector Shorted to Power 04 Injector Shorted to Ground 000620 03 Sensor Supply 2 Voltage High 04 Sensor Supply 2 Voltage Low Continued on next page Trouble Codes Corrective Action Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Switch and Wiring Check Switch and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Check Sensor and Wiring Check Sensor and Wiring Stop and Drain Water Separator Check Oil Level Check Sensor and Wiring Check Sensor and Wiring Check Oil Level Check Air Cleaner Aftercooler or Room Temperature Check Sensor and Wiring Check Sensor and Wiring Check Air Cleaner Aftercooler or Room Temperature Check for plugged air filter Check Cooling System Reduce Power Check Sensor and Wiring Check Sensor and Wiring Check Cooling System Reduce Power Check Cooling System Reduce Power Check Operator s Manual Adding Coolant Contact Servicing Dealer Contact Servicing Dealer Add Fuel or Switch Fuel Tanks Check Sensor and Wiring Check Sensor and Wiring Add Fuel or Switch Fuel Tanks Check Fault Codes or Contact Servicing Dealer Reduce Engine Speed Reduce Engine Speed Check Wiring Check Wiring Check Wiring Check Wiring OURGP12 00001E2 19 15MARO6 1 2 55 11 17
85. 03 No OF 02280753 Figure 1 6 Example of control box identification plate 13 260 EN 2 General description 2 1 Description Electric sockets 7 Circuit breaker Connection termination box 8 Starter battery Circuit breakers 9 Control unit External emergency stop 10 Chassis Protective grilles 11 Filling with fuel Battery charge alternator O O1 gt Figure 2 1 General description of the generating set 14 260 Fittings N Socket control panels and terminals by enclosure type TYPE 0 16 125A e c T c d T i SE ee NZ p s 6 9 E fa Rz Q Pos a 7 OO 9 ED 2 3 zm aH D LE s Us 0 on COMMAND CONTROL CENTRAL CONSOLE CIRCUIT BREAKER CONNECTION TERMINAL BLOCK 15 260 TYPE 1 16 125 OPTION HI05 TO CIRCUIT BREAKERS 1 R1 S1 Ti 1 i 1 MAX CONNECTION CABLE CROSS SECTION 185MM M10 BOLT M10 NUT 16 260 N TYPE 1 16 125A TT EDF OPTION HI05 TO CIRCUIT BREAKERS N1 R1 1 T1 oy
86. 045HFU72 28 L 29 5 qt 6068TF158 6068TF258 4045HFS73 4045HFS82 32 L 34 qt 4045HFS83 4045HFU79 6068HF120 6068HF158 6068HF220 6068HF258 6068HF275 6068HFS72 6068HFS73 6068HFS82 6068HFS83 6068HFU72 6068HFU79 6068HF475 6068HFS76 35 L 37 qt 6068HFS77 6068HFS89 6068HFU74 DPSG CD03523 41 19 15JUL09 4 5 12 When refilling cooling system loosen temperature sensor B or plug at the rear of cylinder head to allow air to escape 13 Run engine until it reaches operating temperature then check coolant level and entire cooling system for leaks 8 2 E i 1 S 8 8 DPSG CD03523 41 19 15JUL09 5 5 072209 45 2 PN 87 159 260 Maintenance As required Additional service information This manual does not allow a complete repair of your engine If you want want more detailed service information the following publications are available from your regular parts channel PC2451 Parts Catalog for Non Emission Certified engines e PC3235 Parts Catalog for Stage Il Emission Certified engines CTM3274 Component Technical Manual for 3029 and 4039 engines English CTM104 Component Technical Manual for 4045 and 6068 base engines English CTM207 Component Technical Manual for e CTM502 Component Technical Manual for HPCR Mechanical Fuel Systems on 4045 and 6068 engines Fuel System on pa and 6068 with 2 Valve Head English Engines English CTM320 Component Technical Manua
87. 1 260 Maintenance Records Using maintenance records To obtain the best performance economy and service life from your engine ensure service is carried out according John Deere oils and coolants have been formulated to this present manual and recorded in the following to give maximum protection and performance to your pages It is recommended that your engine Distributor engine We recommend only genuine John Deere service or your Dealer carry out this service work and stamp the Products and replacement parts appropriate case To protect your rights under the warranty ensure all Keeping an accurate account of all service performed on scheduled services are carried out and recorded If your your engine will give more value to the machine when engine is covered by extended warranty it is important to resell it maintain this record for the duration of the warranty DPSG CD03523 6 19 22JAN07 1 1 100 Hours of operation a Engine oil drain a Engine oil filter replace a Hose connections check Number of hours Observation Dealer or distributor stamp Date Job done by DPSG CD03523 7 19 22JAN07 1 1 02 z 1 072209 PN 10 82 260 Maintenance Records 500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance a
88. 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 1 RECEIPT 4 SERVICING MAINTENANCE 1 1 Standards and safety measures 4 1 Safety 10 1 2 Inspection n eie hes 4 2 Regular 10 1 3 Identification 4 3 Fault detection 10 1 45 5 0 ce ineo 4 4 Mechanical 11 1 5 ADpliGations it rre Het 4 5 Electrical 11 1 6 Contra indications to use 4 6 Dismantling reassembly 12 4 7 Installation and maintenance of the PMG 14 2 TECHNICAL CHARACTERISTICS 4 8 Table of characteristics 14 2 1 Electrical characteristics 4 9 Table of weights 15 2 2 Mechanical characteristics 5 SPARE PARTS 3 INSTALLATION COMMISSIONING 5 1 First maintenance parts 16 3 1 Assembly aset ee eet adc 5 2 Bearing designations 16 3 2 Inspection prior to first use 5 3 Technical support
89. 1000 RPM LOACIAPM ENG RPM 1800 RPM 14 2 57 PSI 8 2 2 l S c Exit Main Menu OURGP11 00000AC 19 03SEP03 6 6 Accessing Active Trouble Codes NOTE The engine does not need to be running to i navigate the diagnostic gauge screens If engine 5 start up is desired See Starting The Engine All Z of the engine values illustrated on the diagnostic d gauge indicate the engine is running 5 o For description of trouble codes see chart in Troubleshooting Section Normal Operation 1 During normal operation the single or four parameter screen will be displayed OURGP11 00000AD 19 03SEP03 1 7 2 When the diagnostic gauge receives a trouble code from an engine control unit the single or four WARNING parameter screen will be replaced with the Warning SU PN 94 FMI 18 message The SPN and FMI number will be displayed FUEL DELIVERY PRESSURE along with a description of the problem and the CORRECTIVE ACTION corrective action needed CHECK FUEL FILTER AND LINES S lt NEXT gt HIDE 8 IMPORTANT Ignoring active trouble codes 1 result in severe engine damage 1 8 c Active Trouble Codes Displayed OURGP11 00000AD 19 03SEP03 2 7 3 Ifthe word Next appears above the arrow keys there are more trouble codes that can be viewed by using WARNING the arrow keys to scroll to the next trouble code PN 94 FMI 18 FUEL DELIVERY PRESSURE CORRECTIVE ACTION 5 CHECK FUEL F
90. 11 00000B0 19 03SEP03 3 7 4 There are three choices for units of measurement English Metric kPa or Metric Bar ENGLISH English is for Imperial units with pressures displayed in PSI and temperatures in F e Metric kPa and Metric bar are for IS units with a pressures displayed in kPa and bar respectively and temperatures in i 2 a Use the Arrow keys to highlight the desired units of g measurement 5 Select Desired Units Continued on next page OURGP11 00000B0 19 03SEP03 4 7 072209 15 14 PN 51 123 260 Operating the Engine 5 Press the Enter key to select the highlighted uni ts ENGLISH METRIC KPA METRIC BAR sg RG13191 UN 30SEP03 Press Enter Key to Select OURGP11 00000B0 19 03SEP03 5 7 6 Press the Menu key to return to the main menu ENGLISH RG13192 UN 26SEP03 Return To Main Menu OURGP11 00000B0 19 03SEP03 6 7 7 Press the Menu key to return to the engine parameter display 98 LOACIAPM 1800 RPM 14 2 BAT VOLT 1000 RPM ENG RPM 57 PSI OL PRES Press Menu Key RG13159 UN 26SEP03 OURGP11 00000B0 19 03SEP03 7 7 Setup 1 Up Display 1 Turn the key switch to the ON position Starting a single engine parameter display press the Menu key 98 LOACIAPM Pie 1800 RPM 14 2 VOLT 1000 RPM ENG RPM 57 PSI OIL PRES
91. 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 400 1 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 630 1 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM Single phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C A Cable sizes NEM 0 50m 51 100m 101 150m mm2 AWG mm2 AWG mm2 AWG 10 4 10 10 7 10 7 16 6 9 10 7 16 5 20 10 7 16 5 25 3 25 10 7 16 5 25 3 32 10 7 25 3 35 2 40 16 5 35 2 50 0 50 16 5 35 2 50 0 63 25 3 50 0 70 2 0 80 35 2 50 0 95 4 0 100 35 2 70 2 0 95 4 0 125 50 0 95 4 0 120 2250MCM C Battery cables Install the battery or batteries in the immediate vicinity of the electric starter motor The cables will be connected directly from the battery terminals to the starter motor terminals The primary instruction to follow is to ensure that the polarities between the battery and starter motor match Never reverse the positive and negative battery terminals when connecting them This could cause severe damage to the electrical equipment The minimum cross section of the cables will be 70 mm It varies according to the power of the starter motor but also the distance between the batteries and the set voltage drops on the line 29 260 EN d Safety
92. 2 134 260 Operating the Engine Cold weather operation Depending on equipment various cold weather starting aids are available to assist in starting the engine at temperature below 0 C 32 F Air intake heater A DO NOT use starting fluid on engines equipped with grid type air intake heater or glow plug s Ether starting fluid is highly flammable and may explode causing serious injury NOTE On engines with electronically controlled fuel system DE10 HPCR the air intake heater operates automatically controlled by the ECU An engine preheater indicator light comes on when the key switch is turned ON In warm weather the light comes on briefly for a light check In cold weather the light remains ON during the automatic operation of the air intake heater or glow plug s Operating time depends on temperature Do not crank engine until light goes OFF 3029 and 4039 engines are optionally equipped with the single glow plug B screwed in cylinder head intake manifold Activate the glow plug preheater position for 30 seconds maximum then start the engine 4045 and 6068 engines except HPCR 4 valve head are optionally equipped with the grid type air heater A installed between cylinder head and air intake pipe For mechanical fuel system activate the heating element preheater position for 30 seconds maximum then start the engine For electronically controlled engines DE10 HPCR 2 valve he
93. 2 3 Engine Configuration 15 3 2000 Hours of operation 02 3 Accessing Stored Trouble Codes 15 5 2500 Hours of 02 4 Accessing Active Trouble 15 7 3000 Hours of 02 4 Engine Shutdown 15 9 3500 Hours of 02 5 Adjusting Backlighting eee 19 10 4000 Hours of operation 02 5 Adjusting Contrast c 15 12 4500 Hours of 02 6 Selecting Units Of Measurement 15 13 5000 Hours of 02 6 Setup 1 Up ind UNUM as 5500 Hours of 02 7 Setup 4 Up Display e i D 6000 Hours of 02 7 Break in period 5 25 6500 Hours of 02 8 Starting the engine T 15 25 7000 Hours of 02 8 Cold weather operation 15 26 7500 Hours of 02 9 Using a booster battery or charger 15 28 8000 Hours of
94. 20 V gt T2 L3 W LL y Lo L1 U AR LEROY SOMER 203 260 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3434 en 2010 10 i Connection codes L L voltage Factory connection L1 V Winding 50 Hz T5 1 phase or LL x 110 120 T12 d 120 130 8 110 120 L m gt L2 V R 250 voltage sensing 0 gt 8 110 V gt T11 gt 100 L R 438 voltage sensing 0 gt T3 110 V gt T2 A FOR LSA 44 2 THE COUPLING B IS NOT POSSIBLE AR Connection not Winding 50 Hz 60 Hz G recommended 6 220 240 220 240 1 7 250 260 T9 70 JD 3 8 200 220 240 R 250 voltage sensing T2 0 gt T8 110 V gt T11 T7 v to R 438 voltage sensing J AR LM voltage 1 2 LL voltage 0 gt T3 220 V gt T2 Tl SINGLE PHASE 4 WIRE type M or M1 DEDICATED WINDING SERIAL CONNECTION T6 M PARALLEL CONNECTION Not possible with LSA 44 2 T3 T1 T2 L LJ L Voltage 50 60Hz Voltage 50 60Hz Output L L L M Link M L L L M Link L L 220 110 110 230 115 T2 T3 T1 T3 T2 T3 115 T1 T3 T2 T4 240 120 120 12 74 T4 251 voltage sensing 0 gt T1 110 V gt T2 251 voltage sensing 0 gt T1 110 V gt T2 3 3 1 Connexion d
95. 250 V 8 A slow blow Ref Designation Qty LSA 43 2 44 2 AREP 4 P Code 198 AVR 1 R 438 AEM 110 RE 017 343 Diode bridge assembly 1 LSA 432 9 100 ALT 432 KD 001 347 Surge suppressor 1 LSA 432 1 13 AEM 000 RE 126 AVR fuse 2 250 V 8 A fast blow 5 2 Bearing designations Ref Designation Qty LSA 43 2 Code LSA 44 2 Code 60 Bearing on shaft extension end 1 6312 2RS C3 RLTOGOETOO7 63152RS C3 RLTO75ETO004 70 Bearing on exciter end 1 6307 2RS C3 RLTO35ET030 63092RS C3 RLTO45ETOSO 5 3 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 serial number and the information given on the genset nameplate Address your enquiry to your usual contact CAUTION Part numbers should be identified from the exploded views and their description from the parts list Ourextensive network of service centres can dispatch the necessary parts without delay Toensurecorrect operation andthesafety ofour machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage LEROY 16 SOMER 212 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 5 4 Exploded views parts li
96. 29HFS70 MEASURE 3 Diesel mm 106 5 mm 110 L 2 9 17 2 1 kW hp 37 50 kW hp 41 56 kW hp kW hp mm 582 mm 888 mm 974 kg 350 8 14 5 UNIT OF 4045HFS72 MEASURE 4 Diesel mm 106 5 mm 110 L 4 5 17 0 1 kW hp 75 100 kW hp 83 111 kW hp kW hp mm 751 mm 1362 mm 1137 kg 505 16 28 3029HFU70 3029TFS70 3 3 Diesel Diesel 106 5 106 5 110 110 2 9 2 9 17 2 1 17 2 1 37 50 28 37 41 56 31 41 582 582 888 888 974 974 350 350 8 8 14 5 14 5 4045HFS73 4045HFU72 4 4 Diesel Diesel 106 5 106 5 110 127 4 5 4 5 19 0 1 17 0 1 94 126 75 100 103 138 83 111 765 751 1365 1362 1162 1137 505 505 16 16 32 28 Continued on next page 3029TFU70 3 Diesel 106 5 110 2 9 17 2 1 28 37 31 41 582 888 974 350 14 5 4045HFU79 4 Diesel 106 5 127 4 5 19 0 1 94 126 103 138 765 1365 1162 505 16 32 CD03523 0000194 19 08JUL09 1 3 65 4 184 260 072209 PN 112 Specifications ITEM UNIT OF MEASURE 4045TFS70 4045TFU70 Number of Cylinders 4 4 Fuel Diesel Diesel Bore mm 106 5 106 5 Stroke mm 110 127 Displacement L 4 5 4 5 Compression Ratio 17 0 1 17 0 1 POWER 1500 rpm kW hp 55 74 55 74 Prime POWER 1500 rpm kW hp 61 81 61 81 Standby POWER 1800 rpm kW hp Prime POWER 1800 rpm kW hp Standby Width overall mm 637 600 Length overall mm 867 1230 Height overall mm 979 1010 Weight
97. 6 Close up of USB ports 1 USB key connection HOST file transfer between USB key and TELYS and vice versa 2 Connection for microcomputer DEVICE file transfer between PC and TELYS and vice versa main module power supply 3 Protective cover 47 260 EN 6 3 1 2 Description of the screen The screen is backlit and requires no contrast adjustments This screen is divided into 4 zones RPA Ke T ma f f t t iA A um Lu a umma wri a gt aD T am omen T od m m e e ARAT cF c e n I7 V ty jar Hr AH CF ROE 172 SERIAL No 08030010000 SOFTWARE 5 3 5 I NOMINAL VOLTAGE 400V FREQUENCY 50Hz NOMINAL KW 320kW EARTH SYSTEM TNS Diagram 6 7 Description of the screen example Zone 1 in this zone the status of the generating set is displayed Zone 2 in this zone pictograms relating to dimensions measured are displayed as well as Alarm and Fault pictograms e Zone 3 in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4 in this zone messages relating to the control of the generating set and the menus displayed Note the information displayed on measurements alarms and faults as well as messages and m
98. 69 Standby Width overall mm 784 960 812 Length overall mm 1500 1509 1532 Height overall mm 1137 1381 1200 Weight dry kg 764 764 764 Engine oil quantity L 32 32 32 Engine coolant quantity 32 35 32 With Fan Approximate CD03523 0000194 19 08JUL09 3 3 General engine pack specifications EPA Tier 2 Emission Certified Engines ITEM UNIT OF MEASURE 3029TF270 4045TF270 6068HF475 Number of Cylinders 3 4 6 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 110 127 127 Displacement L 2 9 4 5 6 8 Compression Ratio 17 2 1 17 0 1 17 0 1 POWER 1500 rpm kW hp Prime POWER 1500 rpm kW hp Standby POWER 1800 rpm kW hp 44 59 67 90 213 286 Prime POWER 1800 rpm kW hp 48 64 74 99 234 314 Standby Width overall mm 519 612 627 Length overall mm 716 860 1161 Height overall mm 819 994 1044 Weight dry kg 316 396 587 Engine oil quantity L 8 12 32 Engine coolant quantity 14 5 25 35 with Fan PApproximate CD03523 00001D3 19 08JULO9 1 1 65 6 yix 186 260 PN 114 Specifications General engine pack specifications EPA Tier 3 Emission Certified Engines ITEM UNIT OF MEASURE 4045HFS80 4045HFS82 4045HFS83 Number of Cylinders 4 4 4 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 110 Displacement L 4 5 4 5 4 5 Compression Ratio 19 0 1 19 0 1 19 0 1 POWER 1500 rpm kW hp Prime POWER 1500 rpm kW hp Standby POWER 18
99. 7 1 1 072209 PN 66 15 29 138 260 Maintenance Observe service intervals Using hour meter as a guide perform all services at the hourly intervals indicated on following pages At each scheduled maintenance interval perform all previous maintenance operations in addition to the ones specified Keep a record of hourly intervals and services performed using charts provided in Maintenance Records Section IMPORTANT Recommended service intervals are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine DPSG CD03523 24 19 22JAN07 1 1 Use correct fuels lubricants and coolant IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine Parts Consult your John Deere engine distributor servicing dealer or your nearest John Deere Parts Network for recommended fuels lubricants and coolant Also available are necessary additives for use when operating engines in tropical arctic or any other adverse conditions TS100 UN 23AUG88 DPSG CD03523 25 19 22JAN07 1 1 Maintenance interval chart Item 10 H daily 500 H 1000 H 2000H 2500H As 1 year 2 years 3 years required Check engine oil and coolant level Check air filter restriction indicato
100. 7 260 072209 PN 105 Troubleshooting SPN 000627 000629 000636 000637 000639 000651 000652 000653 000654 000655 000656 000898 000970 000971 001069 001079 001080 001109 001110 001347 001568 001569 002000 FMI 01 13 02 08 10 02 07 08 10 13 05 06 07 05 06 07 05 06 07 05 06 07 05 06 07 05 06 07 09 31 31 09 31 03 04 03 04 31 31 03 05 07 02 31 13 Description of Fault All Injector Currents Are Low ECU Programming Error Engine Position Sensor Signal Unreliable Engine Position Sensor Signal Missing Engine Position Sensor Signal Rate of Change Abnormal Engine Timing Sensor Signal Unreliable Engine Timing and Position Sensors Out of Sync Engine Timing Sensor Signal Missing Engine Timing Signal Rate of Change Abnormal CAN Bus Error Communication network problem Injector Number 1 Circuit Has High Resistance Injector Number 1 Circuit Has Low Resistance Injector Number 1 Not Responding Injector Number 2 Circuit Has High Resistance Injector Number 2 Circuit Has Low Resistance Injector Number 2 Not Responding Injector Number 3 Circuit Has High Resistance Injector Number 3 Circuit Has Low Resistance Injector Number 3 Not Responding Injector Number 4 Circuit Has High Resistance Injector Number 4 Circuit Has Low Resistance Injector Number 4 Not Responding Injector Number 5 Circuit Has High Resistance Injector Number 5 Circuit Has
101. 8 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 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 15 726 module functions mounted exter nally P F regulation 2F and voltage sensing cir cuit before paralleling 3 F Control through DC voltage used monito ring apply to the terminals for connection of a potentiometer DC voltage internal impedance 1 5 kQ 0 5V enable a voltage setting of 10 LEROY SOMER 236 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f 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 Che
102. 92 Continued on next page DPSG CD03523 41 19 15JUL09 3 5 45 a 1 072209 PN 86 158 260 Maintenance 2500 hours 3 years 4 Open radiator drain valve C Drain all coolant from radiator Close all drain orifices after coolant has drained 6 Fill the cooling system with clean water Run engine until water passes through the thermostat to stir up possible rust or sediment 8 2 lt 7 Stop engine and immediately drain the water from system before rust and sediment settle Z 8 After draining water close all drain orifices and fill 8 the cooling system with cleaning product such as S PMCC2610 or PMCC2638 Cooling System Cleaners e available from your John Deere Dealer Follow manufacturer s directions on label Cooling system capacity 9 After cleaning the cooling system drain cleaner and Engine Model Cooling system capacity fill with water to flush the system Run engine until 3029DF128 3029TF120 14 5 L 15 5 qt water passes through the thermostat then drain out 3029TF158 3029HFS70 water g 3029TF270 3029TFS70 g 3029HFU70 3029TFU70 10 Check cooling system hoses for proper condition 4039DF008 4039TF008 16 5 L 17 5 qt Replace as necessary 4045DF158 20 L 21 qt 11 Close all drain orifices and fill the cooling system with podes pen 26028 specified coolant see DIESEL ENGINE COOLANT 4045HFS80 4045TF270 4045TFS70 4045TFU70 4045HF158 4
103. Buttons To Scroll Quadrant Display OURGP11 00000A9 19 03SEP03 5 5 Engine Configuration Data 98 1000 RPM LOAQIAPM ENG RPM NOTE The engine configuration data is a read only function 1800 RPM 57 PSI BAT VOLT OAL PRES NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine is running Menu Key RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AB 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow GO TO UP DISPLAY keys to scroll through the menu until Engine Config STORED CODES is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY N SELECT UNITS E ADJUST BACKLIGHT 8 1 7 Select Engine Configuration Continued on next page OURGP11 00000AB 19 03SEP03 2 6 15 3 PN 40 112 260 Operating the Engine data ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 3 Once Engine Config menu item has been highlighted press the Enter key to view the engine configuration STORED CODES RG13165 UN 020CT03 OOG Enter Key OURGP11 00000AB 19 03SEP03 3 6 4 Use the Arrow keys to scroll through the engine config
104. CD4045HFS72 DE10 Fuel System CD4045HFS73 HPCR System 2 Valve Head CD4045HFU72 DE10 Fuel System CD4045HFU79 HPCR System 2 Valve Head CD4045TFS70 Mechanical Fuel System CD4045TFU70 Mechanical Fuel System CD6068HFS72 DE10 Fuel System CD6068HFS73 HPCR System 2 Valve Head CD6068HFS76 HPCR System 4 Valve Head CD6068HFS77 HPCR System 4 Valve Head CD6068HFU72 DE10 Fuel System CD6068HFU74 HPCR System 4 Valve Head CD6068HFU79 HPCR System 2 Valve Head Emission Certified Engines EPA Tier 2 CD3029TF270 Mechanical Fuel System CD4045TF270 Mechanical Fuel System CD6068HF275 VP44 Fuel System CD6068HF475 HPCR System 4 Valve Head Emission Certified Engines EPA Tier 3 CD4045HFS80 Mechanical Fuel System CD4045HFS82 HPCR System 2 Valve Head CD4045HFS83 HPCR System 2 Valve Head CD6068HFS82 HPCR System 2 Valve Head CD6068HFS83 HPCR System 2 Valve Head CD6068HFS89 HPCR System 4 Valve Head READ THIS MANUAL carefully to learn how to operate and service your engine correctly Failure to do so could result in personal injury or equipment damage THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it MEASUREMENTS IN THIS MANUAL are given in metric Use only correct replacement parts and fasteners Metric and inch fasteners may require a specific metric or inch wrench WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicat
105. DPSG CD03523 49 19 22JAN07 2 4 55 5 171 260 072209 PN 99 Troubleshooting Symptom High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Engine overheats Problem Improper type of oil Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Engine overloaded Low coolant level Faulty radiator cap Stretched poly V belt or defective belt tensioner Continued on next page Solution Drain fill crankcase with oil of proper viscosity and quality Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine distributor Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authoriz
106. Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Not Engine Fault Check Other Shutdown Devices Not Engine Fault Check Other Shutdown Devices Contact Servicing Dealer Contact Servicing Dealer Check Wiring Check Wiring Check Wiring Check Wiring Shut Down Engine Check Fault Codes Shut Down Engine Check Fault Codes Contact Servicing Dealer Check Pump Wiring Check Fuel Filter and Lines Contact Servicing Dealer Check Fault Codes Contact Servicing Dealer OURGP12 00001E2 19 15MARO06 2 2 072209 55 12 PN 106 178 260 Troubleshooting Intermittent Fault Diagnostics With Electronic Controls Intermittent faults are problems that periodically go away A problem such as a terminal that intermittently doesn t make contact can cause an intermittent fault Other intermittent faults may be set only under certain operating conditions such as heavy load extended idle etc When diagnosing intermittent faults take special note of the condition of wiring and connectors since a high percentage of intermittent problems originate here Check
107. GES Y Less frequent oil services this product has been put to the test during thousands of hours of use on worksites under varying conditions demonstrating its high quality Y Conformity with new environmental legislation adherence to new anti pollution standards required for new EURO 2 and EURO 3 engines SPECIFICATIONS SAE Grade 15W 40 Density at 15 C 0 883 Cinematic viscosity at 40 C Cinematic 105 2 5 cSt E viscosity at 100 C 14 1 2 5 cSt Viscosity index 140 3 Dynamic viscosity at 15 C 3000 mPa s cP Pour point 30 C n M Flash point 220 C 2599 Sulphated ash content 14 96 weight lt z Values given as examples only 2 23 260 EN 2 3 1 2 Specifications of coolants Engine Coolants Make Type Make Type John Deere All GenPARTS GENCOOL PC 26 C Mitsubishi LLC MITSUBISHI Al GenPARTS GENCOOL PC 26 Volvo All GenPARTS GENCOOL PC 26 C GenCOOL PC 26 High protection coolant approved by manufacturers GenCOOL PC 26 is a ready to use highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers e Itis made from antifreeze and G 48 inhibitors It protects up to 26 C Itis free from nitrates amines and phosphates itis aclear fluorescent orange liquid REFERENCES APPROVALS for the antifreeze HEAVY GOODS VEHICLE LI
108. GHTER VEHICLES Approved by MTU MERCEDES BENZ MAN KHD GENERAL Approved by BMW VOLKSWAGEN MERCEDES PORSCHE MOTORS Conforms with VOLVO OPEL SEAT and SKODA specifications Conforms with VOLVO IVECO VAN HOOL and STAYR TRUCK specifications Conforms with the NF R 15 601 standard REINFORCED ANTI CORROSION FEATURES e Protects against high temperature corrosion by oxidisation of ethylene cylinder head protection Protects against high temperature cavitation top of cylinder and coolant pump protection Non corrosive for seals and hoses Improves the efficiency and longevity of the cooling system e GenCOOL PC 26 is especially recommended for engines fitted with aluminium or light alloy radiators HIGH TEMPERATURE SUITABILITY Provides good conditions for thermal exchange Perfect stability at high temperatures e GenCOOL PC 26 is specially adapted for engines with high power densities LONG LASTING PROTECTION High alkaline reserve stability and longevity of corrosion inhibitors Maintains its technical properties during prolonged use at high temperatures neutralisation of acids Ensures maximum heat transfer without the build up of deposits in the cooling system e GenCOOL PC 26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use 24 260 N PACKAGING STORAGE GenCOOL PC 26 is supplied in 210 metallic barrels with smooth interior lini
109. HF158 6 8L 171EC 1100 1200 1300 1400 1500 1600 1700 1800 1900 2100 2300 2400 2500 2700 2800 2900 3000 3100 3500 4000 4300 5200 5500 5600 5700 6000 6200 6400 6500 6600 7500 7600 8600 8700 8800 000000 Order 2B0000000 OPTION CODES CD30748A UN 26AUG99 Engine option code label In addition to the serial number plate OEM engines have an engine option code label affixed to the rocker arm cover These codes indicate which of the engine options were installed on your engine at the factory When in need of parts or service furnish your authorized servicing dealer or engine distributor with these numbers An additional sticker may be also delivered in a plastic bag attached to the engine or inserted in the machine documentation It is recommended to stick this option code list sticker either On this page of your Operator s manual below this section or On the Engine Owner s Warranty booklet under the title OPTION CODES Engine manufacturing configuration NOTE The Machine Manufacturer may have already stuck it at a specific accessible place inside the enclosure or close to a maintenance area The engine option code label includes an engine base code A This base code must also be recorded along with the option codes At times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model The first two digits of each code identify a specific group
110. ILTER AND LIMES a lt NEXT gt 8 2 ro E c Use Arrow Keys To Scroll Continued on next page OURGP11 00000AD 19 03SEP03 3 7 15 7 PN 44 116 260 Operating the Engine IMPORTANT Ignoring active trouble codes can result in severe engine damage 4 To acknowledge and hide the code and return to the single or four parameter display press the Enter Key 1ofx WARNING FMI 18 SPN 94 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt HIDE Hide Trouble Codes RG13242 UN 30SEP03 OURGP11 00000AD 19 03SEP03 4 7 5 The display will return to the single or four parameter display but the display will contain the warning icon Pressing the Enter key will redisplay the hidden trouble code 98 1000 RPM LOADER OM ENG RPM 1800 RPM 14 2 57 PSI areas COOL TEMP 1 BAT VOLT Olt PRES RG13176 UN 26SEP03 Active Trouble Code Icon OURGP11 00000AD 19 03SEP03 5 7 IMPORTANT Ignoring active trouble codes can result in severe engine damage 6 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four parameter display 1 of x WARNING SPN 94 FMI 18 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt HIDE Enter Key RG13242 UN 30SEP03 OURGP11 00000AD 19 03SEP03 6 7 7 The single or four param
111. Ib in Nem Ib in Ib in Nem Ib in Ib in Ib in 1 4 3 7 33 4 7 42 6 53 7 5 66 9 5 84 12 106 13 5 120 17 150 Ib ft Ib ft 5 16 7 7 68 9 8 86 12 106 15 5 137 19 5 172 25 221 28 20 5 35 26 Ib ft Nm Ib ft 3 8 13 5 120 17 5 155 22 194 27 240 35 26 44 325 49 36 63 46 Ib ft Nm Ib ft Nem Ib ft 7 16 22 194 28 20 5 35 26 44 32 5 56 41 70 52 80 59 100 74 lb ft 1 2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115 9 16 48 35 5 60 45 76 56 95 70 125 92 155 115 175 130 220 165 5 8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225 3 4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400 7 8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640 1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960 1 1 8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 1 1 4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 Torque values listed are for general use only based on the strength of the bolt Replace fasteners with the same or higher grade If higher or screw DO NOT use these values if a different torque value or tightening grade fasteners are used tighten these to the strength of the procedure is given for a specif
112. L PRES RG13159 UN 26SEP03 Menu Key Continued on next page OURGP11 00000A9 19 03SEP03 1 5 072209 15 1 PN 38 110 260 Operating the Engine 2 The first seven items of the Main Menu will be displayed GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13160 UN 020CT03 Menu Display OURGP11 00000A9 19 03SEP03 2 5 3 Pressing the Arrow keys will scroll through the menu selections GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13161 UN 020CT03 Main Menu Items OURGP11 00000A9 19 03SEP03 3 5 4 Pressing the right arrow key will scroll down to reveal the last items of Main Menu screen highlighting the next item down ADJUST CONTRAST UTILITIES a o z 1 N o Last Items On Main Menu Continued on next page OURGP11 00000A9 19 03SEP03 4 5 1 5 2 072209 PN 39 111 260 Operating the Engine e P HM f 1000 RPM 0 5 Use the arrow keys to scroll to the desired menu item 1 UP DISPLAY OREO COD or press the Menu Button to exit the main menu and return to the engine parameter display SETUP LUP DISPLAY SELECI UNITS ADJUST BACKLIGHT 96496 c o RG13163 UN 020CT03 Use Arrow
113. LY KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN Warning The anti rust product is toxic and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging SSS Caution fuels and oils are dangerous to inhale Ensure proper ventilation and use a protective mask Never expose the equipment to liquid splashes or rainfall and do not place it on wet ground The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 9 260 EN 1 3 4 Risk of fire burns and explosion The engine should not be operated in environments containing explosive products As not all of the electrical and mechanical components are shielded there is a risk of sparks forming Danger lt lt SS lt lt lt lt lt lt Make sure to create sparks or flames and not to smoke near the batteries as the electrolyte gases are highly flammable especially if the battery is charging Their acid also poses a risk to the skin and in particular to the eyes Never cover the generating set pump unit or lighting tower with any material during operation or just after shutdown wait for the engine to cool Do not touch hot parts such as the exhaust pipe or put combustible materials on
114. Level Indicator P10 Indication of Battery Voltage Indication of Battery Amps 52 260 EN Screen order of appearance according to network type with the generating set on Type of network Order of appearance 3P N 3P 2P N 1P N 1 P3 P3 P3 P3 2 P4 P4 P6 P7 3 P5 P8 P8 P9 4 P8 P9 P9 P2 5 P9 P2 P2 P10 6 P2 P10 P10 7 P10 Change screens by using the scrolling and selection wheel When the wheel is rotated clockwise the screens scroll upwards and vice versa The screens scroll in a loop E g On three phase neutral network then screen 7 then screen 1 and vice versa 6 3 1 6 Display of messages in zone 4 The display zone 4 among other things displays messages relating to the operation of the generating set The messages are as follows Initialisation of TELYS Screen no Screen Data displayed G1 Initialisation of TELYS when the power is switched on and or when loading a configuration SERIAL No 08030010000 Generating set serial no SOFTWARE 6 1 0 Software version of TELYS NOMINAL VOLTAGE 400V Alternator Nominal Voltage G2 FREQUENCY 50Hz Alternator Nominal Frequency NOMINAL KW 320kW Nominal Active Output EARTH SYSTEM TNS Neutral Point Bar graph indicating the display delay of the screen Generating set stopped Screen to start 24 08 2005 Screen Data displayed OPERATION MANUAL Press START Operating mode
115. Low Resistance Injector Number 5 Not Responding Injector Number 6 Circuit Has High Resistance Injector Number 6 Circuit Has Low Resistance Injector Number 6 Not Responding Vehicle Speed or Torque Message Unreliable External Shutdown Commanded External Fuel Derate Switch Active Tire Size Invalid Tire Size Error Sensor Supply 1 Voltage High Sensor Supply 1 Voltage Low Fuel Rail Pressure Sensor Supply Voltage High Fuel Rail Pressure Sensor Supply Voltage Low Engine Protection Shutdown Warning Engine Protection Shutdown High Pressure Fuel Pump Control Valve Signal Out of Range High High Pressure Fuel Pump Solenoid Number 1 Circuit Has High Resistance High Pressure Fuel Pump Not Able to Meet Required Rail Pressure Requested Torque Curve Signal Unreliable Engine in Derate Condition Security Violation Corrective Action Check Battery Voltage and Wiring Contact Service Dealer Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or
116. Menu Key Continued on next page RG13159 UN 26SEP03 OURGP11 00000B1 19 03SEP03 1 18 15 15 124 260 072209 PN 52 Operating the Engine 2 Usethe Arrow keys to scroll through the menu until Setup 1 Up Display is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT GPO Setup 1 Up Display RG13193 UN 020CT03 OURGP11 00000B1 19 03SEP03 2 18 3 Once Setup 1 Up Display menu item has been highlighted press the Enter key to access the Setup 1 Up Display function GO TO t UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT Press Enter Key RG13194 UN 020CT03 OURGP11 00000B1 19 03SEP03 3 18 4 Three options are available for modification of the 1 Up Display a Use Defaults This option contains the following engine parameters for display Engine Hours Engine Speed Battery Voltage Load Coolant Temperature and Oil Pressure b Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters This option can be used to add parameters available for scrolling in the 1 Up Display o Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected s
117. N 07DEC88 DX ALERT 19 29SEP98 1 1 Understand Signal Words A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual A DANGER A WARNING TS187 19 30SEP88 A CAUTION DX SIGNAL 19 03MAR93 1 1 Do Not Open High Pressure Fuel System High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform repairs See your John Deere dealer DX WW HPCR1 19 07JANO3 1 1 TS1343 UN 18MAR92 05 1 98 260 072209 PN 26 Safety Engine lifting procedure The only recommended method for lifting the engine is with JDG23 Engine Lifting Sling A and safety approved lifting straps B that come with engine Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended Lift engine with longitudinal loading on lifting sling and lifting straps only Angular loading greatly reduces li
118. NOTE If rocker arm is equipped with adjusting screw and jam nut A tighten jam nut to 27 N m 20 Ib ft after adjusting valve clearance CD30545 UN 19MAY98 4 Reinstall rocker arm cover and crankcase vent tube 3 Cylinder Engine NOTE Firing order is 1 2 3 a Lock No 1 piston at TDC compression stroke D b Adjust valve clearance on No 1 and 2 exhaust valves and No 1 and 3 intake valves c Rotate flywheel 360 Lock No 1 piston at TDC exhaust stroke E d Adjust valve clearance on No 3 exhaust valve and No 2 intake valve RG6307 UN 03AUG92 4 Cylinder Engine NOTE Firing order is 1 3 4 2 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves c Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C d Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves A Front of engine D No 1 Piston at TDC B Exhaust valve compression stroke C Intake valve E No 1 Piston at TDC exhaust stroke A Front of engine E Exhaust valve B No 1 Piston at TDC I Intake valve compression stroke C No 4 Piston at TDC compression stroke CD30549 UN 16JUN98 i Ma RG4776 UN 310CT97 DPSG CD03523 35 19 31JAN07 2 2 35 4 072209 PN 80 152 260 Maintenance 1000 hours 1 year Pressure testing cooling system Test radia
119. OIL TEMPERATURE ENGINE OIL PRESSURE Enter Selected Parameter OURGP11 00000B2 19 03SEP03 10 14 RG13231 UN 26SEP03 11 Use the Menu keys to return to the 4 Up Custom Setup screen ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL Nole the nurnber to the right of the selected parameer md cating that the parazneter 18 now assigned to that display location Return To 4 Up Custom Setup OURGP11 00000B2 19 03SEP03 11 14 RG13232 UN 26SEP03 12 The selected quadrant has now changed to the new selected parameter Continued on next page 125 F COOL TEMP 1000 RPM ENG RPM 143 F OIL TEMP 57 PSI OIL PRES 4 Up Display OURGP11 00000B2 19 03SEP03 12 14 RG13153 UN 24SEP03 15 24 133 260 072209 PN 61 Operating the Engine 13 Repeat the parameter selection process until all spaces are as desired 14 Press the Menu key to return to the main menu 125 F COOL TEMP 1000 RPM ENG RPM Return To Main Menu RG13154 UN 24SEP03 OURGP11 00000B2 19 03SEP03 13 14 15 Press the Menu key to exit the main menu and return to the engine parameter display GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ERN Select Remaining Parameters 125 COOL TOP 57 PSI PRES RG13155 UN
120. PLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT D 1 z 1 Select Stored Codes Continued on next page OURGP11 00000AC 19 03SEP03 2 6 15 5 PN 42 114 260 Operating the Engine 3 Once the Stored Codes menu item has been highlighted press the Enter key to view the stored codes GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Er RG13169 UN 020CT03 Enter Key OURGP11 00000AC 19 03SEP03 3 6 4 If the word Next appears above the Arrow keys there are more stored codes that may be viewed Use the Arrow key to scroll to the next stored code 1ofx SPN 94 FMI 18 FAULT FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER AND LINES lt NEXT gt RG13245 UN 020CT03 Use Arrow Keys To Scroll OURGP11 00000AC 19 03SEP03 4 6 5 Press the Menu key to return to the main menu Continued on next page 1ofx SPN 110 FMI 16 FAULT ENGINE COOLANT TEMERATURE HIGH CORRECTIVE ACTION CHECK COOLING SYSTEM REDUCE POWER lt NEXT gt HIDE RG13246 UN 020CT03 Return To Main Menu OURGP11 00000AC 19 03SEP03 5 6 15 6 115 260 072209 PN 43 Operating the Engine 6 Press the Menu key to exit the main menu and return to the engine parameter display 98
121. Region e of the signal range definition Broadcast of data values is substituted with the error indicator value f Any signal external to an electronic control module whose current remains off when the ECM commands it on Broadcast of data value is substituted with the error indicator value FMI 6 CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT g A current signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data values is substituted with the error indicator value h Any signal external to an electronic control module whose current remains on when the ECM commands it off Broadcast of data value is substituted with the error indicator value FMI 7 MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of a mechanical system that with a reasonable confidence level is not caused by an electronic or electrical system failure This type of fault may or may not be directly associated with the value of general broadcast information FMI 8 ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD To be considered in cases of FMI 4 and 5 Any frequency or PWM signal that is outside the predefined limits which bound the signal range for frequency or duty cycle outside Region b or the signal definition Also if the signal is an ECM output any signal whose frequency
122. S3 0 046 2 51 18 4 0 5 VS45 0 046 2 51 18 4 0 5 S7 0 036 2 91 18 4 0 5 4 9 Table of weights S75 0 036 2 91 18 4 0 5 L12 0 019 3 66 18 4 0 5 S1 220 76 515 220 76 Field excitation current i exc 400 V 50 Hz S25 220 76 i exc excitation current of the exciter field S35 240 80 LSA 44 2 no load on load M45 270 90 L65 290 102 VS3 0 5 1 8 L8 330 120 VS45 0 5 2 1 S7 0 5 1 9 S75 0 5 2 1 M95 0 6 2 LSA 44 2 Total weight kg Rotor kg L12 0 5 1 9 VS3 405 140 VS45 405 140 S7 460 165 4 8 5 3 phase LSA 44 2 4 pole AREP 575 460 165 excitation M95 515 185 Resistances at 20 C SD 219 Lsa 44 2 Stator Rotor ie A Field Armat VS3 0 046 2 51 0 3 0 5 4 9 0 5 VS45 0 046 2 51 0 3 0 5 4 9 0 5 S7 0 036 2 91 0 21 0 32 4 9 0 5 S75 0 036 2 91 0 21 0 32 4 9 0 5 M95 0 024 3 32 0 17 0 28 4 9 0 5 L12 0 019 3 66 0 16 0 21 4 9 0 5 LEROY SOMER 15 211 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 5 SPARE PARTS 5 1 First maintenance parts Emergency repair kits are available as an option They contain the following items Ref Designation Qty LSA 43 2 44 2 SHUNT Code R 250 AEM 110 RE 019 198 AVR 1 R 251 AEM 110 RE 021 343 Diode bridge assembly 1 LSA 432 9 100 ALT 432 KD 001 347 Surge suppressor 1 LSA 432 1 13 AEM 000 RE 126 AVR fuse 1
123. Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE C cable first A 12 Volt Machine battery C Booster cable ies D Cable to starter motor B 12 Volt Booster battery ies DPSG CD03523 20 19 22JAN07 1 1 1 5 2 8 072209 PN 65 137 260 Operating the Engine Engine operation Warming engine Operate engine at high idle for 1 to 2 minutes before applying the load NOTE This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed Normal engine operation Compare engine coolant temperature and engine oil pressure with specifications below Specification Minimum oil pressure at full load rated speed Coolant temperature 275 kPa 2 75 bar 40 psi 82 94 C 180 202 F Stop engine immediately if coolant temperature is above or oil pressure below specifications or if there are any signs of part failure Symptoms that may be early signs of engine problems could be e Sudden loss of power Oil at normal operating temperature of 115 C 240 F Unusual noise or vibration Excessive black exhaust Excessive fuel consumption Excessive oil consumption Fluid leaks Recommendation for turbocharger engines Should the engine stall when operating
124. Temperature MAT Sensor Connector RG12201 UN 24MAY02 U Alternator Ignition Connector V Optional Instrument Panel or Generator Instrument Panel CD03523 000018E 19 02FEBO07 1 1 55 2 168 260 072209 PN 96 Troubleshooting Engine Wiring Layout Electronic Fuel System With Denso High Pressure Common Rail RG12224 UN 19JUN0O2 6068HFU74 Engine shown A Engine Coolant Temperature E Optional Instrument Panel I Fuel Rail Pressure Sensor M Fuel Temperature Sensor ECT Sensor Generator Instrument Panel J Crankshaft Position Sensor B Electronic Injector Connector F Engine Wiring Harness K Pump Position Sensor C Manifold Air Temperature G Engine Oil Pressure Sensor L Pump Control Valve Solenoid MAT Sensor Connector D ECU Connector H Power and Ground Battery Connections CD03523 000018F 19 02FEBO7 1 1 55 3 072209 PN 97 169 260 Troubleshooting Engine troubleshooting Symptom Engine cranks but will not start Engine hard to start or will not start Engine knocks Problem Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Engine starting under load Improper starting procedure No fuel Air in fuel line Cold weather Slow starter speed Crankcase oil too heavy I
125. The generating set should not be connected to any other power sources such as the mains supply network In specific cases where there is to be a connection to existing electrical networks this must only be installed by a qualified electrician who should take the operating differences of the equipment into account according to whether the mains supply network or generating set is being used Protection against electric shocks is ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications 10 260 EN If the protective plates blanking covers need to be removed to route cables the protector blanking cover must be refitted when the operations are finished Due to high mechanical stresses use only strong flexible wiring with rubber sheathing compliant with IEC 245 4 or equivalent wiring 1 3 6 Dangers presented by electric currents first aid First aid In the event of an electric shock shut off the power immediately and activate the emergency stop on the generating set or lighting column If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire may be cut with an axe Take great care to avoid the electric
126. User and maintenance manual for generating sets R44 33501719701NE 2 1 12 n OO da abba EPI ete n a enu le 3 1 1 General recommendations uoc ie d ted i ete cte a pe oe cr re ast te o Db ate te b ett i na ee e BE te 3 1 2 Pictograms and their mearnifigs re Dto ne iti bale ae e ERE ges ced iz der a de eh 4 1 3 Instructioris and safety regulations ct ce eadein nao rr et t dece 8 SX General EEG 8 1 9 2 Risks related to exhaust gases An Tel Sis ti adea ce da ecce re n e dte cde emot e cbe 9 1 3 3 Risks related to toxic products 2 m ere a Drees Gee E a ect Se B ee 9 1 3 4 Risk of fire b rns and exploslOri iiiter be e nae na DOR Pu ead hiatal idle een dee Dre dn 10 1 3 5 Risks related to electrical networks cccesececesecceeeeseeeeeeeeneeeenneeeeeseeeeeeseeseeesenseeeegeeeeseseeenesseseeeesenseseeedenseenseeeenseeenensineeeeses 10 1 3 6 Dangers presented by electric currents first aid menm nemen 11 1 3 7 Risks related to moving the Set 2 ente tinere ecce ERR Ce ee 11 1 4 Identifyirig Sets it el te eite et be e t f tg tete ttu tpe EUER 12 2 d ca de E ia eg e Ep ia i qai t abet iem e ei bee nra 14 2 1 14 2 2 Te
127. V R 3 2 1 R250 settings SHUNT system Initial potentiometer positions voltage setting potentiometer P1 for the A V R full left remote voltage setting potentiometer in the middle Operate the alternator at its rated speed if the voltage does not rise it is necessary to re magnatise the magnetic circuit slowly adjust the voltage potentiometer of theA V R P1untiltheoutputvoltage reaches its rated value Stability setting with P2 3 2 2 Special type of use Excitation circuit E E must not be left open when the machine is running A V R damage will occur 3 2 2 1 R250 field weakening SHUNT The exciter is switched off by disconnecting the A V R power supply 1 wire or 110V Contact rating 16A 250V AC Do notreclose the power supply until the voltage has reached a value lt 15 of the rated voltage approximately 5 seconds after opening 3 2 2 2 R250 field forcing 400V 10A K Diode iol t an es B M Excitation Inducer The battery must be isolated from the mass Exciter field may be at line potential LEROY SOMER 224 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 3 3 Electrical faults 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 2to 3 s
128. V R Altit m Masse Weight AV D E bearing Rit AR N D E bearing Graisse Grease Valeurs excit Excit values en charge full load vide at load S ALrERNATEURS Ia 27 ALTERNATORS PUISSANCE RATING v Ph Connex Continue kVA Continuous kW 40C Secours kVA Std by kW 27C LEROY SOMER 200 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 2 TECHNICAL 2 2 Mechanical characteristics CHARACTERISTICS Steel frame 2 1 Electrical characteristics PARTNER LSA 43 2 44 2 alternators are generators without sliprings or revolving field brushes wound as 2 3 pitch 12 wire the insulation is class H and the field excitation system is available in either SHUNT AREP or PMG versions see AVR manual 2 1 1 Options Stator temperature detection probes Space heaters Interference suppression conforms to standard EN 55011 group 1 class B Europe 2 1 2 SHUNT system with R 250 AVR Other version R 251 AVR for dedicated single phase or R 448 for additional function Castiron end shields Protected ball bearings greased for life Mounting arrangements IM 1201 MD 35 foot and flange mounted single b
129. ables depending on model s 2 x 2 conductor cables depending on model Figure 4 6 Electrical connection diagram 4 9 Complete wheels technical information COMPLETE TYRES WHEELS Dimensione indices Diameter mm Cross section Radius under load Load Pressure mm mm Kg bar 135 R 13 70T 550 134 265 335 2 4 145 R 13 75T 566 145 272 387 2 4 155 R 13 79T 578 150 277 437 2 4 145 70 R 13 71T 534 150 259 345 2 5 155 70 R 13 75T 548 147 263 387 2 5 185 70 R 13 86 T 594 185 285 530 2 5 165 R 14 C 98 N 622 172 284 650 3 8 155 70 R12 100 N 525 155 244 RE 6 25 185 14C 102 650 188 316 Ein 4 5 195 R 14 C 106 P 666 198 32 950 4 5 195 50 x 10 98 N 450 190 750 6 0 36 260 N 5 Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate Specific skills are required to carry out these operations They must only be entrusted to personnel with the necessary skills Failure to follow these instructions in any way could result in malfunction or very serious accidents Danger 5 1 Installation checks check that the general recommendations given in the installation section ventilation exhaust fluids etc are observed carry out the level checks oil water diesel fuel battery check the generating set earth connection is earthed check that the electrical connections are in order 5 2 Checks after starting the ge
130. ad 1 threshold at 48 Hz with LAM 13 for impacts between 40 and 70 of the rated load 2 threshold at 48 Hz with LAM 25 for impacts gt 70 of the rated load Operating at 60 Hz U F gradient 3 threshold at 58 Hz without LAM for impacts between 30 and 40 of the rated load 4 threshold at 58Hz with LAM 13 for impacts 40 and 70 of the rated load 5 threshold at 58Hz with LAM 25 for impacts gt 70 of the rated load Specific operating 6 threshold at 57Hz without LAM for speed variations at a steady state gt 2 Hz 7 threshold at 65Hz without LAM for variable speed and tractelec gearlec U F gradient 8 special the factory setting 48Hz 2U F gradient a special programme is possible on request This programme must be specified before ordering during the project study 9 threshold at 47 5 Hz without LAM for speed variations at a steady state gt 2 Hz For hydraulic applications it is advisable to select frequency see the nameplate on the position 0 for 50 Hz alternator position 3 for 60 Hz Risk of destruction for the alternator LEROY SOMER 5 221 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 2 3 R250 A V R option Potentiometer for voltage setting 1000 W 0 5 W min setting range 5 Remove the STA jumper For wiring upthe external potentiometer the earth wires must be isolated as well as the pot
131. ad A rov High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect fuel lines between the high pressure fuel pump and nozzles Only bleed the fuel system at the fuel filter bleed screw A 1 Loosen the air bleed screw A two full turns on final filter base only 2 Operate fuel supply pump primer lever B until fuel flow is free from air bubbles 3 Tighten bleed screw securely Continue operating primer until pumping action is not felt 4 Start engine and check for leaks If engine will not start repeat steps 1 4 TS1343 UN 18MAR92 Fuel supp A ly pump primer lever DPSG CD03523 46 RG7725 UN 08JAN97 RG12220 UN 24MAY02 RG12221 UN 24MAY02 19 09FEBO07 3 3 50 7 166 260 072209 PN 94 Troubleshooting General troubleshooting information Troubleshooting electronically controlled engine problems can be difficult The first thing to do is to identify the type of problem which can be mechanical or electrical Know the engine and all related systems e Study the problem thoroughly Relate the symptoms to your knowledge of engine and An engine wiring layout is provided in this section to systems identify electrical components engine controller sensors Diagnose the problem starting with the easiest things connectors first Ww Double check before beginning the disassembly Later in this sectio
132. ad turn key switch ON but DO NOT crank engine until engine preheater indicator light turns OFF HPCR 4 valve head engines are equipped with glow plugs one per cylinder C Turn key switch ON but DO NOT crank engine until preheater indicator light turns OFF A Grid Type heater 4045 and C Multiple Glow Plugs HPCR 6068 non HPCR 4 valve 4 valve head engines head engines ba B Single Glow Plug 3029 and 4039 engines Glow PI Continued on next page TS1356 UN 18MAR92 C we 4 wet M gt C b CD30750 UN O03SEP99 CD30925 UN 23JAN07 ugs on HPCR 4 valve head engine DPSG CD03523 19 19 06FEBO7 1 3 15 26 135 260 072209 PN 63 Operating the Engine Coolant heater Connect plug of coolant heater A to a proper power source 110 or 220 V At an ambient temperature of 15 C 5 F the heating process takes approximatively 2 hours Extend heating period if ambient temperature is lower KR o zd Q 2 2 N N x 21 Fuel preheater Fuel preheater A switches ON and OFF automatically in relation with the ambient temperature SHN DEERE WAL FILTER LX1017708 UN 09OCT97 DPSG CD03523 19 19 06FEBO7 3 3 15 27 136 260 072209 PN 64 Operating the Engine Using a booster battery or charger A 12 volt booster battery can be connected in parallel with b
133. ading 3 1 2 1 Slings Attach the lifting vehicle slings to the rings on the generating set designed for this procedure Hang the slings carefully Check that the slings are correctly attached and the equipment is solid Lift the generating set carefully Direct and stabilise the set towards the chosen position Carefully set down the equipment while continuing to position it 000000 Release the slings then detach and remove the lifting rings e 2 2 Fork lift truck Position the forklift arms under the base frame except with generating sets fitted with forklift pockets in which case position the forklift arms in these pockets making sure that only its cross members are resting on the arms Lift the equipment handling it gently oo Set down the generating set in its unloading position Figure 3 1 Transporting a generating set using a forklift truck 26 260 N 3 2 Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container if the generating set is fitted with this option The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Three different fittings are available Diagram 3 2 Fluid retention container integrated into the tank chassis Diagram 3 3 Offset fluid retention container underneath the gener
134. ain strictly defined pure volatile degreasing agents can be used such as Normal petrol without additives inflammable Toluene slightly toxic inflammable Benzene or benzine toxic inflammable Ciclohexare non toxic inflammable The insulating components and the impregnation system are not at risk of damage from solvents see the list of authorized products Avoid letting the cleaning product run into the slots Apply the productwith a brush sponging frequently to avoid accumulation in the housing Dry the winding with a dry cloth Let any traces evaporate before reassembling the alternator These operations must be performed ata cleaning station equipped with a vacuum system that collects and flushes out the products used 4 2 5 Mechanical servicing CAUTION Cleaning the machine using a water spray or a high pressure washer is strictly prohibited Any problems arising from such treatment are not covered by our warranty The machine should be cleaned with a degreasing agent applied using a brush Check thatthe degreasing agent will not affect the paint Compressed air should used to remove any dust If filters have been added to the machine after manufacture and do not have thermal protection the service personnel should clean the air filters periodically and systematically as often as necessary every day in very dusty atmospheres Cleaning can be performed using water for dry dust or in a bath contai
135. and coolant 20 1 Troubleshooting Maintenance records sese 02 1 RISE ical i cornea TO LEUTE 55 8 Metric bolt and screw torque values 65 9 Endllie LL Ae EAE EIE 55 4 Mixing 10 3 General information cccccccccccccccccccccceccccecceesese 55 1 U Operating the engine Unified inch bolt and screw torque values 65 8 Break in period HS 15 25 Units of measure changing EP UP CDM NES 15 13 Changing Generator Frequency 15 29 Standby power units 15 29 V Starting the 15 25 Stopping the 15 29 valve clearance Using a booster battery or charger 15 28 Adjust 3029 and 4039 35 3 S Adjust 4045 and 6068 engines 40 1 Serial number w Engine Control Unit 03 5 Wiring harness Ur PUSH PUMP iii te ihi 03 5 With Denso High Pressure Common Rail 55 3 Engine Control Unit ECU serial number 03 With Stanadyne DE10 55 2 Index 2 2 192 260 N 9 2 Appendix B Alte
136. arance adjust 300 Series Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 66 19 22JAN07 1 1 6000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Cooling system drain and flush if COOL GARD is not used n Valve clearance adjust POWERTech n Air intake system check n Vibration damper check Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 67 19 22JAN07 1 1 072209 02 7 PN 16 88 260 Maintenance Records 6500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 68 19 22JAN07 1 1 7000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Air intake system check Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 69 19 22JAN07 1 1 02 8
137. arc that will be generated by this Begin emergency procedures Resuscitation If breathing has stopped begin artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 1 3 7 Risks related to moving the set To unload the generating sets pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions you must ensure that the following points are observed A Y The lifting machinery or equipment is suited to the work required in good condition and with sufficient lifting capacity The slings are positioned in the rings provided for this operation the forklift arms are resting fully underneath all of the base frame cross beams or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set according to models For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set pump unit or lighting column the generating set pump unit or lighting column must be lifted up with an adjustable boom All the chains and cables must be parallel with each other and as perpendicular as possible with the upper edge of the generating set pump unit or lighting column If other equipment fitted on the generating set pump unit or lighting column alters it
138. arge indicator flashing AAW voltage flashing flashing bars Oil pressure temperature indicator Oil pressure High or low oil level High or low oil 1 Alarm temperature Alarmi Fault gt Fault Alarm Fault E Emergency stop Emergency stop fault Overload or short circuit Tripping of circuit breaker following an overload or short circuit gt Engine speed Underspeed fault Overspeed fault Non starting fault 50 260 N 6 3 1 5 Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised The pictograms below are given as examples Generating set stopped 9i ic men Pictograms Data displayed H H Hu J Fuel Level Indicator c Indication of Temperature of High Temperature coolant HT units according to settings menu P1 0502 L V Indication of Battery Voltage c Indication of Oil Temperature units according to settings menu Generating set start up or generating set started or generating set switching off in progress Screen Generating set started Pictograms Data displayed o H n RPM Engine Speed Indication Indication of Temperature of High Temperature e coolant units according to settings menu P2 i O i Indication of Oil Pressure units according to settings d BAR nets Indication of Oil Te
139. arry 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 PERKINS PE and VOLVO VO engines the codes displayed are SPN and FMI codes 6 3 4 5 Horn reset Depending on the settings made menu 363 HORN the activation of an alarm and or a fault leads to the horn sounding and the following screen appearing HORN STOP PRESS OK This screen will display first any messages relating to 25 12 2005 the alarms and faults that appear as soon as OK is pressed 15 30 62 260 EN 7 Maintenance schedule 7 1 Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule given as a guideline N B the environment in which the generating set is operating determines this schedule If the generating set is used in extreme conditions shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel oil and coolant which conform to the specifications given in this manual 7 2 Engine 2000 hrs 2500 hrs OPERATION 500 hours every As required 2 years 3 years Inspect the engine compartment e Check the engine oil fuel refrigerant levels Check the air filter clogging
140. ating set chassis 27 260 Diagram 3 4 Offset fluid retention container integrated into the chassis and tank Generating sets fitted with the offset tank option DW above also have a high level indicator in the retention container In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers either via the drain port or by using the drain pump for containers fitted with this pump Y Note Never allow these fluids to drain onto the ground ensure they are collected in a designated container 3 3 Choice of location It should be determined on the basis of use There are no specific rules governing the choice of location other than proximity to the electric distribution panel and disturbances caused by the noise However fuel supply burnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered N Incorrect exhaust and ventilation Ground too uneven or soft Reduced access Set incorrectly positioned Fuel filling impossible Opening cover doors impossible Diagram 3 5 Examples of problems that may be encountered 28 260 EN 3 4 Electricity 8 Connections general information As with low voltage electrical installations use and
141. attery 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 _ 11 MANUAL lt gt AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS GS OK Esc Q 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 Press START AVAILABLE POWER AIR PREHEATING START UP 100 096 IN PROGRESS 10 seconds 24 08 2005 24 08 2005 24 08 2005 The following pictogram is displayed f the engine is equipped with an Warning the number of successive air preheating system there is a and automatic starting attempts is oki delay adjustable before the limited to 3 engine starts preheating EM activation period The following pictogram will flash The following information is displayed f the motor is not fitted with an air preheating system or once the ete 6 Speed of rotation preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to ej Coolant temperature start up the engine 2 Oil pressure 2 9 el Oil Temperature 57 260 EN 6 3 3 Switching off Open the circuit breaker manually OR
142. attery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems RG4678 UN 14DEC88 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the POSITIVE post of the booster battery 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies RG4698 UN 14DEC88 24 Volts System 6
143. ature sensor 0 Fuel temperature high most severe 3 Fuel temperature sensor input voltage high 4 Fuel temperature sensor input voltage low 15 Fuel temperature high 16 Fuel temperature high moderately high 31 Fuel temperature sensor faulty 249 260 N 9 2 SPN SID PID PPID Description Commentary e gt 9 175 175 Cil temperature sensor 0 Oil temperature extremely high 3 Oil temperature sensor input voltage high 4 Oil temperature sensor input voltage low 5 Oil temperature sensor open circuit 177 Transmission oil temperature sensor 9 Transmission oil temperature invalid wih See 189 Rated engine speed 0 Engine speed de rated 31 Engine speed de rated 190 190 190 Engine speed sensor 0 Overspeed extreme 2 Engine speed sensor data intermittent 9 Engine speed sensor abnormal update 11 Engine speed sensor signal lost 12 Engine speed sensor signal lost 15 Overspeed 16 mI Overspeed moderate 228 261 Speed sensor calibration 13 Engine timing abnormal calibration 252 252 Software 11 a Incorrect engine software 234 253 Check system parameters 2 Incorrect parameters 281 281 Action alert output status 3 A
144. cated Dry Size Ib in Ib in Ib in Ib in Ib in Ib in Nem Ib in Ib in M6 4 7 42 6 53 8 9 79 11 3 100 13 115 16 5 146 15 5 137 19 5 172 lb ft Ib ft Ib ft Ib ft M8 11 5 102 14 5 128 22 194 27 5 243 32 23 5 40 29 5 37 27 5 47 35 16 6 Ib ft Ib ft M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70 Ib ft M12 40 29 5 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190 M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300 M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410 M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580 M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800 M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000 M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475 M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 Torque values listed are for general use only based on the strength of Shear bolts are designed to fail under predetermined loads Always the bolt or screw DO NOT use these values if a different torq
145. chnical specitications reb eed et P Pe gie a dee ee qct ded bee teet e dd 21 2 3 ea a ts EE t RE C EUER eA ee 23 2 31 Specifications 22 eee Re nete bent tensis deeem de RE 23 Pom MEE Fe r o ERE HO 23 2 3 1 2 Specificatioris of coolants d e E E LL abt De Ape A T CTA 24 3 Iristallatiori 5 RES RE EE RERO CARE EE UE EE s 26 3 1 Unloading nete Remate eb dete et aee edt S 26 3 131 Safety during unloading 3 e Act er pr Ey ce ee EE RU S lel 26 3 4 2 Instructions for unloading vii eis poit eo eti ete Pe d e OE e Lie C Ra coL ETE ER CE 26 94 25 Slifgs IB i eem e unti itii enfe f 26 3 1 2 22 Forklift truck uiae poene uiu nm e i HERE 26 3 2 Fluid retentioni AEE AAEE Bend ee UC e 27 Ghoice of DD GERE E a ids 28 3 4 Electricity nennen biam diii neue bete uui 29 3 5 SpeCialbarranGements 30 4 Ee E A A EUR EE Umen Idi 31 4 1 Trailer linkage eR a E HERD RII I aciei o oo d ceti 31 4 2 Check betore towing e pete Dt De Ee bic eee nein ees dei Se Et en eens 31 4 3 32 4 4 Unhitching the trailer a fb D p t e psv et tito b Diete doit i eps ee
146. ck 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 ST1 jumper open to connect the 7310r R 734 3 phase sensing module ST2 jumper open if rapid response time used 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 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 Action Factory setting Pot 400V 50Hz 7 t Voltage E z n minimum fully anti clockwise 4 0 380 V 5 Not set tabili ot se E Stability centre position Voltage quadrature droop Not set operation with C T fully anti 0 quadrature loop fully clockwise 19 anti clockwise Stability adjustments in standalone operation Excitation ceiling Limit of
147. container when the fuel begins to flow out tighten the drain plugs Bleed the supply circuit A Drain plug B Air bleed plug C Main fuel filter D Final fuel filter 39 260 6 2 Generator set with NEXYS control panel 6 2 1 Control panel presentation Diagram 6 1 View of the front side Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for starting up shutting down the module and RESET function Electronic card protection fuse Screen scroll button press successively to access the various screens which are available STOP button press to switch off the generating set START button press to switch on the generating set Normal operation LEDs and alarm and fault warning LEDs Slot reserved for panel fascia options Mounting bolt ooeoeodooooo o LCD for displaying alarms and faults operating states electrical and mechanical quantities 40 260 Diagram 6 2 Description of the LEDs A lit LED indicates D Module being supplied green lights up and remains lit Q 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 Generalalarm orange flashing General fault red flashing
148. ction alert output open short to B Action alert output short to ground 5 Action alert output open circuit 282 282 Overspeed output status 3 Overspeed output open short to B 4 Overspeed output short to ground 285 285 Coolant temperature output status 3 EM temperature lamp open short to 4 Coolant temperature lamp short to ground 286 286 Oil pressure output status 3 Oil pressure output open short to B Oil pressure output short to ground 5 Oil pressure output open circuit 323 323 Shutdown output status 3 Shutdown output open short to B Shutdown output short to ground 5 Shutdown output open circuit 250 260 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Commentary 324 324 Warning output status Warning output open short to B Warning output short to ground Warning output open circuit 443 443 ENGINE RUN output status Engine run output open short to B Engine run output short to B 523 Gear selection Gear selection invalid Not possible with Genset application 608 250 98 Data link faulty J1587 Start Stop redundancy J1939 communication bus 611 Injector wiring status Injector wiring shorted to power source 620 262 232 Injector wiring shorted to ground 5 Volt sensor power sup
149. ctions 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 Adjustment ineffective Faulty AVR potentiometer Voltage Adjust AVR stability If no effect try normal rapid recovery Check the speed possibility of cyclic irregularity oscillations potentiometer modes ST2 Loose connections Faulty AVR Speed too low when on load or LAM set too high Voltage correct at no load and too low when on load Run at no load and check Voltage between E and E SHUNT lt 20 V AREP PMG lt 10 V Check the speed or LAM set too high the voltage between E and E on the AVR Voltage between E and E SHUNT gt 30 V Faulty rotating diodes Short circuit in the main field Check the resistance Faulty exciter armature AREP PMG gt 15 V Caution For single phase operation chec k that the sensing wires coming from the AVR are correctly connected to the operating terminals Voltage disappears during operation e Check the AVR the surge suppressor the rotating diodes and replace any defective components value The voltage does not return to the rated Exciter winding open circuit Faulty exciter armature Faulty
150. cts Safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with John Deere equipment include such items as lubricants coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques Check the MSDS before you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment TS1132 UN 26NOV90 See your John Deere dealer for MSDS s on chemical products used with John Deere equipment DX MSDS NA 19 03MAR93 1 1 Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all times Make sure rotating shields turn freely Wear close fitting clothing Stop the engine and be sure the PTO driveline is stopped before making adjustments or performing any type service the engine or PTO driven equipment TS1644 UN 22AUG95 CD PTO 19 22JANO7 1 1 0 5 5 072209 PN 30 102 260 Safety Practice Safe Maintenance Understand service procedure before doing work Keep area clean and dry Never lubricate service or adjust machine while it is moving Keep hands feet and clothing from powe
151. cuum cleaner is recommended to clean Keep bystanders away from the area asbestos If not available apply a mist of oil or water on the material containing asbestos DX DUST 19 15MAR91 1 1 Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with John Deere equipment include such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source TS1133 UN 26NOV90 Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer DX DRAIN 19 03MAR93 1 1 0 5 8 072209 PN 33 105 260 Fuels Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area In general diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed Diesel fuels specified to EN 590 or ASTM D975 are recommended Ren
152. d repairs N Fault observed Origin Solutions Erratic braking of trailer Faulty shock absorber Replace the shock absorber Braking too weak Jaws worn Replace the jaws Jaws not run in Fault will disappear only after running in Incorrect linkage setting Adjust the setting Significant friction on the slide Grease the sliding parts Slide corrosion Remove the corrosion and grease Coupling height does not match that of the towing vehicle Adjust the height so that the two parts are in the same horizontal plane Drum temperature abnormally high Incorrect linkage setting Adjust the settings Incorrect brake setting High levels of dust in the drums Adjust the settings Remove the dust Jaws springs drums damaged Replace the damaged parts Brake cables or link rod damaged Replace the damaged parts Jerky braking Incorrect linkage setting Adjust the settings Interfering parts on the slide Remove clean and grease Corroded slide Remove the corrosion and grease Damage to slide guide rings Replace the rings and possibly the slide and grease Faulty shock absorber Replace the shock absorber Trailer tending to swerve upon braking Cross bar s not balanced Different brake setting on the two sides Adjust the cross bar s Adjust the brake settings Cables da
153. djust 300 Series Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 8 19 22JAN07 1 1 1000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Air intake system check Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 9 19 22JAN07 1 1 02 2 83 260 072209 PN 11 Maintenance Records 1500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 10 19 22JAN07 1 1 2000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean a Cooling system drain and flush if COOL GARD is not used n Valve clearance adjust POWERTech n Air intake system check n Vibration damper check Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 59 19 22JAN07 1 1 02 3 072209
154. dor cap CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engines Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Test Radiator Cap 1 Remove radiator cap and attach to D05104ST tester as shown 2 Pressurize cap to specification listed Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable If gauge does not hold pressure replace radiator cap Specification Radiator Cap 70 kPa 0 7 bar 10 psi for 10 seconds minimum 3 Remove the cap from gauge turn it 180 and retest cap to confirm measurement Test Cooling System NOTE Engine should be warmed up to test overall cooling system RG6557 UN 20JAN93 RG6558 UN 20JAN93 Test cooling system 1 Allow engines to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level IMPORTANT DO NOT apply excessive pressure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck Pressurize cooling system to specification listed for radiator cap 4 With pressure applied check all cooling system hose connections radiator and overall engine for leaks If leakage is detected correct as nec
155. e is the current selected parameter Use the Arrow keys to highlight the value in the quadrant you wish to change to a new parameter 125 F 1000 RPM COOL TEMP ENG RPM 57 PSI BAT VOLT OIL PRES RG13228 UN 26SEP03 7 t Select Parameters OURGP11 00000B2 19 03SEP03 7 14 8 Press the Enter key and a list of engine parameters will be displayed 125 F 4000 RPM COOL TEMP ENG RPM NEITEN 57 PSI BAT VOLT OIL PRES g 2 RN 1 S a List Of Engine Parameters Continued on next page OURGP11 00000B2 19 03SEP03 8 14 072209 15 23 PN 60 132 260 Operating the Engine 9 The parameter that is highlighted is the selected parameter for the screen Use the arrow keys to highlight the new parameter to be placed in the 4 Up Display ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL TEMPERATURE ENGINE OIL PRESSURE Select Desired Engine Parameter 3 The numaer to the night cf tbe serameg indicates the quadrat which is disalayed 1 Upper belt Quanieent 2 Lower Leh Quadrant 3 Upper Fight Quadrent da Lower Right Quaker 4 OURGP11 00000B2 19 03SEP03 9 14 RG13230 UN 26SEP03 10 Press the Enter key to change the selected parameter in the quadrant to the new parameter ENGINE SPEED 3 ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL 2 ENGINE
156. e cables or connections when the generating set is in operation Do not touch internal Switch off the generating set for maintenance operations wiring or connections while the genset is operating Disconnect power before servicing DANGER e USE DIESEL FUEL ONLY Handle fuel with care itis highly flammable Do not refuel the genset while smoking or when near open flame or sparks Use diesel fuel only The fuel is highly flammable handle with care Do not smoke near the generating set or expose it to a naked flame or sparks Shut down the generating set engine before filling the fuel tank Fill with fuel Always stop the engine before outside S la MR EN To prevent fire risks clean the generating set regularly Wipe away any dirt and traces of grease or fuel Prevent fires by keeping genset clean of accumulated trash and grease Always clean up spilled fuel WARNING DANGER Engine exhaust can cause sickness or The exhaust gases from the engine are toxic and can affect health or even esp cause death open well Use the generating set outdoors only in well ventilated areas or fit an exhaust ventilated areas or vent exhaust outside with an exhaust pipe extension extension to discharge the exhaust gases outside Figure 1 2 Pictograms and their meanings 5 260 aiibi Heteoolant ean cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare
157. e l excitatrice Series connection shunt excitation Parallel connection AREP or PMG excitation White White AN Single phase dedicated SHUNT version R 251 AVR no connection for 2000 2 wire output without terminal block LEROY 8 SOMER 204 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i 3 3 2 Sch ma de connexion des options LSA 43 2 44 2 4 POLE ALTERNATORS CR 791 T interference suppression kit standard for CE marking Voltage potentiometer n Connections 6 D T1 T1 T1 T2 T2 T2 T2 72 T9 4 T3 T3 T3 T3 e J LY Je STA Voltage adjustment by remote potentiometer Anti condensation heater Thermistor PTC temperature 101 102 LSA 43 2 44 2 Ns 130 C 103 2S Phi Blue a Pho 150 E Black xH Ph3 180 C 104 Red white m 3 3 3 Connection checks Electrical installations must comply with the current legislation in force in the country of use Check that The residual circuit breaker complies with legislation on protection of personnel in force in the country of use and has been correctly installed on the alternator power outputas c
158. e wrench until marks A and B are aligned f Record torque wrench measurement and compare with specification below Replace tensioner assembly as required Specification Spring Force eene 18 22 N m 13 16 lb ft A Mark on swing arm B Mark on tensioner mounting base i Align marks RG7977 UN 14NOV97 RG12054 UN 08JAN02 DPSG CD03523 34 19 30JAN07 2 2 Check and adjust engine valve clearance 3029 and 4039 Engines NOTE Valve clearance must be adjusted after the first 500 hours of operation then every 1000 hours thereafter Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 or JDG820 Flywheel Turning Tool A rotate engine flywheel in running direction clockwise viewed from water pump until No 1 piston front has reached top dead center TDC on compression stroke Insert timing pin JDE81 4 or JDG1571 B into flywheel bore Continued on next page CD30544 UN 19MAY98 DPSG CD03523 35 19 31JAN07 1 2 35 3 151 260 072209 PN 79 Maintenance 1000 hours 1 year 3 Check and adjust valve clearance to specifications according to following procedures Specification Valve clearance engine cold lIntake a rere ne ties 0 35 mm 0 014 in ISTE 0 45 mm 0 018 in
159. earing with SAE coupling disc IM 1001 B 34 double bearing with SAE flange and standard cylindrical shaft extension Drip proof machine self cooled Degree of protection IP 23 2 2 1 Options Air inlet filter Regreasable bearings only for LSA 44 2 and SHUNT or AREP version IP 44 protection MAIN FIELD STATOR 12 wires marked T1 to T12 Exit ad A A T1 T7 T2 T8 T9 Armature p Amm e E bak 5 Field ba a 2E DAC KR Coon T4 10 T5 T11 T6 T12 connection Power supply and voltage reference 2 1 3 AREP system with R 438 AVR MAIN FIELD STATOR 12 wires marked T1 to T12 Exiter Auxiliary windings X AMA T r7 T2 T8 T9 Armature 3 NC CS 5 cEEEEEENI Field 5 6 X X C T4 T10 5 Tu T6 T12 PARALLEL e ee connection Voltage reference 2 1 4 PMG system with R 438 AVR MAIN FIELD Exiter 2 Armature 5 oe 1 5 A e 53 Field 6 Q C PARALLEL e e e connection STATOR 12 wires marked T1 to T12 T1 T7 T2 T8 T3 T4 T10 5 T6 T12 R 438 Voltage reference LEROY SOMER 201 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2
160. econds The alternator starts up and its voltage is still correct when the battery is removed Lack of residual magnetism The alternator starts up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to the A V R Faulty diodes Induced short circuit The alternator starts up but its voltage disappears when the battery is removed Faulty A V R Exciter field short circuited Short circuit in the main field Check the resistance Voltage too low Check the drive speed Correct speed Check the A V R connections A V R may be faulty Field windings short circuited Rotating diodes burnt out Main field winding short circuited Checkthe resistance Speed too low Increase the drive speed Do not touch the A V R pot P1 before returning to the correct speed Voltage too high Adjust A V R potentiometer Adjustment ineffective Faulty A V R 1 faulty diode Voltage oscillations Adjust A V R stability potentiometer Check the speed possibility of cyclic irregularity Loose terminals Faulty A V R Speed too low on load or U F gradient 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 A V R Check the speed or U F gradient set too high Faulty rotating diodes Sho
161. ed on the understanding that this does not give total protection 30 260 4 Trailer EN 4 1 Trailer linkage Before attaching the trailer check the trailer hook on the tow vehicle it should fit the trailer ring perfectly A Trying to tow a trailer with a non matching device bar wires cords etc could lead to serious accidents Also check no incipient fractures or excessive wear on the hitching system Danger locking system is operating properly To hitch the trailer proceed as follows 0000000 Lock the wheels to stop the trailer from moving Lift up the rear trailer supports and lock them Release the parking brake Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook Hitch the trailer remove the locks on each side of the wheels then lift up the front wheel fully using its handle Connect the electrical circuit of the trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook on the tow vehicle CORRECT CORRECT Tow vehicle Tow vehicle Trailer Trailer O INCORRECT INCORRECT Tow vehicle Tow vehicle Trailer Trailer Diagram 4 1 Coupling a trailer 4 2 Check before towing Before towing check the following lt lt 4 lt lt 44 45454 lt Tightness of the generating set enclosure bolts Wheel tightness Hitching hook locked Tyre pressu
162. ed in the Serial Number Section Accurately record all the numbers Your dealer also needs these numbers when you order parts File the identification numbers in a secure place off the engine or machine RIGHT HAND AND LEFT HAND sides are determined by standing at the drive or flywheel end rear of the engine and facing toward the front of the engine SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine Information relative to emissions regulations Depending on final destination this engine can meet the emissions regulations according to the US Environmental Protection Agency EPA California Air Resources Board CARB and for Europe the Directive 97 68 EC relating the measures against the emissions of gaseous and particulates pollutants from internal combustion engines In this case an emission label is stuck on the engine Emission regulations prohibit tampering with the emission related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications It is also illegal to install a part or component where the principal effect of that component is to bypass defeat or render inoperative any engine component or device which would affect the engine conformance to the emissions regulations To summarize it is illegal to do anything except return the engine to its or
163. ed servicing dealer or engine distributor Reduce load Fill radiator to proper level check radiator and hoses for loose connections or leaks Have serviceman check Check automatic belt tensioner and check belts for stretching Replace as required DPSG CD03523 49 19 22JAN07 3 4 55 6 172 260 072209 PN 100 Troubleshooting Symptom High fuel consumption Problem Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Defective turbocharger Low engine temperature Solution Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace if necessary Use correct grade of fuel Use proper type of fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Check thermostat DPSG CD03523 49 19 22JAN07 4 4 55 7 173 260 072209 PN 101 Troubleshooting Electrical troubleshooting Symptom Undercharged syst
164. ee 05 1 Checking belt 4045 and 6068 Engines with manual 30 6 Fuels Lubricants and Coolant l Diesel FUEI c ccccccccesecsecsecssesecsseeceeeseesseeaes 10 1 Maintenance 1000 hours 1 year Handling and Storing Diesel Fuel 10 1 Cleaning crankcase vent tube 35 1 Diesel Engine Break In Oil 10 2 Checking air intake 35 1 Diesel Engine 10 2 Checking automatic belt tensioner Lubricant Storage sss 10 3 4045 and 6068 Engines 35 2 Continued on next page Original Instructions All information illustrations and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice COPYRIGHT 2009 DEERE amp COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2007 2008 072209 PN 1 77 260 Contents Check and adjust engine valve clearance 3029 and 4039 Engines Pressure testing cooling system Maintenance 2000 hours 2 years Check and adjust engine valve clearance 4045 and 6068 Engines Checking engine speed Mechanical fuel sys
165. em 0 Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source NOTE Engines with mechanical fuel system have a single fuel filter while electronically controlled engines DE10 and HPCR fuel systems have X9811 UN 23AUG88 two fuel filters primary and final Whenever the fuel system has been opened up for service lines disconnected or filters removed it will be necessary to bleed air from the system On dual fuel filter system bleed air only from final filter Continued on next page DPSG CD03523 46 19 09FEBO07 1 3 50 5 072209 PN 92 164 260 Maintenance As required A Mechanical and DE10 fuel systems 1 Loosen the air bleed screw A two full turns On DE10 fuel system loosen only air bleed screw on final fuel filter 2 Operate supply pump primer lever B until fuel flow is free
166. em Battery uses too much water Batteries will not charge Starter will not crank Starter cranks slowly Entire electrical system Problem Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Stretched poly V belt or defective belt tensioner Engine under load Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse Low battery output Crankcase oil too heavy Loose or corroded connections Faulty battery connection Continued on next page Solution Remove accessories or install higher output alternator Increase engine rpm when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belts Remove load Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Replace fuse See your authorized servicing dealer
167. ement is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt 7 Bleed the fuel system DPSG CD03523 30 19 07FEBO7 1 1 30 4 072209 PN 74 146 260 Maintenance 500 hours Checking belt 3029 and 4039 Engines 1 Inspect belt for cracks fraying or stretched out areas Replace as necessary 2 Check belt tension using one of following methods a Use of JDG529 Tension Gauge A E Specification Belt tension New belt 578 622 N 130 140 Ib force Used belt ttt 378 423 N 85 94 Ib force 1 NOTE Belt is considered used after 10 minutes E of operation b Use of tension tester B and straightedge C A 89 N 20 Ib force applied halfway between pulleys should deflect belt by 19 mm 0 75 in 3 If adjustment is necessary loosen alternator nuts D and E Pull alternator frame outward until belt is correctly tensioned amp IMPORTANT Do not against the alternator i rear frame Do not tighten or loosen 2 belts while they are hot 4 Tighten alternator bracket nuts firmly 5 Run engine for 1
168. enerating set stops mir immediately also causing the main circuit breaker to be Li ILI tripped nni 2 Insulation fault optional with an insulation fault causing the 8 8 activation of the control unit performing insulation the generating set stops immediately 43 260 N Underspeed fault indicates an incorrect rotation speed below 1000 rpm Associated message i i AUi pa rr Emergency stop or external emergency stop fault Associated message CC AU Jl STOP fault activated if the STOP button is pressed whilst the AUT LED is flashing to indicate that the generating set is operating in automatic mode Associated message a a List of faults which will cause the generating set to stop and generate a fault code Oil pressure fault Indicates that the oil pressure is incorrect Associated pictogram C etc AU pa O Engine temperature fault Indicates that the engine temperature is too high Associated pictogram e C eit AU Non starting fault Indicates that there have been three consecutive unsuccessful starting attempts Associated pictogram 44 260 EN Associated pictogram c t Overspeed fault Indicates an excessive generating set running speed Associated pictogram D Low fuel level fault Indicates the need to top up the fuel List of alarms associated with a pictogra
169. entiometer terminals wires at the same voltage as the power 2 4 LAM characteristics Load Acceptance Module 2 4 1 Voltage drop The LAM system is integrated in the A V R Itis active as standard It can be adjusted to 13 or 25 Role of the LAM Load Adjustment Module On application of a load the rotation speed of the generator set decreases When it passes below the preset frequency threshold the LAM causes the voltage to drop by approximately 13 or 25 and consequently 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 duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engines To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the lowest frequency in steady state Itis advised to use the LAM at 25 for load impacts gt at 70 of the genset rated power Voltage 4 Voltage 085U M f 1 i i D P 1 48 or 58 Hz 50Jor 60 Hz 9 fN ST3 2 4 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 voltage according to the following principles if the speed dro
170. enus relating to control of the generating set will depend on the equipment level of each generating set Certain screens may therefore not be present 48 260 N 6 3 1 3 Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms Display Activation conditions Fixed TELYS in manual mode MANU 5 1 For 5 seconds when switching from AUTO mode Flashing to MANU mod MANU Mode mo e Fixed TELYS in automatic mode AUTO AUTO For 5 seconds when switching from MANU Flashing mode to AUTO mode AUTO Mode Flashing Generating set in start up phase Fixed Generating set started Fixed Generating set stabilised voltage and frequency Flashing appearance of constant movement from left to right The generating set is powering the installation ne Fixed The installation is supplied of Not used Not used 49 260 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 lt Alarm Fault Alarm Fault 4 low fuel level high fuel level lt Coolant level temperature indicator Alarm Alarm High level High No preheating Lowlevel fault alarm temperature fault fault 4 alarm battery Inm wal Battery ch
171. er is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used If the tensioner stop on swing arm A is hitting the fixed stop B check mounting brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed see REPLACING FAN AND ALTERNATOR BELTS RG8098 UN 18NOV97 A Swing arm stop B Fixed cast stop RG13744 UN 11NOV04 Later design tensioner Continued on next page DPSG CD03523 34 19 30JANO07 1 2 072209 35 2 PN 78 150 260 Maintenance 1000 hours 1 year Checking tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below a Release tension on belt using a breaker bar and Socket on tension arm Remove belt from pulleys b Release tension on tension arm and remove breaker bar c Put a mark A on swing arm of tensioner as shown d Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base NOTE Earlier engines have a LEFT HAND thread roller cap screw while later engines have a 12 7 mm 1 2 in square hole in tensioner e Install torque wrench on roller cap screw or in square hole so that it is aligned with center of roller and tensioner as shown Rotate the swing arm using a torqu
172. er to table in Diesel Engine Oil and Filter Service Intervals e BEFORE using diesel fuel with sulfur content greater than 0 5096 5000 ppm contact your John Deere dealer IMPORTANT Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines DX FUEL1 19 28APRO9 1 1 Handling and Storing Diesel Fuel Ah Ton Handle fuel carefully Do not fill the fuel tank when engine is running DO NOT smoke while you fill the fuel tank or service the fuel system Fill the fuel tank at the end of each day s operation to prevent water condensation and freezing during cold weather Keep all storage tanks as full as practicable to minimize condensation Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering Monitor water content of the fuel regularly When using bio diesel fuel the fuel filter may require more frequent replacement due to premature plugging Check engine oil level daily prior to starting engine A rising oil level may indicate fuel dilution of the engine oil IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an original vented cap When fuel is stored for an extended period or if there is a slow turnover of fuel add a fuel conditioner to stabilize the fuel and prevent water conden
173. ery cabling incorrect Tighten the ends of the battery cables or replace them if necessary One or two cells release a lot of gas at high charge Cell s faulty Fit a new battery The battery discharges very quickly Short service life Charge status too low Short circuit in the current circuit High self discharge through electrolyte contamination etc Sulphation storage of discharged battery Incorrect battery part no Repeated deep discharging Battery stored too long without charge Check the load Replace the battery Define the correct battery part no for the recommended use It is recommended to charge the battery using a regulator High water consumption The battery explodes Overload Charging voltage too high Spark after battery charging Short circuit Connection or charging Internal fault and low electrolyte level disconnection during Check the charger voltage regulator Replace the battery Ventilate well 67 260 68 260 N 9 Appendix 9 1 Appendix A Engine user and maintenance manual 69 260 70 260 User guide and maintenance manual JOHN DEERE Engine 3029DF amp TF120 3029TFS amp HFS70 TF amp HF270 4045TFS70 TF270 4045DF270 4045HFS72 HF275 4045HFS73 HF279 4045HFS80 HF280 4045HFS82 amp 83 HF285 6068HFS72 HF275 6068HFS73 HF279 6068HFS82 amp 83 HF285 6068HFS89 HF485
174. es check that the adjustment screw 8 reaches the FORWARD stop on the brake backing plate e Adjust the brake setting using screw 8 with the cables not connected to the cross bar s The shoes should rub the drum slightly Connect the brake cables to the cross bars s and tighten the nuts and lock nuts leaving the end of the threaded end protruding by around 10 mm Fig 4 4 IMPORTANT Wherever possible cables must cross over to achieve the highest possible gain curve Fig 4 5 Check that the parking lever 1 is in the REST position and that the compensating spring 4 is completely free on its rod unscrew the nuts 5 fully Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position Fit the transmission and adjust the assembly using the tensioner 6 until a gap J1 of 1 mm max is obtained between the linkage 9 and slide 2 Adjust the compensating spring 4 at one end pressing it against the anchorage plate and at the other end leaving a 2 mm gap J2 max between the spring and nuts 5 90 Tighten all the lock nuts Checking the setting trailer on axle stands Pull the parking lever 2 notches the wheels cannot turn in a FORWARD direction The wheels can turn in REVERSE adjustment screw 8 switches to the REAR position parking lever fully The wheels will not turn either in FORWARD or REVERSE and the cross bar s must remain parallel with the axle body C
175. essary and pressure test system again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket Have your engine distributor or servicing dealer correct this problem immediately CD03523 00000EC 19 22JANO07 1 1 072209 PN 81 35 5 153 260 Maintenance 2000 hours 2 years Check and adjust engine valve clearance 4045 and 6068 Engines Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 or JDG820 Flywheel Turning Tool A rotate engine flywheel in running direction clockwise viewed from water pump until No 1 piston front has reached top dead center TDC on compression stroke Insert timing pin JDE81 4 B into flywheel bore Continued on next page CD30544 UN 19MAY98 DPSG CD03523 36 19 31JAN07 1 2 40 1 154 260 072209 PN 82 Maintenance 2000 hours 2 years 3 Check and adjust valve clearance to specifications according to following procedures Specification Valve clearance engine cold lIntake a ern eere 0 35 mm 0 014 in ISTE 0 45 mm 0 018 in 4 If valves need adjusting loosen the locknut on rocker arm adjusting screw Turn adjusting screw until feeler gauge slips with a sligh
176. et of parameters one at a time momentarily pausing at each Continued on next page USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13196 UN 26SEP03 1 Up Display Options OURGP11 00000B1 19 03SEP03 4 18 15 16 072209 PN 53 125 260 Operating the Engine 5 Use Defaults To select Use Defaults use the Arrow keys to scroll to and highlight Use Defaults in the menu display USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13195 UN 26SEP03 Select Defaults OURGP11 00000B1 19 03SEP03 5 18 6 Press the Enter key to activate the Use Defaults function USE BEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13197 UN 29SEP03 Defaults Selected OURGP11 00000B1 19 03SEP03 6 18 7 The display parameters are reset to the factory defaults then the display will return to the Setup 1 Up Display menu RESTORED TO DEFAULTS Restored To Defaults Continued on next page RG13149 UN 24SEP03 OURGP11 00000B1 19 03SEP03 7 18 15 17 126 260 072209 PN 54 Operating the Engine 8 Custom Setup To perform a custom setup of the 1 Up Display use the arrow buttons to scroll to and AMATUR highlight Custom Setup on the display AUTOMATIC SCAN OFF RG13198 UN 26SEP03 Select Custom Setup OURGP11 00000B1 19 03SEP03 8 18 9 Press the Enter key to display a list of engine parameters
177. eter screen will display the warning icon until the trouble code condition is corrected 1000 RPM 1800 RPM ies 142 57PSl areas COOL TEMP BAT VOLT Ol PRES RG13243 UN 010CT03 Active Trouble Code Condition OURGP11 00000AD 19 03SEP03 7 7 15 8 117 260 072209 PN 45 Operating the Engine Engine Shutdown Codes 1 During normal operation the single or four parameter screen will be displayed RG13172 UN 26SEP03 Normal Operation OURGP11 00000AE 19 03SEP03 1 6 2 When the diagnostic gauge receives a severe trouble code from an engine control unit the single or four 9 SHUTDOWN parameter screen will be replaced with the Shutdown SPN 100 FMI 1 message The SPN and FMI number will be displayed SCE OIL PRESSURE LOW along with a description of the problem and the CORRECTIVE ACTION corrective action needed CHECK OIL LEVEL lt NEXT gt Shutdown Message If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code RG13238 UN 29SEP03 OURGP11 00000AE 19 03SEP03 2 6 3 To acknowledge and hide the trouble code and return to the single or four parameter display press the tox SHUTDOWN Enter key SPN 100 FMI 1 FAULT IMPORTANT Ignoring the shutdown message can ee CORRECTIVE ACTION result in severe engine damage CHECK
178. etting up The various adjustments during tests must be made by a qualified engineer The screwdriver for making adjustments must be suitable for use with electrical equipment It is essential that the drive speed specified on the genset nameplate is reached before commencing adjustment The AVR is used to make any adjustments to the alternator Access to the AVR adjustments is via the panel provided for this purpose After operational testing replace all access panels or covers LEROY SOMER 5 205 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 SERVICING 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 alternator in its original state 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 the appropriate personal protective equipment for mechanical and electrical hazards Before carrying out any work on the alternator ensure that it cannotbe started by a manual or automatic system by isolating the power in any cabinet or enclosure and make sure you have understood the operating principles of the system 4 2 Regular maintenance 4 2 1 Checks after start up After ap
179. ewable diesel fuel produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels Required Fuel Properties In all cases the fuel shall meet the following properties Cetane number of 45 minimum Cetane number greater than 50 is preferred especially for temperatures below 20 C 4 or elevations above 1500 m 5000 ft Cold Filter Plugging Point CFPP should be atleast 5 C 9 F below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature Fuel lubricity should pass a maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 Sulfur Content for Interim Tier 4 and EU Stage IIIB Engines Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates Use ONLY ultra low sulfur diesel ULSD fuel with a maximum of 0 001596 15 ppm sulfur content Sulfur Content for Other Engines Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates Use of diesel fuel with sulfur content less than 0 1096 1000 ppm is STRONGLY recommended Use of diesel fuel with sulfur content 0 1096 1000 ppm to 0 50 5000 ppm may result in REDUCED oil and filter change intervals Ref
180. excitation 60 Hz only Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA43 2 Stator L N Rotor Field Armature Md 25 51 0 058 1 35 13 9 0 23 S7 1 3 8 S25 0 058 1 35 13 9 0 23 S75 1 42 S35 0 046 1 41 13 9 0 23 M95 12 4 M45 0 037 1 57 13 9 0 23 L12 1 3 8 L65 0 027 1 76 13 9 0 23 L8 0 019 1 96 13 9 0 23 Fiel ru 4 8 6 Dedicated single phase LSA 44 2 ield excitation current i exc A 240 V 60 Hz 4 pole SHUNT excitation 60 Hz only i exc excitation current of the exciter field Resistances at 20 C Q LSA 43 2 no load on load 51 0 59 144 LSA 44 2 Stator L N Rotor Field Armature S25 0 59 1 68 VS3 0 0194 2 51 18 4 0 5 S35 0 66 1 65 VS45 0 0194 2 51 18 4 0 5 M45 0 61 148 S7 0 0140 2 91 18 4 0 5 L65 0 62 148 M95 0 0088 3 32 18 4 0 5 EB 0 4 146 Field excitation current i exc A 240 V 60 Hz i exc excitation current of the exciter field 4 8 4 3 phase LSA 44 2 4 pole SHUNT LSA 44 2 no load on load excitation VS3 0 44 1 18 Resistances at 20 C VS45 0 44 1 25 S7 0 43 1 2 LSA 44 2 StatorL N Rotor Field Armature M95 0 55 1 28 V
181. excitation and 10A short circuit current maximum minimum fully anti clockwise 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 ofthe 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 ILEROY SOMER 9 237 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R The best response times are obtained atthe 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 ST5 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
182. ey RG13226 UN 020CT03 OURGP11 00000B2 19 03SEP03 3 14 4 Two options are available for the 4 Up Display USE DEFAULTS a Use Defaults This option contains the following CUSTOM SETUP engine parameters for display Engine Speed Battery Voltage Coolant Temperature and Oil Pressure b Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default AN parameters Select Factory Defaults RG13244 UN 020CT03 OURGP11 00000B2 19 03SEP03 4 14 5 To reset the display parameters to the factory defaults scroll to and highlight Use Defaults Press the Enter key to activate the Use Defaults function RESTORED TO A message indicating the display parameters are DEFAULTS reset to the factory defaults will be displayed then the display will return to the Setup 4 Up Display menu a ui 7 Y 1 z o o a Restored To Defaults Continued on next page OURGP11 00000B2 19 03SEP03 5 14 1 5 22 072209 PN 59 131 260 Operating the Engine 6 Custom Setup To perform a custom setup of the USE DEFAULTS CUSTOM SETUP 4 Up Display use the arrow buttons to scroll to and highlight Custom Setup on the display RG13227 UN 26SEP03 OG Custom Setup OURGP11 00000B2 19 03SEP03 6 14 7 The quadrant with the highlighted parameter valu
183. f range and the case where the actual value is at the edge of a diagnostic region and 2 for the older SPN 611 to 615 where the problem is in determining which of two or more circuits which may interact is the one that needs repair SPNs 611 through 615 are defined as System Diagnostic Codes and are used to identify failures that cannot be tied to a specific field replaceable component Specific subsystem fault isolation is the goal of any diagnostic system but for various reasons this cannot always be accomplished These SPNs allow the manufacturer some flexibility to communicate non specific component diagnostic information Since SPNs 611 615 use the standard SPN FMI format it allows the use of standard diagnostic tools electronic dashboards satellite systems and other advanced devices that scan Parameter Groups containing the SPN FMI formats Because manufacturer defined codes are not desirable in terms of standardization the use of these codes should only occur when diagnostic information cannot be communicated as a specific component and failure mode Possible reasons for using a System Diagnostic Code include 1 Cost of specific component fault isolation is not justified or 2 New concepts in Total Vehicle Diagnostics are being developed or 3 New diagnostic strategies that are not component specific are being developed Due to the fact that SPNs 611 615 are manufacturer defined and are not component specific FMIs 0 13 and 15 31
184. f to carry out maintenance parts replacement and even total reconditioning of generating sets Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance the start up and shutdown procedures for the engines As the 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 sets control units should be taken into consideration In addition according to the manufacturing criteria of the generating sets some engines may be fitted with specific electrical wiring different to that described in the engine documentation Some user and maintenance manuals for the engines fitted to generating sets cover control units and include Important 3 260 N 1 2 Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator s or maintenance technician s attention to the potential dangers and explain the action to be taken in the interest of safety These notices are reproduced in this publication for ease of identification by the operator Replace any notice that is missing or illegible Publications delivered with the generating set must be referred to Caution danger Caution risk of explosion Naked flames and Caution risk of Protective clothing unprotected lights electric shoc
185. from air bubbles 3 Tighten bleed screw securely continue operating hand primer until pumping action is not felt 4 Start engine and check for leaks RG7947 UN 13NOV97 If engine does not start it will be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next Fuel filter bleed screw RG8013A UN 15JAN99 CD30771 UN 24SEP99 KR o m iL A o z 2 eo A o e Q o Mechanical injection pump return line DE10 Fuel return line At Fuel Injection Pump c Securely tighten return line connector a Slightly loosen fuel return line connector C at fuel injection pump b Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return line connection Continued on next page DPSG CD03523 46 19 09FEBO7 2 3 072209 50 6 PN 93 165 260 Maintenance As required At Fuel Injection Nozzles a Using two open end wrenches loosen fuel line connection at injection nozzle b Crank engine over with starting motor but do not start engine until fuel free from bubbles flows out of loosened connection Retighten connection to 27 N m 20 Ib ft c Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing dealer or engine distributor B HPCR fuel system 2 or 4 valve he
186. fting capacity of sling and straps RG7784 UN 11NOV97 NOTE If engine does not have lifting straps universal straps can be procured through service parts under larger components such as power take off part numbers JD 244 1 and JD 244 2 transmission generator air compressor etc are attached to engine the lifting straps 1 If not equipped install lifting straps and torque to 200 provided with engine or through parts channel N m 145 Ib ft are not intended for this purpose Technician is responsible for providing adequate lifting 2 Attach JDG23 Engine Lifting Sling A to engine lifting devices under these situations See machine straps B and overhead hoist manuals for additional information on IMPORTANT Lifting straps are designed to lift the removing engine Aromanachine engine and accessories such as radiator 3 Carefully move engine to desired location air filter and other small components If DPSG CD03523 95 19 22JAN07 1 1 Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your John Deere dealer There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator s ma
187. genset to an external grounding source See operator s manual for instructions as NOTICE VOLTAGE SELECTOR To be operated only by qualified personnel 31811170401 Equipment damage may occur Properly adjust output voltage before connecting load 31811170501 VOLTAGE SELECTOR SWITCH MUST HOT BE TURHED WHILE THE GENSET IS RUNNING 31911170701 WARNING DANGER A poor earth connection can lead to serious injuries or death Always connect the earth terminal of the generating set to an external earth terminal WARNING Voltage selector This function should be used by qualified persons only WARNING Adjust the output voltage correctly before connecting a load WARNING The voltage selector must not be used when the generating set is operating Figure 1 2 continued Pictograms and their meanings 7 260 N 1 3 Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows You should also refer to any local and national regulations that apply in accordance with your own jurisdiction KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries 1 3 1 General advice Use
188. guidelines References NFC 15 100 2002 France IEC 60364 5 54 In order to protect personnel against electric shocks this generating set is equipped with a differential residual current protector factory set to trigger instantly with a sensitivity of 30 mA must only be performed by qualified and authorised personnel Any modification to this setting could endanger personnel Any modification would render the user liable and When the generating set is disconnected from a facility after use the master differential protector must be returned to its factory settings and this must be checked by trained personnel Important For effective protection against electric shocks the generating set needs to be earthed To do this use a copper wire with a minimum cross section of 25 mm for a stripped cable and 16 mm for an insulated cable connected to the generating set earth socket and galvanised steel earthing rod embedded vertically into the ground The earthing rod resistance value should comply with the values shown in the table below Note use the highest differential setting from the installation as a guideline R Ul The resistance value is calculated in the following way Maximum resistance value of the earth socket according to the differential unit operational current operation time should not be longer than 1 second An differential Earth R Q Ul 50V Earth R Q
189. hands Do not open radiator while hot Moving parts can cause serious injury Do not operate with doors open Do not operate with guards removed Stop genset before servicing Avold skin contact with exhaust manifolds turbochargers and mufflers Keep flammable materials clear of the hot parts Do nottouch until the machine has sufficiently cooled Battery gas can explode Keep sparks and flames away from batteries Sulfuric acid in battery electrolyteis poisonous WARNING DANGER Hot coolant can cause serious burns Switch off the engine Do not remove the filler cap until it is completely cold Do not open the radiator when it is hot DANGER Rotating parts can cause serious injury Do not operate the generating set with the doors open Do not remove the enclosures Shut down the generating set before any maintenance or servicing operation DANGER Avoid any contact with the exhaust pipes turbochargers and silencers Keep flammable materials away from hot parts Wait for the machine to cool down completely before touching it WARNING DANGER The gas from the battery electrolyte is explosive Keep the batteries away from any flames The battery electrolyte sulphuric acid is toxic Risk of poisoning Figure 1 2 continued Pictograms and their meanings 6 260 Improper grounding can cause serious injury or death Always complete the grounding path from the ground terminal on this
190. he J1587 standard has an equivalent in the J1939 standard SPN PPID corresponds to PID but is only used by VOLVO FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combination Terminology used by PERKINS CID Component parameter This term used by PERKINS has an equivalent in the J1939 standard SPN FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by JOHN DEERE SPN Suspect Parameter Number This represents the system or component at fault for example SPN 100 indicates an oil pressure problem or a problem with the oil pressure sensor FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault 61 260 Terminology used by Displaying faults The MDEC general system faults are indicated on the equipment in the following way fault code numbers generated by the ECU Engine control unit In the event of a fault the screen will display the following message 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 c
191. he NDE shield see section 4 6 5 1 Remove both ball bearings 60 and 70 using a puller with a central screw 4 6 6 2 Reassembly Heat the new bearings by induction or in a drying oven at 80 C do not use an oil bath and fit them to the machine Checkthat both the preloading wavy washer 79 and the new O ring seal 349 have been fitted on the NDE shield 36 Refit the NDE shield and pass the bundle of wires between the top bars of the shield Refit the DE shield 30 and tighten the 4 fixing screws Check that the machine assembly is correctly mounted and that all screws are tightened LEROY SOMER 13 209 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 4 6 7 Accessing the main field and stator 4 6 7 1 Dismantling Follow the procedure for dismantling the bearings see sections 4 6 5 1 and 4 6 6 1 Remove the coupling disc single bearing alternator or the DE shield two bearing alternator and insert a tube of the corresponding diameter on the shaft end Restthe rotor on one of its poles then slide it out Use the tube as alever arm to assist dismantling After extraction of the rotor be careful notto damage the fan If the fan is dismantled it is essential that it is replaced for the 43 2 NOTE If intervention is required on the main field rewinding replacement of components the rotor as
192. heck the transmission setting after 180 miles 300 km running in period and if necessary adjust the gap J1 using the tensioner Parking Thelever must be fully pulled up so that the compensating spring is fully compressed gt Every 900 miles 1500 km check the braking settings and distribution on all the wheels Important The brake controls are designed to draw trailers behind flexible suspension touring vehicles If used behind an HGV be sure to provide the fitted ball joint with a shock absorber to prevent premature wear gt During any manoeuvres with the trailer coupled do not turn more than 90 or force reverse gt specifications of our brake controls are indicated on a manufacturer s plate and the items on this should be supplied to us when requesting replacement parts in particular for the shock absorber of a special type approved by the Service des Mines to correspond to European standards it is advisable to have a spare shock absorber to enable instant repairs 33 260 N PARKING LEVER 1 NUT 5 COMPENSATING TENSIONER6 CROSS BAR7 BRAKECABLE SPRING 5 7 N tl Mrf u P i gt SLIDE 2 d a LINKAGE CASING STOP J2 SETTING SCREW 8 AUTOMATIC Zt DE BACKWARD JAW 9 SIMPLE JAW A o o RETRACTOR Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 34 260 4 7 Faults an
193. ibration damper assembly is not repairable and should be replaced every 4500 hours or 5 years whichever occurs first RG8018 UN 15JAN99 3 Check vibration damper radial runout by positioning a dial indicator so probe contacts damper outer circumference 4 With engine at operating temperature rotate crankshaft using JDG820 or JDE83 Flywheel Turning Tool 5 Note dial indicator reading If runout exceeds specifications given below replace vibration damper Specification Damper Maximum radial r riout aceto UD es 1 50 mm 0 060 in RG7508 UN 23NOV97 DPSG CD03523 40 19 22JAN07 1 1 072209 40 4 PN 85 157 260 Maintenance 2500 hours 3 years Drain and flush cooling system NOTE Drain and flush cooling system every 2500 hours 3 t years when John Deere COOL GARD coolant is N used Otherwise every 2000 hours 2 years CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 DPSG CD03523 41 19 15JUL09 1 5 1 Slowly open the radiator cap 2 Remove engine block drain plug A RG4894 UN 14DEC88 3 On POWERTech engines remove oil cooler housing drain plug B o o z lt m z 5 N o g ZX0161
194. ic application For plastic insert or crimped steel original Make sure fastener threads are clean and that you type lock nuts for stainless steel fasteners or for nuts on U bolts see the properly start thread engagement When possible lubricate tightening instructions for the specific application Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts wheel bolts under predetermined loads Always replace shear bolts with identical grade or wheel nuts unless different instructions are given for the specific application Grade 2 applies for hex cap screws not hex bolts to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 mm long and for all other types of bolts and screws of any length 4 ubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or 7 8 in and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or 1 4 to 3 4 in fasteners with JDM F13B zinc flake coating DX TORQM 19 24 9 1 1 65 8 188 260 072209 PN 116 Specifications Metric Bolt and Screw Torque Values TS1670 UN 01MAY03 Bolt or Class 4 8 Class 8 8 or 9 8 Class 10 9 Class 12 9 Screw Lubricated Lubricated Dry Lubricated Dry Lubri
195. icals prevent bubble formation Y Never use petrol or other inflammable substances to clean the parts Use only approved cleaning solvents Y Do not use a high pressure cleaner for cleaning the engine and equipment The radiator hoses electrical components etc may be damaged Y A Avoid accidental contact with parts at high temperatures exhaust manifold exhaust Y Before any maintenance operation on a lighting column light cut the electrical power supply and wait for the bulbs to cool down Consumables Y A Observe regulations in force concerning use of fuel before using your generating set pump unit or lighting tower Y Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit Environment Y The operator must take the necessary measures to comply with the aesthetics of the site of use The whole site must be maintained in a good state of cleanliness Y The premises must be kept clean and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust which could ignite or cause an explosion The cleaning equipment must be suited to the risks posed by the products and dust Y The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements 8 260 4544 44 Facilities must be operated under the constant supervision of a qualified person who must regularly check
196. iginal published specifications Continued on next page DPSG CD03523 1 19 O6JUL09 1 2 072209 PN 2 74 260 Introduction List of emission related components Piston Fuel injection pump CALIFORNIA PROPOSITION 65 WARNING Intake manifold Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm DPSG CD03523 1 19 O6JUL09 2 2 Turbocharger Charge air cooling system 072209 PN 3 75 260 Introduction 072209 PN 4 76 260 Contents Page Page Identification Views Mixing of 10 3 if nati j Diesel Engine 10 3 Identification views 01 1 Operating n Wam Temperature Climates 10 4 Maintenance Records o tina the Engi Using maintenance 02 1 perating tne Engine 100 Hours of 02 1 Using Diagnostic Gauge to Access 500 Hours of 02 2 Engine Information Optional equipment 15 1 1000 Hours of 02 2 Main Menu Navigation enne 15 1 1500 Hours of 0
197. ion 3 3 To modify the connection change the position of the terminal cables The winding code is specified on the nameplate N Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped Connections codes L1 U NE 3 phases L L voltage 50 Hz 190 208 Factory connection 60 Hz TI T5 6 T12 I N T10 T4 eim T3 OU p eum T2 T1 AR Winding 190 240 220 230 g 190 208 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 50 Hz 380 415 60 Hz 380 480 Winding N 440 460 gt L3 W 380 416 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 380 V gt T2 50 Hz gt L2 V M L1 U Winding 60 Hz 6 220 240 220 240 250 260 200 220 240 R 250 voltage sensing 0 gt T1 110 V gt T4 R 438 voltage sensing 0 gt T10 220 V gt T1 1 phase r 3 phases L3 W LM voltage 1 2 LL voltage Winding 50 Hz 60 Hz 6 220 240 220 240 7 250 260 200 220 240 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 2
198. ire department near your telephone TS291 UN 23AUG88 DX FIRE2 19 03MAR93 1 1 05 3 100 260 072209 PN 28 Safety Handle Starting Fluid Safely Starting fluid is highly flammable Keep all sparks and flame away when using it Keep starting fluid away from batteries and cables To prevent accidental discharge when storing the pressurized can keep the cap on the container and store in a cool protected location Do not incinerate or puncture a starting fluid container TS1356 UN 18MAR92 DX FIRE3 19 16APR92 1 1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine TS206 UN 23AUG88 DX WEAR 19 10SEP90 1 1 Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises TS207 UN 23AUG88 DX NOISE 19 03MAR93 1 1 05 4 072209 PN 29 101 260 Safety Handle Chemical Produ
199. it Keep all flammable or explosive materials e g petrol oil cloth etc out of the way when the set is running Proper ventilation is required for your generating set pump unit or lighting column to work properly Without this ventilation the engine would very quickly rise to an excessively high temperature causing accidents or damage to the equipment and to surrounding property Do not remove the radiator cap if the engine is hot and the coolant is pressurised due to risks of burns Depressurise the air oil and cooling circuits before removing or disconnecting all the fittings pipes or connected components Watch out for the possible presence of pressure when disconnecting a device from a pressurised system Do not try to find pressure leaks by hand Oil at high pressure can cause bodily damage Some preservative oils are flammable Also some are dangerous to inhale Ensure proper ventilation Use a protective mask Hot oil causes burns Avoid contact with hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine with the oil filler cap off oil may splash out Never coat the generating set pump unit or lighting column with a thin layer of oil to protect it from rust Never top up the oil or coolant if the generating set pump unit or lighting column is running or if the engine is hot A generating set can only operate when stationary and cannot be installed on a vehicle o
200. it the main menu and return to the engine parameter display 98 1000 RPM LOAUQRFM ENG RPM 1800 RPM 57 PSI VOLT OAL PRES RG13159 UN 26SEP03 Exit Main Menu OURGP11 0000237 19 210CT03 6 6 Adjusting Contrast 98 1000 RPM LOAUQRFM ENG RPM 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the 1800 RPM 57 PSI Menu key BAT VOLT IL PRES RG13159 UN 26SEP03 Menu Key OURGP11 00000AF 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Adjust Contrast GO TO 1 UP DISPLAY at STORED CODES is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Select Adjust Contrast RG13161 UN 020CT03 OURGP11 00000AF 19 03SEP03 2 6 3 Once the Adjust Contrast menu item has been highlighted press the Enter key to activate the GNE ma Adjust Contrast function SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST Press Enter Key RG13185 UN 020CT03 Continued on next page OURGP11 00000AF 19 03SEP03 3 6 15 12 K 121 260 Operating the Engine 4 Use the Arrow keys to select the desired contrast intensity ADJUST CONTRAST 71 C i 2 Adjust Contrast Intensity RG13186 UN 29SEP03 OURGP11 00000AF 19 03SEP03 4
201. itation will occur when water is used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible DX COOL6 19 03NOV08 1 1 10 4 109 260 072209 PN 37 Operating the Engine Using Diagnostic Gauge to Access Engine Information Optional equipment RG13132 UN O9SEP03 Diagnostic Gauge A Diagnostic Gauge B Menu Key C Arrow Keys D Enter Key NOTE Generator sets powered by an electronically controlled engine DE10 or HPCR fuel system can be optionally equipped with the diagnostic gauge shown Depending on the generator set manufacturer other instrumentations can be used Refer to the generator set documentation for more information The diagnostic gauge A allows the operator to view many readouts of engine functions and trouble codes DTCs The gauge is linked to the electronic control System and its sensors This allows the operator to monitor engine functions and to troubleshoot the engine systems when needed Press the menu key B to access the various engine functions in sequence The displays can be selected as either customary English or metric units The following menu of engine parameters can be displayed on the diagnostic gauge window Engine hours Engine rpm System voltage Percent engine load at the current rpm E Red STOP ENGINE Indicator Light F A
202. k must be worn prohibited No smoking Caution toxic Eyes and ears must be Entry prohibited to non materials protected authorised persons Caution Periodic maintenance pressurised fluids must be carried out Jet washing prohibited Caution high temperature risk of burns Caution rotating or moving parts risk of getting caught in the machinery Battery level must be checked Earth Lifting point must be Caution corrosive product used Retention tank level high Fork pockets for lifting Important refer to the documentation accompanying the generating set Important emission of toxic exhaust gases Do not use in a confined or badly ventilated area Figure 1 1 Pictograms and their meanings 4 260 Thisis safety alert symbol When you see this symbol on your genset be alert to the potential for persona injury Follow recommanded precautions and safe operating practices Important N WARNING DANGER This symbol warns of a safety hazard The presence of this symbol indicates a risk of injury Observe the safety instructions and precautions for use Important Carefully read the instructions supplied with the generating set before using or servicing the equipment Read the operator s manua supplied with the genset before operation or servicing WARNING DANGER Risk of electrocution ELECTRIC SHOCK HAZARD Do not touch th
203. l drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Air intake system check Number of hours Date Job done by Observation Dealer or distributor stamp DPSG CD03523 73 19 22JAN07 1 1 02 10 91 260 072209 PN 19 Maintenance Records 9500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace o Belt check tension and wear 300 Series and POWERTech with manual tensioner o Valve clearance adjust 300 Series Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 74 19 22JAN07 1 1 10000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter replace a Check belt and tensioning system Crankcase vent tube clean n Air intake system check n Cooling system drain and flush n Valve clearance adjust POWERTech a Thermostat replace n Vibration damper check n Injection nozzles replace Number of hours Observation Date Job done by Dealer or distributor stamp DPSG CD03523 75 19 22JAN07 1 1 02 11 92 260 072209 PN 20 Serial Numbers PowerTech label A label is located on the rocker arm cover which identifies each engine as a John Deere PowerTech engine
204. l de62 772000 http www leroy somer com 216 260 LEROY SOMER 4067 en 2009 05 b CE oV EE E U pe iven to F1 Slow fuse 10 250V8A ual cer This manne end U P1 Voltage 8 ey ST4 Option External potentiometrer for voltage adjusting poe eec R250 AVR Installation and maintenance 217 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 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 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 recommendations or symbols to alert the user to potential risks of accidents It is vital that you understand and take notice of the following warning symbols WARNING Warning symbol for an operation capable of damaging or destroying the machine or surrounding e
205. l for HPCR EN ME 1 6a Technical Manual for OEM Fuel System on 4045 and 6068 with 4 Valve Head Engine accessories English only Engines English CTM77 Component Technical Manual for Alternators CTM331 Component Technical Manual for DE10 and Starter Motors English only Fuel Systems on 4045 and 6068 engines English RG4624 UN 15DEC88 DPSG CD03523 42 19 31JAN07 1 1 Do not modify fuel system IMPORTANT Modification or alteration of the injection pump the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser Do not attempt to service injection pump or fuel injectors yourself Special training and special tools are required See your authorized servicing dealer or engine distributor CD30768 UN 24SEP99 DPSG CD03523 43 19 22JAN07 1 1 072209 50 1 PN 88 160 260 Maintenance As required Welding Near Electronic Control Units IMPORTANT Do not jump start engines with arc welding equipment Currents and voltages are too high and may cause permanent damage 1 Disconnect the negative battery cable 2 Disconnect the positive battery cable 3 Short the positive and negative terminals together Do not attach to vehicle frame 4 Clear or move any wiring harness sections away from welding area 5 Connect welder ground close to welding point and away from control
206. lose as possible to the alternator In this case disconnect the blue wire of the R 791 interference suppression module linking the neutral Any protective devices in place have not tripped f there is an external AVR the connections between the alternator and the cubicle are made in accordance with the connection diagram There is no short circuit between phase or phase neutral between the alternator output terminals and the generator set control cabinet part of the circuit not protected by circuit breakers or cubicle relays The alternator has been connected with the busbar separating the terminals as shown in the terminal connection diagram XU anim The equipotential earth links have been implemented correctly cross section and continuity of the earths 3 4 Commissioning The alternator can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The alternator is tested and set in the factory When first used with no load make sure that the drive speed is correct and stable see the genset nameplate On application of the load the alternator should achieve its rated speed and voltage however in the event of abnormal operation the alternator setting can be altered follow the adjustment procedure see section 3 5 If the operation is still incorrect the cause of the malfunction must be located see section 4 4 amp 4 5 3 5 S
207. lt in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables remove the cable from the negative terminal first When reconnecting the battery connect the positive lead first Charge the battery in a well ventilated place with all the filler caps opened Ensure that the battery terminals are correctly tightened A loose cable clamp can cause sparks that could result in an explosion Before servicing electrical components or performing electric welding set the battery switch to the OFF position or disconnect the battery negative cable to cut off the electrical current Electrolyte contains dilute sulphuric acid Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns Wear safety goggles and rubber gloves when working with the battery topping up fluid charging etc If electrolyte comes into contact with your skin or clothes wash it off immediately with plenty of water then carefully wash the area with soap Danger If electrolyte comes into contact with your eyes rinse immediately with plenty of water and seek medical attention as soon as possible If electrolyte is accidentally swallowed gargle with plenty of water and drink large quantities of water Consult a doctor immediately Large quantities of electrolyte should be rinsed off using a neutralising agent A common method is to use a solution of 500g of
208. lter The compressor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage Y Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube causing bodily injury Y Do not touch the lighting column lights when they are switched on Maintenance Y Follow the maintenance table and its instructions Y Always use tools in good condition which are suited to the work to be done Ensure you have understood the instructions before beginning any operation Y Goggles should be worn when carrying out maintenance operations and watches bracelets etc should be removed Y only original parts Y Disconnect the battery and the pneumatic starter if fitted before undertaking any repairs to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt to start Y Only use the correct crankshaft turning techniques for turning the crankshaft manually Do not try to turn the crankshaft by pulling it or levering the fan This method may cause serious bodily or material damage or damage the vanes of the fan reducing the service life of the fan Y Clean off any trace of oil fuel or coolant using a clean cloth Y Do not use a soapy solution containing either chlorine or ammonia as these two chem
209. lters An indicator light on the instrument panel will signal the operator that water should be drained from filter bowls Check fuel filters C and D for water and debris as follows a Loosen drain plug s A at bottom of fuel filter s or bowl s two or three turns b Loosen air bleed plug s B two full turns and drain water into a suitable container c When fuel starts to drain out tighten drain plug s securely d Bleed fuel system 229 e gt JOHN DEP __ PE CD30929 UN 07FEB07 CD30929 Drain fuel filter s C Primary fuel filter D Final fuel filter A Drain plug B Air bleed plug DPSG CD03523 27 19 07FEBO07 4 4 25 3 072209 PN 70 142 260 Maintenance 500 hours Changing engine oil and filter IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications NOTE Change engine oil and filter for the first time after 100 hours maximum of operation 2 then every 500 hours thereafter Change oil z and filter at leat once a year l 2 1 Run engine approximately 5 minutes to warm up oil il Shut engine off E 2 Open oil pan drain valve A 3 Drain crankcase oil from engine while warm Continued on next page DPSG CD03523 29 19 01JUL09 1 3 30 1 PN 71 143 260 Maintenance 500 hours
210. m Associated pictogram fo Low fuel level alarm Indicates the need to fill up with fuel Associated pictogram re AUi et Alternator charging fault alarm indicates a problem affecting the alternator charging rate 45 260 6 3 Generator set with TELYS control panel 6 3 1 Control panel presentation 6 3 1 1 View of the front panel Diagram 6 4 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 4 MENU button for accessing the menus Lighting for the emergency stop button 46 260 Diagram 6 5 Description of the LEDs A lit LED indicates 1 Alarm activated flashing yellow 2 Fault found flashing red 3 Module on green on continuously Diagram 6
211. maged or incorrectly fitted Replace the damaged parts Refit the cables Poor load distribution Check the load distribution When starting the trailer holds back the towing vehicle Damage to slide or to guide rings Replace the faulty parts and grease Slide corrosion Remove the corrosion and grease Tie rod damaged Replace the tie rod and adjust the settings Linkage damaged or incorrectly set Replace the damaged parts and adjust the settings Brake on Loosen the brake Play in the coupling head Head worn see wear indicator Replace the head Ball joint worn Replace the ball joint Parking braking too weak Compensating spring incorrectly set Adjust the setting Braking system incorrectly set Adjust the setting Notched sector damaged Replace the sector and adjust the setting Lever ratchet worn Replace the lever and adjust the setting Cable ruptured Replace the cable and adjust the setting 35 260 4 8 Electrical connection diagram 2 white side lights on flexible support depending on model N 2 two coloured side marker lights depending on model 2 x 6 function rear lights depending on model 7 metal pin male plu He N 2 x 2 conductor cables 2 plate lights Metal socket F3 connector 7 7 conductor cable 2 x 2 conductor c
212. mber WARNING Indicator Light Coolant temperature Oil pressure Throttle position ntake manifold temperature Current fuel consumption Active service diagnostic codes Stored service diagnostic codes from the engine Set the units for display View the engine configuration parameters NOTE Engine parameters which can be accessed will vary with the engine application Six languages for readouts are available and can be selected during setup of gauge The diagnostic gauge includes a graphical backlit Liquid Crystal Display LCD screen The display can show either a single parameter or a quadrant display showing four parameters simultaneously The diagnostic gauge uses two arrow keys C for scrolling through the engine parameter list and viewing the menu list and an enter key D for selecting highlighted items The red E and amber F lights are used to signal active trouble code received by the diagnostic gauge CD03523 000018B 19 22JANO7 1 1 Main Menu Navigation NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine is running 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key 98 LOADIRPM 1000 RPM ENG RPM 1800 RPM 57 PSI BAT VOLT OI
213. mbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics ofits products at any time in orderto incorporate the latest technological developments The information contained in this document may therefore be changed without notice LSA 43 2 44 2 4 POLE ALTERNATORS WARNING SYMBOLS We would like to draw your attention to the following two safety measures that must be complied with a During operation do notallow 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 A set 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 alternator 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 plus any other directives that may be applicable Copyright 2004 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 HROT 198 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010
214. meter 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 22 260 N 2 3 Fuel and consumables All specifications product features are given in the motor and alternator maintenance manuals attached to this manual In addition we recommend the consumables to be used in the specifications section 2 3 1 Specifications 2 3 1 1 Oil grades Engine Oil Make Type Make Type Johni Deere All John Deere John Deere PLUS 50 GenPARTS GENLUB TDX 15W40 MITSUBISHI All GenPARTS GENLUB TDX 15W40 Volvo All GenPARTS GENLUB TDX 15W40 GENLUB TDX 15W 40 Top of the range lubricant recommended for diesel engines for generating sets used under severe conditions USES Y Particularly suited to more modern engines with or without turbochargers intercoolers or sophisticated injection systems e g HEUI injector pumps Y All types of use can cope with the most demanding applications Y Depolluted engines complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel especially ecological diesel with low sulphur content PERFORMANCE ACEA API CH 4 v Meets level of the specifications defined by European manufacturers in the ACEA standards 98 edition ADVANTA
215. mperature units according to settings menu zn Pictograms Data displayed H t 7 Fuel Level Indicator P3 M n e y Alternator composite Voltage Indicator Default screen in Lf operation k Total Active Power Indicator 5 Alternator Frequency Indicator n 012 Alternator composite Voltage Indicator be d 0 3 y U23 Alternator composite Voltage Indicator P4 a 1 4 t 3 U31 Alternator composite Voltage Indicator a Hz Alternator Frequency Indicator 51 260 Pictograms Data displayed C E E V1 Alternator single Voltage Indicator 2 e 3 3 y V2 Alternator single Voltage Indicator P5 J p 3 3 V3 Alternator single Voltage Indicator 5 Ge Hz Alternator Frequency Indicator c J U12 Alternator composite Voltage Indicator i c V2 Alternator single Voltage Indicator P6 E i c V1 Alternator single Voltage Indicator o fe Alternator Frequency Indicator c J t V1 Alternator single Voltage Indicator P7 A Single phase Alternator current indicator S 00 Alternator Frequency Indicator Single phase Alternator current indicator 2 Al Two phase Alternator current indicator P8 1 n Three phase Alternator current indicator H n Neutral Alternator current indicator k Lf Total Active Power Indicator ke ow Total Reactive Power Indicator P9 k 1 Total Effective Power Indicator 092 Total Power Factor Indicator lagging or leading 90 7 Fuel
216. mproper type of fuel Water dirt or air in fuel system Clogged fuel filter Dirty or faulty injection nozzles Injection pump shut off not reset Low engine oil level Injection pump out of time Low coolant temperature Engine overheating Continued on next page Solution Verify correct starting procedure Check fuel in tank and manual shut off valve Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement Remove load Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors Turn key switch to OFF then to ON Add oil to engine crankcase See your authorized servicing dealer or engine distributor Remove and check thermostat See Engine Overheats DPSG CD03523 49 19 22JAN07 1 4 55 4 170 260 072209 PN 98 Troubleshooting Symptom Engine runs irregularly or stalls frequently Below normal engine temperature Lack of power Low oil pressure Problem Low coolant temperature Clogged fuel filter
217. n is a list of possible engine problems Determine cause and make a thorough repair and diagnostic trouble codes that may be encountered After making repairs operate the engine under normal accompanied by possible causes and corrections This conditions to verify that the problem and cause was troubleshooting information is of a general nature corrected See also the generator documentation for a complete information of your application A reliable program for troubleshooting engine problems should include the following basic diagnostic thought process CD03523 000018D 19 08FEBO7 1 1 072209 55 1 PN 95 167 260 Troubleshooting Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection Pump A Coolant Temperature Sensor G Starter Relay Connector Connector H Oil Pressure Sensor B Fuel Temperature Sensor Connector Connector I Main System Fuse 10 amp C Injection Pump Solenoid J Power and Ground Battery Connector Connections D SAE 1939 CAN Connector K Fuse Holder E Crankshaft Position Sensor L Transient Voltage Protection Connector TVP Module Connector F ECU Connector M Remote ON OFF Connector N CAN Network Diagnostic Connector O Instrument Panel Connector Harness P 23 pin Optional Feature Connector Extended feature ECU only Q 21 pin Instrument Panel Connector R Engine Wiring Harness S Fuel Heater Connector T Manifold Air
218. n label Special Equipment Field Installed Shipping DPSG CD03523 14 19 22JAN07 2 2 Record fuel injection pump model number Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No CD30749 UN 24SEP99 DPSG CD03523 15 19 22JAN07 1 1 03 4 96 260 072209 PN 24 Serial Numbers Record Engine Control Unit ECU Serial Number Record the part number and serial number information found on the serial number label A on the Engine Control Unit ECU mounted on or near the engine Part No Serial No RG14635 UN 13APRO06 A Serial Number Label Record Engine Control Unit ECU Serial Number CD03523 0000189 19 06FEBO7 1 1 Record High Pressure Fuel Pump Model Number Record the high pressure fuel pump model and serial number information found on the serial number plate A Model No RPM Manufacturer s No Serial No RG13718 UN 11NOV04 A Serial Number Plate Record High Pressure Fuel Pump Serial Number CD03523 000018A 19 O6FEBO7 1 1 072209 03 5 PN 25 97 260 Safety Recognize Safety Information This is a safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices T81389 U
219. nd accurately we suggest you fill in its specifications on the non contractual nameplate below 1 4 Storage Prior to commissioning machines should not be stored in humid conditions at relative humidity levels greater than 9096 the machine insulation can drop very rapidly to just above zero at around 10096 The state of the anti rust protection on unpainted parts should be monitored For storage over an extended period the alternator can be placed in a sealed enclosure heatshrunk plastic for example with dehydrating sachets inside away from significant and frequent variations in temperature to avoid the risk of condensation during storage If the area is affected by vibration try to reduce the effect of these vibrations by placing the generator on a damper support rubber disc or similar and turn the rotor a fraction of a turn once a fortnight to avoid marking the bearing rings 1 5 Applications These alternators are designed mainly to produce electricity in the context of applications involving the use of generators 1 6 Contra indications to use Use of the alternator is restricted to operating conditions environment speed voltage power etc compatible with the characteristics indicated on your genset SOMER LSA Date N Hz Min 1 R P M Protection Cos P F Cl ther Th class R gulateur A
220. nerating set carry out the mechanical checks oil pressure water temperature absence of noise etc carry out the electrical checks voltage and frequency carry out the safety checks emergency stop oil pressure water temperature etc 6 Using the generator set 6 1 Pre Start Inspection Inspecting the engine compartment Inspect the engine carefully Wipe all the grease fittings and caps before carrying out any maintenance in order to reduce the risk of contaminating the circuits 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 Important Check the oil level using the dipstick A e Top up the oil as required Use an oil whose viscosity is suited to the seasonal conditions Pour the oil through the rocker cover filling port B 37 260 N Checking the coolant level A Warning Fluid may abruptly exit the cooling circuit and cause serious burns Only remove the filler cap once the engine and cap have cooled sufficiently to enable them to be handled with bare hands Firstly loosen the cap slightly by one notch to eliminate any pressure then remove it Remove the cap from the radiator E and check the coolant level The level should reach the lower section of the filler neck Fill the radiator with
221. nge but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region h of the signal range definition Broadcast of data values is continued as normal FMI 18 DATA VALID BUT BELOW NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region j of the signal range definition Broadcast of data values is continued as normal FMl 19 RECEIVED NETWORK DATA IN ERROR Any failure that is detected when the data received via the network is found substituted with the error indicator value i e FE16 see J1939 71 This type of failure is associated with received network data The component used to measure the real world signal is wired directly to the module sourcing the data to the network and not to the module receiving the data via the network The FMI is applicable to Region f and g of the signal range definition This type of fault may or may not be directly associated with the value of general broadcast information FMI 20 30 RESERVED FOR SAE ASSIGNMENT FMI 31 ConbDITION EXISTS Used to indicate that the condition that is identified by the SPN exist
222. ngs be stored for 2 years in its original container and packaging e Avoid zinc coated containers RECOMMENDATIONS FOR USE Compatible with the original fluid e It is recommended that the cooling system is completely drained when replacing the fluid SPECIFICATIONS UNITS SPECIFIED VALUES TRIAL METHODS D m Density at 20 C kg m3 1 059 3 R 15 602 1 pu tos werze o Glassware corrosion test with antifreeze mg test piece R 15 602 7 Copper Weld Brass Steel Cast iron Cast aluminium Corrosion on warm plate test with antifreeze mg cm week 0 17 R 15 602 8 25 260 3 Installation 3 1 Unloading 3 1 1 Safety during unloading To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions you need to ensure that the following points are observed Lifting machinery or equipment appropriate to the work required Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members Ground able to take the load of the set and the lifting machinery without stress otherwise lay down beams of sufficient strength and stability Set put down as close as possible to its point of use or transportation in a clear area with free access Example of equipment to be used Y crane slings cross bar safety catch shackles Y Fork lift truck 3 1 2 Instructions for unlo
223. ning soap or detergent in the case of greasy dust Petrol or chloroethylene can also be used After cleaning the alternator itis essential to checkthe 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 To do this check that the protective devices are fitted correctly the connections comply with the diagrams in the manuals supplied with the machine the speed of the unit is correct see section 1 3 Repeat the operations defined in section 3 10 LEROY SOMER 206 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 4 Mechanical defects Fault Action Excessive overheating of one or both If the bearing has turned blue or if the grease has turned black change the Bearing bearings temperature gt 80 C on the bearing bearing retainers with or without abnormal Bearing not properly seated noise End shields misaligned flanges not properly fitted Air flow intake outlet partially clogged or hot air is being recycled from Excessive overheating of alternator frame the alternator or engine Temperature more than 40 C above the ambient Alternator operating at too high a voltage gt 105 of Un on load abnormal temperature Alternator overloaded Misalignment coupling Excessive
224. ntainers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain DX LUBST 19 18MAR96 1 1 Mixing of Lubricants In general avoid mixing different brands or types of oil Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance Consult your John Deere dealer to obtain specific information and recommendations DX LUBMIX 19 18MAR96 1 1 Diesel Engine Coolant The engine cooling system is filled to provide year round protection against corrosion and cylinder liner pitting and winter freeze protection to 37 C 34 F John Deere COOL GARD is preferred for service If John Deere COOL GARD is not available use a low silicate ethylene glycol or propylene glycol base coolant concentrate in a 5096 mixture of concentrate with quality water The coolant concentrate shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system John Deere COOL GARD meets this requirement Freeze protection A 5096 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F A 5096 mixture of propylene glycol engine coolant in water provides freeze protection to 33 C 27 F If protection at lo
225. nual TS201 UN 23AUG88 Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need assistance contact your John Deere dealer DX READ 19 16JUNO09 1 1 0 5 2 072209 PN 27 99 260 Safety Prevent Machine Runaway Avoid possible injury or death from machinery runaway Do not start engine by shorting across starter terminals Machine will start in gear if normal circuitry is bypassed NEVER start engine while standing on ground Start engine only from operator s seat with transmission in neutral or park TS177 UN 11JAN89 DX BYPAS1 19 29SEP98 1 1 Handle Fuel Safely Avoid Fires Handle fuel with care itis highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean up spilled fuel TS202 UN 23AUG88 DX FIRE1 19 03MAR93 1 1 Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and f
226. o B Short circuit high or low side to ground Cylinder 2 circuit open Cylinder 2 circuit shorted Cylinder 2 balancing error mechanical failure Cylinder 2 unknown error mechanical failure 252 260 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Commentary 653 653 Cylinder 3 status injector Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground ODO Oo RR N 654 654 Cylinder 3 circuit open Cylinder 3 circuit shorted Cylinder 3 balancing error mechanical failure Cylinder 3 unknown error mechanical failure Cylinder 4 status injector Short circuit high side to B Short circuit high side to low side or low side to B 655 655 Short circuit high or low side to ground Cylinder 4 circuit open Cylinder 4 circuit shorted Cylinder 4 balancing error mechanical failure Cylinder 4 unknown error mechanical failure Cylinder 5 status injector Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground Cylinder 5 circuit open Cylinder 5 circuit shorted 656 656 Cylinder
227. of Change Abnormal 13 Low Pressure Fuel Out of Calibration 17 High Pressure Fuel System Pressure Slightly Low 000097 00 Water in Fuel Continuously Detected 03 Water in Fuel Signal Out of Range High 04 Water in Fuel Signal Out of Range Low 16 Water in Fuel Detected 000100 01 Engine Oil Pressure Signal Extremely Low 03 Engine Oil Pressure Signal Out of Range High 04 Engine Oil Pressure Signal Out of Range Low 18 Engine Oil Pressure Signal Moderately Low 000105 00 Intake Manifold Air Temperature Signal Extremely High 03 Intake Manifold Air Temperature Signal Out of Range High 04 Intake Manifold Air Temperature Signal Out of Range Low 16 Intake Manifold Air Temperature Signal Moderately High 000107 00 Air Filter Pressure Differential Extremely High 000110 00 Engine Coolant Temperature Signal Extremely High 03 Engine Coolant Temperature Signal Out of Range High 04 Engine Coolant Temperature Signal Out of Range Low 15 Engine Coolant Temperature Signal Slightly High 16 Engine Coolant Temperature Signal Moderately High 000111 01 Engine Coolant Level Low 000158 17 ECU Power Down Error Internal ECU Problem 000160 02 Axle Speed Signal Unreliable 000174 00 Fuel Temperature Signal Extremely High 000174 03 Fuel Temperature Signal Out of Range High 04 Fuel Temperature Signal Out of Range Low 16 Fuel Temperature Signal Moderately High 000189 00 Engine Speed Derate Condition Exists 000190 00 Engine Speed Extremely High 16 Engine Speed Moderately High
228. of the LAM with a diesel engine with or without a LAM U F only 7 2 9 RAJS AV R OpION cM 7 3 INSTALLATION 5 8 3 1 Electrical checks on the AVR ecrire eee te knit a eroe Lee n Lund 8 92 5 OEMS 8 3 9 Blectrical faults ooo reete he RD abe eden 11 4 SPARE PARTS ce N K 12 D MIEMBRO 12 4 2 Technical support service esie eene rte eo iei ep eei ere ned nk ender 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 unit s 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 3 231 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 1 SUPPLY to that of the alternator characteristic 1 1 AREP excitation system For both
229. om Setup and Automatic Scan functions have been set press the USE DEFAULTS Menu key to return to the main menu CUSTOM SETUP AUTOMATIC SCAN ON RG13224 UN 26SEP03 OURGP11 00000B1 19 03SEP03 17 18 19 Press the Menu key to exit the main menu and return gt to the engine parameter display 8 1000 RPM 1800 RPM 57 PSI BAT VOLT OAL PRES RG13159 UN 26SEP03 Exit Main Menu OURGP11 00000B1 19 03SEP03 18 18 Setup 4 Up Display 98 1000 RPM 1 Turn the key switch to the ON position From the dnd VD single or four engine parameter display press the 1800 RPM 57 PSI Menu key VOLT IL PRES RG13159 UN 26SEP03 Menu Key OURGP11 00000B2 19 03SEP03 1 14 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Setup 4 Up Display is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS S ADJUST BACKLIGHT 9 i 2 Select Setup 4 Up Display Continued on next page OURGP11 00000B2 19 03SEP03 2 14 15 21 PN 58 130 260 Operating the Engine 3 Once the Setup 4 Up Display menu item has been highlighted press the Enter key to activate the STORED Setup 4 Up Display menu ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT o Press Enter K
230. om high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A X9811 UN 23AUG88 DX FLUID 19 03MAR93 1 1 Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can accidentally burst when heat goes beyond the immediate flame area TS953 UN 15MAY90 DX TORCH 19 10DEC04 1 1 Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Remove paint before heating Remove paint a minimum of 100 mm 4 in from area to be affected by heating If paint cannot be removed wear an approved respirator before heating or welding f you sand or grind paint avoid breathing the dust Wear an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and
231. once briefly the green START button Y fthe motor is equipped with an air preheating system there is a 10 second delay before the motor starts preheating activation period following screen appears ooga 7 ac The third line displays the air preheating time in remaining with pictograms representing a YU iu resistor an hourglass v fthe 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 following screen appears A The number of successive and automatic starting attempts is limited to 3 Warning 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 42 260 EN 6 2 3 Switching off Trigger the circuit breaker located at the base of the centre console Let the motor run under no load for 1 to 2 minutes to allow it to cool Press the STOP button to stop the generating set switch off the MICS Nexys module by switching the key to OFF without forcing it 6 2 4 Alarms and faults am am UN ems The appearance of a fault an alarm causes the following
232. onnector 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 60 260 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 except for MTU engines that have a specific transmission protocol see appendix if applicable Terminology used by the SAE CAN J1939 standard SPN Suspect Parameter Number This represents the system or component at fault for example SPN 100 indicates an oil pressure problem or a problem with the oil pressure sensor FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by VOLVO SID System Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to an assembly of components for example the injection system PID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to a specific component for example a sensor PPID Parameter Identifier This term used in t
233. onse 1 normal ST2 time fast ST1 r1 Option P2 Single Voltage R731 3 ph detection 4 P3 Stability phase e d t d detection A in 3 ph detection ST1 open LEROY 1 SOMER 232 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 1 2 PMG excitation system This excitation system consists of a PMG permanent magnet generator This is fitted atthe rear of the machine and connected to the R438 AVR The PMG supplies the AVR with constant voltage which is independent of the main MAIN FIELD PMG SYSTEM e e e alternator winding As a result the machine has a short circuit current capacity and good immunity to distortions generated by the load The AVR monitors and corrects the alterna tor output voltage by adjusting the excitation current 50 60 Hz selection via the ST3 jumper STATOR 6 wires marked T1 to T6 STATOR 12 wires marked T1 to T12 gt e Armature z T4 1 5 11 Te T12 lel 14 15 16 ST5 ST3 Hu n Frequency Ja Hos ST10 a LAM 13 25 Excitation K P5 ceiling ST1 1 1 knee point 65 Hz F1 Slow fuse ma REPRE E 250V8A e
234. operation of the measuring device or its connection to the module Broadcast of data values is substituted with the error indicator value Incorrect data includes any data not received and any data that is exclusive of the situations covered by FMls 3 4 5 and 6 Data may also be considered incorrect if it is inconsistent with other information collected or known about the system FMI 3 VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE a A voltage signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data values is substituted with the error indicator value b Any signal external to an electronic control module whose voltage remains at a high level when the ECM commands it to low Broadcast of data value is substituted with the error indicator value FMI 4 VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE c A voltage signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data values is substituted with the error indicator value d Any signal external to an electronic control module whose voltage remains at a low level when the ECM commands it to high Broadcast of data value is substituted with the error indicator value FMI 5 CuRRENT BELOW NORMAL OR OPEN CIRCUIT e A current signal data or otherwise is below the predefined limits that bound the range
235. or duty cycle is not consistent with the signal which is emitted Broadcast of data value is substituted with the error indicator value FMI 9 ABNORMAL UPDATE RATE Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not at the update rate expected or required by the ECM outside Region c of the signal range definition Also any error that causes the ECM not to send information at the rate required by the system This type of fault may or may not be directly associated with the value of general broadcast information 257 260 EN FMI 10 ABNORMAL RATE OF CHANGE Any data exclusive of the abnormalities covered by FMI 2 that is considered valid but whose data is changing at a rate that is outside the predefined limits that bound the rate of change for a properly functioning system outside Hegion c of the signal range definition Broadcast of data values is continued as normal 11 CAUSE NoT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known Broadcast of data value is substituted with the error indicator value FMIz12 BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU used here to mean the packaged unit that includes some microprocessor and its associated components and circ
236. or spare part requests contact your nearest SDMO agent 246 260 N 9 4 Appendix D List of John Deere Volvo and Perkins fault codes 5 8 SPN SID PID PPID 2 X Description Commentary c gt 9 28 Throttle 3 Position 3 Throttle Voltage high short to V Short to V 4 Throttle Voltage low short to V Short to V 29 Throttle 2 Position 3 Throttle Voltage high short to V Short to V 4 Throttle Voltage low short to V Short to V 14 Throttle Voltage out of range 84 Vehicle speed 2 Vehicle invalid or missing Not possible with genset 31 Vehicle speed mismatch application 91 91 91 132 Accelerator pedal position pour 3 Throttle Voltage high short to V 4 Throttle Voltage low short to V 7 Throttle calibration invalid Not possible with genset 8 a PWM throttle abnormal pulse width application codes declared 9 Throttle invalid CAN value by the CAN 1587 for 10 Throttle voltage out of range low 13 Throttle calibration aborted 14 Throttle voltage out of range 94 94 Fuel rail pressure sensor 1 Fuel supply pressure extremely low 3 Fuel rail pressure input voltage high Short
237. orque and check that there is lateral play on the crankshaft 3 1 2 2 Two bearing alternator Semi flexible coupling Careful alignment of the alternator and the heat engine is recommended checking that the differences in concentricity and parallelism of the two parts of the coupling do not exceed 0 1mm CAUTION This alternator has been balanced with a half key 3 1 3 Location Ensure that the ambient temperature in the room where the alternator is placed cannot exceed 40 C for standard power ratings for temperatures gt 40 C apply a derating coefficient Fresh air free from damp and dust must be able to circulate freely around the air intake grilles on the opposite side from the coupling 3 2 Inspection prior to first use 3 2 1 Electrical checks 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 three possible methods for restoring the above minimum values a Dry out the machine for 24 hours in a drying oven at a temperature of approximately 110 C without the AVR b Blow hot air into the air inlet having made sure that the machine is rotating with the exciter field disconnected c Run in short circuit mode disconnect the AVR Short circuit the three output terminals power using connections capable of supporting the rated current try not to exceed 6 A mm
238. ort circuit current of 3 IN so as to offer selective protection 3 2 3 Special type of use 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 WA Diode ip ciliis x Battery B Exciter field Forced excitation B Volt Time Applications Guaranteed voltage build up Parallel operation de energized Parallel operation at standstill Frequency starting Sustained voltage on overload S SORER 11 239 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 3 3 Electrical faults Effect Check Cause Connect a new battery No voltage at of 4 to 12 volts to terminals E and E respecting the polarity for 2 to 3 seconds The alternator builds up and its voltage is still correct when the ba
239. ove normal Combining SPN 000110 with FMI 03 yields engine coolant temperature input voltage too high or the equivalent of 2 digit fault code 18 If diagnosing an application that shows DTCs as SPNs and FMls using the following list determine the equivalent 2 digit code and have your dealer use the diagnostic procedure in the component technical manual for that 2 digit code Always contact your servicing dealer for help in correcting diagnostic trouble codes which are displayed for your engine CD03523 0000190 19 02FEBO7 1 1 Using blink code method for retrieving Diagnostic Trouble Codes DTC s NOTE The method below applies to applications having a fault lamp on instrument panel refer to the generator documentation for more information The Electronic Control Unit ECU has the ability to display DTCs using blinking sequence of the fault lamp NOTE The ECU blinks the codes in 2 digit codes only See LISTING OF DIAGNOSTIC TROUBLE CODES DTCS later in this Group 1 Press down Override Shutdown Switch while turning the ignition switch ON 2 The Fault Lamp will begin to flash a code number For example flash three times short pause flash two times long pause This example is code 32 3 The ECU begins the flashing sequence by flashing a code 32 this indicates the start of blinking active codes If there are any active DTCs the ECU will flash its 2 digit number If there is more than one active DTC
240. ply FMI not VOLVO informed by Sensor power supply open short to B 626 45 Sensor power supply short to ground Start enable device intake heater and ether Start enable device output short to B Start enable device output short to ground Start enable device output open circuit Not use the control panel is in charge to manage the start enable device 627 Power supply Injector supply voltage problem For 6125HF070 only 628 240 ECU unswitched power missing For 6068HF275 VP44 only Memory fault in EMS2 629 254 ECU status controller error CIU module status RAM cell test failure CPU watchdog reset test failure 630 253 Main and fuelling ASIC test fail RAM address test failure Watchdog trip failure ECU to injection pump communication error Possible only with 6068HF475 VP44 Data set memory EEPROM 632 Injection status Fuel shutoff error Fuel shutoff non functional 251 260 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Commentary 636 21 Pump position sensor Cam position sensor Speed sensor CAM Pump position sensor cam position sensor input noise Pump position or CAM position in function of the type of injec
241. proximately 20 hours of operation check that all fixing screws on the alternator are still tight plus the general state of the alternator and the various electrical connections in the installation 4 2 2 Cooling circuit It is advisable to check that circulation of air is not reduced by partial blocking of the air intake and outlet grilles mud fibre grease etc and to check whether the ventilation guards are corroded or scratched 4 2 3 Bearings The bearings are permanently greased approximate life ofthe grease 20 000 hours or 3 years As an option they are regreasable for the LSA 44 2 It is advisable to lubricate the alternator during operation Time intervals and quantity of grease are given in the table below NDE DE bearing 6315 C3 6309 C3 Quantity of grease 30g 15g Regreasing interval 6000 hrs 10 000 hrs Lubrication intervals are given for grease type LITHIUM standard NLGI 3 In the factory the grease used for lubrication is ESSO UNIREX N3 Before using another grease check for compatibility with the original one Monitor the temperature rise in the bearings which must not exceed 50 C above the ambient temperature Should this value be exceeded the alternator must be stopped and checks carried out 4 2 4 Electrical servicing Cleaning product for the windings CAUTION Do use trichlorethylene perchlorethylene trichloroethane or any alkaline products Cert
242. ps between 46 Hz and 50 Hz the rated voltage follows a fast gradient as it is restored 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 lt 46 Hz Drop N gt 46 Hz Time LEROY SOMER 222 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 2 5 Typical effects of the LAM with a diesel engine or without a LAM U F only 2 5 1 Voltage UN d 4 T without eee LAM 08 i 4 Time Load on shaft kW i LEROY SOMER 223 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 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 that the position of the jumper corresponds to the operating frequency Check whether the ST4 jumper or the remote adjustment potentiometer have been connected 3 2 Settings The different settings made during the trialaretobedoneby qualified personnel Respecting the load speed specified on the nameplate is vital in order to start a settings procedure After operational testing replace all access panels or covers The only possible settings on the machine are to be done with the A
243. quipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The information contained in this document may therefore be changed without notice LEROY SOMER 218 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R SUMMARY DS SUPPLY dE 4 1 1 SHUNT excitation system aa a E a a a nennen nnne nennen ener rentrer 4 2 RO50 MADE 5 2 4 Characteristics s cR E tec de in d Si tea 5 2 2 U F fonction and LAM ccccccccccccessessseeeeeeeecececaeessssseececceeceeceuauesseeceeeeseeessaaaeaaeeeeeess 5 2 9 R250 AVIRODIIOR cid aree eie reo rete eset delice ees 5 2 4 vade ea TUE eee 6 2 5 Typical effects of the LAM esiosan ct tere rer e tiia trie efi echa en e en 7 INSTALLATION 8 3 1 Electrical checks on the AVR ainoana a e a nnn nnne nnns 8 9 2 SCUINGS st 8 R e a E aN te cbe Aen 8 3 3 9 A SPARE PARTS wevivsctsscccwcssecdecesccccuvacvunacsduuatnccucatsstecosssceacscevaicddchtinactsstaddvensnucuzdacuendensinseaics 10 41 5 Designation ineft DURO Hee ER
244. r Change engine oil and filter Replace fuel filter element s Check belt tension and automatic tensioner Check and adjust valve clearance Clean crankcase vent tube Check air intake hoses connections and system Pressure test cooling system Check vibration damper 6 cyl Check engine speed and speed drop governor Drain and flush cooling systemf Drain water and sediment from fuel filter Clean filter element see note a Test thermostat and injection nozzles see your dealer Test glow plugs HPCR 4 valve head Clean air filter element when restriction indicator is red Replace filter element after 6 cleanings or once a year PChange oil and filter after the first 100 hours of operation then every 500 hours maximum thereafter see DIESEL ENGINE OIL information Change oil and filter at least once a year Check belt tension every 500 hours on 3029 and 4039 engines and on 4045 and 6068 engines with manual tensioner Check automatic belt tensioner every 1000 hours 1 year on 4045 and 6068 engines when equipped Have your authorized servicing dealer or engine distributor adjust valve clearance as follows After the first 500 hours of operation then every 1000 hours thereafter on 3029 and 4039 engines Every 2000 hours on 4045 and 6068 engines Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours 5 years Drain
245. r driven parts Disengage all power and operate controls to relieve pressure Lower equipment to the ground Stop the engine Remove the key Allow machine to cool Securely support any machine elements that must be raised for service work Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine TS218 UN 23AUG88 DX SERV 19 17FEB99 1 1 Work In Ventilated Area Engine exhaust fumes can cause sickness or death If itis necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 UN 23AUG88 DX AIR 19 17FEB99 1 1 0 5 6 072209 PN 31 103 260 Safety Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body fr
246. r other mobile equipment without a prior study taking into account the various specific features of using the generating set 1 3 5 Risks related to electrical networks Y lt lt lt lt lt lt The electrical equipment supplied with the generating set complies with standard NF C15 100 France or with the standards of the countries in question The earth connection must be installed in accordance with the standards in force in each country in question and with the neutral System sold Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Never accidentally touch stripped cables or loose connections Never handle a generating set with wet hands or feet Maintain electrical wires and connections in good condition Using equipment in poor condition can lead to electrocution and damage to equipment Always disconnect the power to the equipment or facility generating set voltage battery voltage and network voltage before any operation The electrical connections must be made in accordance with current standards and regulations in the country of use Do not use faulty poorly insulated or provisionally connected wires Never reverse the positive and negative terminals on batteries when connecting them This could cause severe damage to the electrical equipment Follow the wiring diagram supplied by the manufacturer
247. re Signalling lights working for on road trailers Enclosure doors closed Parking brake released for on road trailers Guide wheels jockey wheels and stands lifted if fitted Towbar arm locking levers tightened and pinned if fitted with an adjustable towbar Brake test for on road trailers Safety cable fitted for on road trailers 31 260 4 3 Operation On site trailer N These trailers are not fitted with a main brake and so cannot be braked in motion the tyres allow for a maximum speed of 27 km h So it is absolutely prohibited to exceed this speed Nor are these trailers fitted with signalling lights On road use is prohibited On road trailer The driving speed must be suited to the condition of the road and the handling of the trailer Driving at high speed causes heating of the tyres so it is 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 A Warning 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 Nonetheless the tightness must be checked whenever you are about to tow the trailer
248. riod between oil changes 40 C 1040F Depending on Emission Regulation requirements the oil recommendations are different Refer to the chart to 30 C 86 F identify the proper oil to be used 2 z m 3 20 689F Non Emission Certified Engines EPA Tier 3 Emission Certified oz and Stage 11 EPA Tier 2 Engines s o Emission Certified Engines lt 109C 509F iz o John Deere PLUS 50 John Deere PLUS 50 mn Preferred Preferred 0 C 329F ACEA E7 ACEA E6 5 ACEA E7 ACEA E6 ACEA E4 10 C 14 F Multi viscosity diesel engine oils are preferred 209C 40F If diesel fuel with sulfur content greater than 0 5 is used ic H H Na H or if oil does not meet the classification above reduce m 9 the service interval by 50 5 40 C 40 F 1 DO NOT use diesel fuel with sulfur content greater than 5 1 Oil Viscosities for Air Temperature Ranges PLUS 50 is a trademark of Deere amp Company CD ENOIL 19 01JUL09 1 1 072209 10 2 PN 35 107 260 Fuels Lubricants and Coolant Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used Use clean containers to handle all lubricants Whenever possible store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation Make certain that all co
249. rnator user and maintenance manual 193 260 194 260 User guide and maintenance manual LEROY SOMER Alternator 43 2 amp 44 2 SHUNT AREP amp PMG 33522059401 6 1 3434 i 01 10 2010 195 260 196 260 LEROY SOMER 3434 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS Installation and maintenance 197 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i This manual concerns the alternator which you have just purchased The latest addition to a whole new generation of alternators this range benefits from the experience of the world s leading manufacturer using advanced technology and incorporating strict quality control SAFETY MEASURES Before using your alternator for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this alternator must be performed by a qualified technician Our technical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommendations or symbols to alert the user to potential risk of accident It is vital that you understand and take notice of the different warning symbols used CAUTION Warning symbol for an operation capable of damaging or destroying the alternator or surrounding equipment Warning sy
250. rt circuit in the main field Check the resistance Faulty induced excitaion Warning For single phase operation check that the sensing wires coming from the A V R are correctly connected to the operating terminals see the alternator manual Voltage disappears during operation Check the A V R 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 induced excitation Faulty A V R Main field open circuit or short circuited Warning after setting up or trouble shooting replace all access panels or covers LEROY SOMER 225 260 LEROY SOMER Installation and maintenance 4067 en 2009 05 b R250 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 019 4 2 Technical support service Ourtechnical support service will be pleased to help you with any information needed For replacement part orders it is necessary to indicate the type and the code number of the A V R Please contact your usual correspondant An extensive network of service centres is available to rapidly supply any necessary parts In order to ensure the correct operation and safety of our machines we strongly recommend that original manufacturer s spare parts are used Failure to do so will discharge the manufacturer from liabilty in the
251. ry 3 years In all other cases carry out this operation every 2000 hours every 2 years g Operation to be carried out by one of our agents Replace the injectors every 5000 hours and the thermostat every 10000 hours If in doubt about the operation of one of these components contact one of our agents 7 3 Alternator gt After 20 hours in operation check the tightness of all the mounting bolts the general condition of the machine and the various electrical connections of the installation gt The bearings fitted on the machine are greased for life to around the service life of the grease depending on use 20 000 hours or 3 years 63 260 N 8 Battery Fit the battery so that it is properly ventilated Maintenance should only be carried out by qualified personnel If replacing the batteries use the same type of batteries Do not throw the old battery in the fire Only use insulated tools the operator should not be wearing a watch chain or any metal object Never use sulphuric acid or acid water to top up the electrolyte level Use an approved battery fluid Batteries release oxygen and hydrogen gas which are flammable Never bring flames or sparks near the battery risk of explosion Discharge any static electricity before handling the batteries by first touching an earthed metal surface Do not use the battery when the fluid level is below the minimum required level Using a battery with a low electrolyte level could resu
252. s centre of gravity special lifting devices may be necessary to maintain correct balance and completely safe working conditions The ground must be able to withstand the load of the generating set pump unit or lighting column and its lifting machinery without stress otherwise put down beams of sufficient strength in a stable configuration Position the generating set pump unit or lighting column as close as possible to its place of use or transport in a clear space with free access Never perform work on a generating set pump unit or lighting tower just hanging from a lifting device 11 260 N 1 4 Identifying sets Generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documentation contained in the appendices of this manual 6 IZ 10 21 7 3 14 16 PRESSION ACOUSTIQUE SOUND PRESSURE PLAQUE CDNST CTEUR I MANUFACTUR im 7m 15m ome cz CI pont m dB A ELA 78 676 64 Masse Kg Weight ry PUISSANCE ACOUSTIQUE SOUND POWER EC 2000 14 0 D Lwa A dB 8 15 18 1 Generating set 9 Maximum ambient temperature for the rated power 2 Manufacturer name C 3 Model 10 Rated frequency Hz 4 Serial number 11 Generating set rotation speed RPM 5 Year of manufacture 12 Rated voltage V 6 Rated output
253. s 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 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 anytime in order to incorporate the latest tech nological developments The information contained in this document may therefore be changed without notice LEROY SOMER 230 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R CONTENTS 1 SUPPLY 4 1 1 AREP exoaitatloniSVSEelm uc co io o treat tr etant PE 4 1 2 PMG excitation system cec DE hA a Lap E cR De Re EORR 5 1 3 SHUNT or separate excitation 5 1 5 2 R438 ALV R coc cecee 6 VENIM 6 2 2 Frequency compared with voltage without LAM see 6 2 3 LAM Load Acceptance Module 6 2 4 Typical effects
254. s when no more applicable FMI exists or in cases when the reported SPN name spells out the component and a non standard failure mode This type of fault may or may be directly associated with the value of general broadcast information This FMI will mean not available when the associated SPN is also not available as when the remainder of the packet is filled with binary ones after all data has been transmitted 259 260 260 260
255. sary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacture spare parts In the event of failure to comply with this ad vice the manufacturer cannot be held res ponsible for any damage LEROY SOMER 241 260 13 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 NOTES 14 LEROY SOMER 242 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 NOTES LEROY SOMER 243 260 15 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOUL ME CEDEX FRANCE 338 567 258 RCS ANGOUL ME S A au capital de 62 779 000 www leroy somer com 244 260 9 3 Appendix C Common spare parts GenPARTS Starter motor solenoid 330361644 Radiator cap 330901058 Alternator diode 330360144 Fan belt 330360175 Thermostat 330360012 Thermostat seal 330361286 Alarm oil pressure sensor 330360059 Alarm water temperature sensor 330360061 330910115 GENLUB 330910095 330910098 330910099 GENCOOL 330910100 245 260 N 330510021 330510020 330560552 330510015 330560632 cc gt Diode bridge 330410713 2 cc LLI E Varistor 330410335 Note For all technical assistance
256. sation Contact your fuel supplier for recommendations DX FUEL4 19 19DEC03 1 1 10 1 106 260 072209 PN 34 Fuels Lubricants and Coolant Diesel Engine Break In Oil New engines are filled at the factory m John Deere After the break in period use John Deere PLUS 50 or ENGINE BREAKIN GIL During the break in penod other diesel engine oil as recommended in this manual add John Deere ENGINE BREAK IN OIL as needed to maintain the specified oil level IMPORTANT Do not use PLUS 50 oil or engine oils meeting any of the following during the first 100 Change the oil and filter after the first 100 hours of hours of operation of a new or rebuilt engine operation of a new or rebuilt engine Aft i haul fill th i ith John D ies DoR er engine overhaul fill the engine with John Deere ENGINE BREAK IN OIL x pans If John Deere ENGINE BREAK IN OIL is not available API CH 4 ACEA E4 use a diesel engine oil meeting one of the following during API CG 4 ACEA E3 the first 100 hours of operation API CF 4 API Service Classification CE API CF 2 API Service Classification CD API CF API Service Classification CC ACEA Oil Sequence E2 These oils will not allow the engine to ACEA Oil Sequence E1 break in properly PLUS 50 is a trademark of Deere amp Company DX ENOIL4 19 13SEP06 1 1 Diesel Engine Oil 50 C 1220F Use oil viscosity based on the expected air temperature range during the pe
257. sel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 127 Displacement L 6 8 6 8 6 8 Compression Ratio 17 0 1 17 0 1 17 0 1 POWER 1500 rpm kW hp 92 125 109 146 105 143 Prime POWER 1500 rpm kW hp 101 137 121 162 116 158 Standby POWER 1800 rpm kW hp 108 147 124 169 Prime POWER 21800 rpm kW hp 119 162 137 186 Standby Width overall mm 652 598 652 Length overall mm 1364 1117 1364 Height overall mm 1070 984 1070 Weight dry kg 651 533 651 Engine oil quantity 20 20 20 Engine coolant quantity 28 28 28 with Fan PApproximate DPSG CD03523 55 19 08JULO9 3 3 65 3 pr 183 260 PN 111 Specifications General engine pack specifications Stage ll Emission Certified Engines ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 31800 rpm Standby Width overall Length overall Height overall Weight dry Engine oil quantity Engine coolant quantity With Fan PApproximate ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 31800 rpm Standby Width overall Length overall Height overall Weight dry P Engine oil quantity Engine coolant quantity with Fan PApproximate UNIT OF 30
258. sembly must be rebalanced 4 6 7 2 Reassembling the main field Follow the dismantling procedure in reverse order Take care not to knock the windings when refitting the rotor in the stator If the fan is being replaced on the 43 2 assemble the parts as shown in the following diagram Fit a tube and a threaded screw On the 44 2 the fan is fixed by screws on the hub jin P Follow the procedure for reassembling the bearings see sections 4 6 5 2 and 4 6 6 2 After operational testing replace all access panels or covers Installation and maintenance of the PMG For the LSA 43 2 and LSA 44 2 the PMG reference is PMG 1 See the PMG maintenance manual ref 4211 CAUTION and operation at rated load with separate field excitation All values are given at 10 for exact values consult the test report and are subject to change without prior warning For 60 Hz machines the resistance values are the same and the excitation current i exc is approximately 5 to 10 weaker 4 8 1 3 phase LSA 43 2 4 P SHUNT excitation Resistances at 20 C Q LSA43 2 Stator L N Rotor Field Armature S1 0 155 1 35 18 4 0 23 15 0 155 1 35 18 4 0 23 25 0 155 1 35 18 4 0 23 35 0 128 1 41 18 4 0 23 M45 0 105 1 57 18 4 0 23 L65 0 083 1 76 18 4 0 23 L8 0 063 1 96 18 4 0 23 Field excitation current i exc A 400 V 50 Hz i exc excitation c
259. signal 2000 ECU status 6 Vehicle ID missing 13 Security violation 2017 J1939 Communication bus 2791 19 Internal EGR status 520192 8 Piston cooling switch 520193 267 Sea water pressure 520194 4 Starter input sensor start request 520195 6 Key off input sensor stop request CIU 256 260 N SAE J1939 73 March 2004 FMI and Description FMI 0 DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE Most SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition Hegion e of the signal range definition Broadcast of data values is continued as normal FMI 1 DATA VALID BUT BELOW NORMAL OPERATIONAL RANGE Most SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region e of the signal range definition Broadcast of data values is continued as normal FMIZ2 DATA ERRATIC INTERMITTENT OR INCORRECT Erratic or intermittent data includes all measurements that change at a rate that is not considered possible in the real world condition and must be caused by improper
260. ss various engine functions two arrow keys C to scroll through the engine parameter list and view the menu list and an enter key D for selecting highlighted items Trouble Code Display On Instrument Panel RG13740 UN 11NOV04 2 Read and record DTC s displayed on LCD of A Diagnostic Gauge C Arrow Keys diagnostic gauge A For procedure to access diagnostic B Menu Key D Enter Key trouble codes refer to Using Diagnostic Gauge to Access Engine Information earlier in this manual 3 Go to the LISTING OF DIAGNOSTIC TROUBLE 4 Contact your nearest engine distributor or servicing CODES DTCs later in this section to interpret the dealer with a list of DTC s so that necessary repairs can DTC s present be made CD03523 0000192 19 02FEBO07 1 1 55 1 0 072209 PN 104 176 260 Troubleshooting Listing of Diagnostic Trouble Codes DTCs NOTE Not all of these codes are used on all OEM engine applications SPN FMI Description of Fault 000028 03 Throttle 3 Signal Out of Range High 04 Throttle 3 Signal Out of Range Low 000029 03 Throttle 2 Signal Out of Range High 04 Throttle 2 Signal Out of Range Low 000084 31 Vehicle Speed Signal Unreliable 000091 03 Throttle 1 Signal Out of Range High 04 Throttle 1 Signal Out of Range Low 09 Throttle 1 Communication Signal Erratic 000094 03 Low Pressure Fuel Signal Out of Range High 04 Low Pressure Fuel Signal Out of Range Low 10 Low Pressure Fuel Rate
261. st 5 4 1 Single bearing LSA 43 2 44 2 Wc bm N j PY 213 260 N Nbr Description N Nbr Description 1 1 Stator assembly 120 1 Terminal block support AREP 4 1 Rotor assembly 124 1 Terminal block 15 1 Fan 198 1 Voltage regulator AVR 16 6 Fixing screws 44 2 only 207 1 AVR damper seal 28 1 Earth terminal 217 1 Terminal block 30 1 DE shield 290 1 PMG housing 33 1 Air outlet grille 291 1 Adaptation shaft 36 1 Shield on exciter end 292 1 Magnetic rotor 37 4 Tie rod 293 1 Stator 41 1 Cover front panel 294 2 Fixing screws 47 1 Cover rear panel 295 1 Tie rod 48 1 Cover top panel 296 1 Cable gland washer nut 49 34 Fixing screws 297 1 End plate 51 1 Air intake grille 320 1 Hub 43 2 L7 amp 44 2 only 59 3 Inspection door 322 1 Coupling disc 70 1 NDE bearing 323 Fixing screws 79 1 Preloading wavy washer 324 1 Clamping washer 43 2 S1 to L6 90 1 Exciter field 325 Spacer shim 43 2 L7 amp 44 2 only 91 4 Exciter field fixing screw 343 1 Diode bridge assembly 100 1 Exciter armature 347 1 Surge suppressor 107 1 Diode crescent support 349 1 O ring LEROY SOMER 17 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 5 4 2 Two bearing LSA 43 2 44 2
262. t drag Hold the adjusting screw from turning with screwdriver and tighten locknut to 27 N m 20 Ib ft Recheck clearance after tightening locknut Readjust clearance as necessary 5 Reinstall rocker arm cover and crankcase vent tube 4 Cylinder Engine NOTE Firing order is 1 3 4 2 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves c Rotate flywheel 360 Lock No 4 piston at TDC compression stroke C d Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves c Rotate flywheel 360 Lock No 6 piston at TDC compression stroke C d Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves A Front of engine E Exhaust valve B No 1 Piston at TDC I Intake valve compression stroke C No 6 Piston at TDC compression stroke A Front of engine B No 1 Piston at TDC compression stroke C No 4 Piston at TDC compression stroke RG7409 UN 06AUG96 RG4776 UN 310CT97 E Exhaust valve I Intake valve RG4777 UN 310CT97 DPSG CD03523 36 19 31JAN07 2 2 40 2 155 260 072209 PN 83 Maintenance 2000 hours 2
263. t output open short to B General fault output short to ground 1347 Pump control valve status Pump control valve 1 status for 6081HF070 Pump control valve current high Pump control valve error mismatch Fuel rail pressure control error Pump control valve fuel flow not detected 1348 Pump control valve 2 status Only for 6081HF070 Pump control valve 2 error mismatch Pump control valve 2 fuel flow not detected 1485 1485 Pump power relay status ECU main relay of VOLVO EMS EDC Pump power relay fault ECU main relay short circuit high 1568 Torque curve selection Torque curve selection invalid Torque curve input voltage high Torque curve selection missing 1569 Fuel supply status 31 Fuel de rate 255 260 N 2 SPN CID SID PID PPID 2 Description Commentary 507 1639 1 Fan speed signal missing 2 Fan speed signal erratic Not possible with Genset 16 Fan speed higher than expected application 18 Fan speed lower than expected 1675 Engine starter motor relay 1690 1690 Analogue throttle status EN Abnormal pulse
264. tem eee eee Adjust speed droop governor Mechanical fuel system Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY Maintenance 2500 hours 3 years Drain and flush cooling system Maintenance As required Additional service information Do not modify fuel system Welding Near Electronic Control Units Keep Electronic Control Unit Connectors Clean Clean or replace air filter one piece Clean or replace air filter element Replacing fan and alternator belt 4045 and 6068 Bleeding the fuel system Troubleshooting General troubleshooting information Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection PUMP arsane n Engine Wiring Layout Electronic Fuel System With Denso High Pressure Common Rail oriasi i Engine 9 Electrical troubleshooting Displaying Of Diagnostic Trouble Codes D TGS tror etin Using blink code method for retrieving Diagnostic Trouble Codes DTC s Using diagnostic gauge for retrieving Diagnostic Trouble Codes DTC s
265. test delay Date and time depending on settings 24 08 2005 13 12 AUTOMATIC STOP Operating mode operation in Auto Mode PROGRESS Generation set cooling in progress Countdown for Engine Stop delay cooling OR G10 Gradual Stop delay Coolant temperature OR COOLING DOWN Overload Gradual Stop delay OR OFF load test 1 min 30 sec delay Date and time depending on settings 24 08 2005 Generating setstop IN PROGRESS 24 08 2005 Screen Screen Data displayed no G 11 OFF Generating set stop in progress Date and time depending on settings 55 260 EN Operating mode changeover switching from Manual Mode to Auto Mode following auto start demand WARNING Immediate start OK Esc Seren Screen Data displayed Start Demand AUTO Do you wish to change G 12 to Auto Mode Operating mode operation in Manual Mode AUTOMATIC start demand Generating set stop request due to fault or by pressing STOP in Auto Mode to AUTO mode OK Esc Screen Screen Data displayed no Manual Mode activated Operating mode operation in Auto Mode Do you wish to change generating set in operation G13 Warning message for switching to Manual Mode after the STOP button has been pressed or a fault has appeared 56 260 EN 6 3 2 Starting A Check that the generating set circuit breaker has triggered Danger Connect the generating set b
266. that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply Apart from the combustion devices it is prohibited to use fire in any form This restriction must be clearly displayed Spreading of waste water sludge and waste is prohibited The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the combustion device manufacturer The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber Burning of waste in the open air is prohibited Always protect your hands when checking for leaks Pressurised liquids may penetrate body tissue and cause serious damage Risk of blood contamination Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil Except by special agreement once closed the gas supply main unit must only be re opened by the gas distributor However the user may access it under certain conditions Check these for each site 1 3 2 Risks related to exhaust gases and fuels The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high Always use generating sets pump units or lighting towers in a well ventilated place where gases cannot accumulate In case of indoor use Y Be sure to evacuate exhaust gases outdoors Y Provide appropriate ven
267. tilation so that personnel present are not affected Danger SS S4 Observe the local regulations in force for generating sets pump units or lighting towers as well as local regulations for use of fuel petrol diesel fuel and gas before using your generating set pump unit or lighting tower Fuel filling should be carried out when the engine is off except for generating sets with an automatic filling system Engine exhaust gases are toxic do not run the generating set pump unit or lighting column in unventilated premises If installed in a ventilated room additional requirements for fire and explosion protection must be observed A leaking burnt gas exhaust may increase the sound level of the generating set pump unit or lighting column To check on its efficiency regularly examine the burnt gas exhaust Pipes must be replaced as soon as their condition demands it 1 3 3 Risks related to toxic products Glycol is a toxic product and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging The corrosion inhibitor contains alkali Do not swallow it This substance should not come into contact with the eyes In the event of contact with the eyes rinse immediately with plenty of water for at least 15 minutes Avoid prolonged or repeated contact with the skin In the event of contact with the skin wash thoroughly with water and soap CONSULT A DOCTOR IMMEDIATE
268. tion Permanent loss of signal o j m A Pump position position sensor input missing Not informed by VOLVO Pump position sensor cam position sensor input pattern error 637 22 N IJN 4 Crank position sensor flywheel Crank position input noice Permanent loss of signal Crank position Cam position out of synchronisation Crank position input missing Not informed by VOLVO Crank position sensor input pattern error 639 247 231 Communication status Bus Off error Passive bus error 11 Data registers read back failure 12 13 Loss of message error Bus CAN error 640 Engine shutdown vehicle status Engine shutdown vehicle request invalid 651 651 Engine shutdown vehicle request Cylinder 1 status injector Short circuit high side to B Short circuit high side to low side or low side to B 652 652 Short circuit high or low side to ground Cylinder 1 circuit open Cylinder 1 circuit shorted Cylinder 1 balancing error mechanical failure Cylinder 1 unknown error mechanical failure Cylinder 2 status injector Short circuit high side to B Short circuit high side to low side or low side t
269. to V 4 Fuel rail pressure input voltage low Short to V 5 Fuel rail pressure sensor open circuit 10 Fuel rail pressure lost detected 13 Fuel rail pressure higher than expected 16 Fuel supply pressure moderately high 17 Fuel rail pressure not developed 18 Fuel supply pressure moderately low 97 97 Water in fuel sensor 0 Water in fuel continuously detected 3 Water in fuel input voltage high Short to V 4 Water in fuel input voltage low Short to V 16 Water in fuel detected 31 Water in fuel detected 98 98 Oil level sensor 1 Oil level value below normal 3 Oil level sensor input voltage high Short to V 4 Oil level sensor input voltage low Short to V 5 Oil level sensor open circuit 99 99 Engine Oil filter Differential Pressure 247 260 EN 8 SPN CID SID PID PPID FMI 2 o Description Commentary gt E 100 100 100 Oil pressure sensor 1 Engine oil pressure extremely low 3 Oil pressure sensor input voltage high Short to V 4 Oil pressure sensor input voltage low Short to V 5 Oil pressure sensor open circuit 17 Engine oil pressure low 18 Engine oil pressure moderately low 102 273 102 Manifold air pressure sensor 0 Manifold air
270. to first stop to relieve pressure before removing completely TS281 UN 23AUG88 CD30756 UN 26AUG99 Remove radiator cap E and check coolant level which should be at bottom of filler neck Fill radiator with proper coolant solution if level is low See DIESEL ENGINE COOLANT Check entire cooling system for leaks DPSG CD03523 27 19 07FEBO7 2 4 3 If air filter has a dust unloader valve C squeeze valve tip to release any trapped dirt particles 4 Check air intake restriction indicator D When indicator is red air filter needs to be cleaned IMPORTANT Maximum air intake restriction is 6 25 kPa 0 06 bar 1 0 psi 25 in H20 A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine 5 Make a thorough inspection of the engine compartment NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination Continued on next page RG4687 UN 20DEC88 CD30757 UN 26AUG99 DPSG CD03523 27 19 07FEBO7 3 4 072209 25 2 PN 69 141 260 Maintenance Daily or every 10 hours 6 NOTE Engines with mechanical fuel system have a single fuel filter while electronically controlled engines DE10 and HPCR fuel systems have two fuel filters primary and final Moreover these electronically controlled engines may be equipped with a water sensor at the fuel fi
271. to the potential risks to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure Warning This symbol indicates a dangerous situation if the warning is not heeded Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any other object in case of exposure Important In order to obtain optimum efficiency and the longest possible life for the electrical generating sets maintenance operations must be carried out according to the periods indicated in the attached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training Dealers have this qualification and can answer all of your questions They can also supply you with spare parts and other services The left and right sides can be seen from the back of the electrical generating set the radiator is at the front Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum For any replacement of parts contact your nearest dealer for our company who will have the necessary equipment and can offer properly trained and informed staf
272. ts 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 EROY SOMER 234 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R LAM action eliminated by cutting the ST5 jumper Voltage A Underspeed and LAM ST5 disconnected Un 4 0 85 UN M 48 or 57 5 Hz Say iC N 50 or 60 Hz 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 voltage ac cording to the principle If the speed drops between 46 and 50 Hz the rated voltage follows a fast gradient as it is restored 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 X Drop N lt 46 Hz Time Drop N gt 46 Hz 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only 2 4 1 Voltage Un Load on the shaft kW LEROY SOMER 7 235 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 2 5 R43
273. ttery 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 potentiometer Adjust AVR stability 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 high Voltage between E
274. ue value or replace shear bolts with identical property class Replace fasteners with tightening procedure is given for a specific application For stainless steel the same or higher property class If higher property class fasteners are fasteners or for nuts on U bolts see the tightening instructions for the used tighten these to the strength of the original Make sure fastener specific application Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement When by turning the nut to the dry torque shown in the chart unless different possible lubricate plain or zinc plated fasteners other than lock nuts instructions are given for the specific application wheel bolts or wheel nuts unless different instructions are given for the specific application ubricated means coated with a lubricant such as engine oil fasteners and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or M6 to M18 fasteners with JDM F13B zinc flake coating with phosphate and oil coatings or M20 DX TORQ2 19 24 9 1 1 65 9 072209 PN 117 189 260 Specifications 65 1 0 072209 PN 118 190 260 Index Page Page A Engine wiring layout With Denso High Pressure Common Rail 55 3 Air filter With Stanadyne DE10 55 2 Clean or replace
275. uits It can be assumed that the communications subsystem is not the part that has failed and the manufacturer has determined that there is no serviceable component smaller than the ECU involved in the failure Broadcast of data value is substituted with the error indicator value if appropriate as there may or may not be any broadcast involved This error is to include all internal controller trouble codes that can not be caused by connections or systems external to the controller FMI 13 OUuT OF CALIBRATION A failure that can be identified to be the result of not being properly calibrated This may be the case for a subsystem which can identify that the calibration attempting to be used by the controller is out of date Or it may be the case that the mechanical subsystem is determined to be out of calibration This failure mode does not relate to the signal range definition as do many of the FMls FMI 14 SPECIAL INSTRUCTIONS Special Instructions is the FMI to be used when the on board system can isolate the failure to a small number of choices but not to a single point of failure When the FMI is used there is clear necessity for the service technician to take some action to complete the specific diagnosis and the manufacturer has provided instructions for the completion of that diagnosis There are two cases where this will be used 1 for emission related diagnostics where the particular failure cannot be separated between a sensor out o
276. units 6 After welding reverse Steps 1 5 TS953 UN 15MAY90 DX WW ECUO2 19 11JUN09 1 1 Keep Electronic Control Unit Connectors Clean IMPORTANT Do not open control unit and do not clean with a high pressure spray Moisture dirt and other contaminants may cause permanent damage 1 Keep terminals clean and free of foreign debris Moisture dirt and other contaminants may cause the terminals to erode over time and not make a good electrical connection 2 Ifa connector is not in use put on the proper dust cap or an appropriate seal to protect it from foreign debris and moisture 3 Control units are not repairable 4 Since control units are the components LEAST likely to fail isolate failure before replacing by completing a diagnostic procedure See your John Deere dealer RG16946 UN 31MAR09 5 The wiring harness terminals and connectors for electronic control units are repairable DX WW ECU04 19 11JUN09 1 1 50 2 161 260 072209 PN 89 Maintenance As required Clean or replace air filter one piece Clean air filter when restriction indicator A is red Air filter can be cleaned up to six times Thereafter or at least once a year it must be replaced Proceed as follows 1 Thoroughly clean all dirt around air filter area i 2 Loosen clamp B then remove air filter bi IMPORTANT Never reinstall an air filter which shows l evidence of
277. uration data ENGINE SPEED PT 1 1000 RPM RG13166 UN 29SEP03 Use Arrow Keys To Scroll OURGP11 00000AB 19 03SEP03 4 6 5 Press the Menu key to return to the main menu ENGINE SPEED PT 1 1000 RPM a ui o o Y z 1 o Return To Main Menu Continued on next page OURGP11 00000AB 19 03SEP03 5 6 1 5 4 072209 PN 41 113 260 Operating the Engine 6 Press the Menu key to exit the main menu and return to the engine parameter display 98 1000 RPM LOAUQRFM ENG RPM 1800 RPM 57 PSI VOLT OAL PRES RG13159 UN 26SEP03 Exit Main Menu OURGP11 00000AB 19 03SEP03 6 6 Accessing Stored Trouble Codes 98 SEU REM LOAUQRFM ENG RPM NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine 1800 RPM 57 PSI start up is desired See Starting The Engine All BAT VOLT ou pres of the engine values illustrated on the diagnostic gauge indicate the engine is running RG13159 UN 26SEP03 For description of trouble codes see chart in Troubleshooting Section Menu Key 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AC 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Stored Codes is highlighted GO TO 1 UP DIS
278. urrent of the exciter field LSA 43 2 no load on load S1 0 5 1 3 15 0 5 1 5 25 0 5 1 6 35 0 5 1 8 M45 0 4 1 6 L65 0 4 1 6 L8 0 4 1 6 4 8 2 3 phase LSA 43 2 4 P AREP excitation Resistances at 20 C Q Stator Wind Widing LSA 43 2 L N Rotor X1 X2 71 75 Field Armat S1 0 155 1 35 0 32 0 52 46 0 23 15 0 155 1 35 0 32 0 52 46 0 23 25 0 155 1 35 0 32 0 52 46 0 28 S35 0 128 1 41 0 29 0 5 4 6 0 23 M45 0 105 1 57 0 26 0 51 4 6 0 23 L65 0 083 1 76 0 26 0 44 46 0 23 L8 0 063 1 96 0 21 0 4 4 6 0 23 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field Mounting is impossible with the regreasable bearings LSA 43 2 no load on load option with the LSA 44 2 51 1 26 4 8 Electrical ch isti 55 8 Electrical characteristics S25 1 3 2 Table of average values S35 1 3 6 Alternator 2 and 4 poles 50 Hz 60 Hz Winding n 6 and M M45 08 32 or M1 connected in dedicated single phase 400 V for the excitation values L65 0 8 3 2 The voltage and current values are given for no load operation L8 0 8 3 2 LEROY 14 SOMER 210 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 8 3 Dedicated single phase LSA 43 2 4 pole SHUNT
279. us Attempting to fuel without command 11 Pump supply voltage out of range 12 Pump self test error 19 Pump detected communication error 31 Pump initiated engine protection 254 260 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Commentary 1078 ECU Pump timing status ECU Pump timing moderately out of synchronisation 11 ECU Pump timing out of synchronisation speed 31 ECU Pump timing extremely out of synchronisation 1079 Sensor supply voltage 5 Volt Analog throttle reference Sensor supply voltage high gt 5 5 Volt Sensor supply voltage low 4 44 Volt 1080 211 Sensor supply voltage Oil pressure 5V sensor supply 2 pressure Coolant temp fuel Sensor supply voltage high gt 5 5 Volt Sensor supply voltage low lt 4 40 Volt 1109 Engine ECU status 31 Engine shutdown warning 1110 Engine status 31 Engine shutdown 1111 268 Check parameters 1136 55 Programmed parameter fault ECU Temperature 1184 173 Exhaust gas temperature sensor 1188 32 Wastegate 1231 1239 CAN bus 2 Rail pressure system 1266 1266 General fault output status General faul
280. vibration Defective mounting or play in coupling Vibration Rotor balancing fault Excessive vibration and humming noise coming from the machine Alternator operating in single phase mode single phase load or faulty contactor or installation fault Stator short circuit Abnormal noise Alternator damaged by a significant impact followed by humming and vibration System short circuit Mis paralleling Possible consequences Broken or damaged coupling Broken or bent shaft end Shifting and short circuit of main field Fan fractured or coming loose on shaft Irreparable damage to rotating diodes or AVR 4 5 Electrical faults disappears when the battery is removed Fault Action Effect Check Cause The alternator builds up and its voltage is Lack of residual magnetism still correct when the battery is removed The alternator builds up but its voltage Check the connection of the voltage reference to the No Connect between E and qoes not reach the rated value when AVR voltage E a new battery of 4to the battery is removed Faulty diodes at no load 12 volts respecting Armature short circuit on start up the AVR polarities for 2 to 3 seconds The alternator builds up but its voltage Faulty AVR Field windings disconnected Main field winding open circuit Check the resistance Voltage too low Correct speed Check the drive speed Check the AVR conne
281. wer 5 8 L h Fuel Fuel type Diesel Standard fuel tank 100L High autonomy fuel tank 230L 21 260 EN Lubrication Oil capacity with filter 6 0 L Min Oil pressure 1 bar Nominal oil pressure 5 bar Oil consumption 100 load 0 009 L h Oil sump capacity 5 3L Type of lubricant Genlub Cooling Engine capacity with radiator 16 1 L Max coolant temperature 105 C Fan power 1 5 kW Ventilator air flow 1 86m3 s Refrigerant type Gencool Thermostat 82 94 C Emissions HC 150 mg Nm3 CO 190 mg Nm3 NoX 3800 mg Nm3 PM 60 mg Nm3 Alternator data e Compliant with NEMA MG21 standards UTE NF C51 111 VDE 0530 BS 4999 IEC 34 1 CSA e The alternator is protected against short circuits e Vacuum impregnation epoxy winding IP23 protection rating Type LEROY SOMER LSA432815 Number of phases 3 Power factor cos Phi 0 8 Number of poles 4 Excitation type AREP Voltage regulator R438 Short circuit current 3 IN Number of bearings 1 Coupling Direct Control unit s NEXYS Standard specifications Frequency meter Voltmeter Ammeter Alarms and faults Oil pressure Coolant temperature Fail to start Overspeed Alternator min max Fuel level low Emergency shutdown Engine parameters Working hours counter Engine speed Battery voltage Fuel Level Air Preheating Standard specifications Volt
282. wer temperatures is required consult your John Deere dealer for recommendations Water quality Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives IMPORTANT Do not mix ethylene glycol and propylene glycol base coolants DX COOL8 19 16NOVO1 1 1 072209 PN 36 10 3 108 260 Fuels Lubricants and Coolant Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants Always use a recommended glycol base engine coolant even when operating in geographical areas where freeze protection is not required John Deere COOL GARD Premix is available in a concentration of 5096 ethylene glycol However there are situations in warm temperature climates where a coolant with lower glycol concentration approximately 2096 ethylene glycol has been approved In these cases the low glycol formulation has been modified to provide the same level of corrosion inhibitor as John Deere COOL GARD II Premix 50 50 COOL GARD is a trademark of Deere amp Company IMPORTANT Water may be used as coolant in emergency situations only Foaming hot surface aluminum and iron corrosion scaling and cav
283. with Fan PApproximate ITEM UNIT OF 4039DF008 4039TF008 4045DF158 4045HF120 4045HF158 MEASURE Number of 4 4 4 4 4 Cylinders Fuel Diesel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 106 5 Stroke mm 110 110 127 127 127 Displacement L 3 9 3 9 4 5 4 5 4 5 Compression Ratio 17 8 1 17 8 1 17 6 1 17 0 1 17 0 1 POWER 1500 kW hp 35 48 55 75 41 56 91 122 88 120 rpm Prime POWER 1500 kW hp 38 52 61 83 42 57 102 137 96 131 rpm Standby POWER 1800 kW hp 41 56 67 91 48 65 108 147 rpm Prime POWER 1800 kW hp 47 64 73 99 51 69 120 163 rpm Standby Width overall mm 588 588 606 598 798 Length overall mm 1016 1016 1038 861 1209 Height overall mm 960 979 959 980 1197 Weight dry kg 475 487 493 396 599 Engine oil quantity 12 12 8 12 12 Engine coolant 16 5 16 5 20 28 28 quantity With Fan Continued on next page DPSG CD03523 55 19 08JUL09 1 3 072209 65 1 PN 109 Specifications PApproximate ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight dry Engine oil quantity Engine coolant quantity with Fan PApproximate ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 15
284. y The power of the charger must be suitable for the battery to be charged and the charging time available You need to use an automatic charger able to provide a sufficient voltage and charging current as well as a compensation voltage to handle spontaneous battery discharge 66 260 8 5 Faults and remedies EN Fault observed Probable origin Measures or observations The acid heats up when a new battery is filled Incorrect composition Incorrect storage Prolonged storage in a damp place Cool Load Check the acid density The acid escapes through the filler holes Overfilled battery Reduce the battery fluid level Battery tray not leaktight Replace the battery Incorrect operation from start up Short circuit in the power circuit Consumption fault Acid level too low Excessive charge voltage leading to a Check the charger and repair if significant accumulation of gas necessary Acid level too low Recharge Check the electrical installation Acid density too high The battery has been filled with acid instead of battery fluid Reduce the acid level by filling with distilled water Repeat the operation if necessary Starting problems Starting test incorrect Battery empty Battery exhausted or faulty Capacity too low Battery sulphated Recharge the battery Fit a new battery Battery terminals melted Incorrect electrical connection Batt

Generating set R44 - User manual - SDMO

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