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User and maintenance manual for generating sets

1. R731 3 ph x A in 3 ph detection ST1 open E voltage LEROY SOMER 192 202 LEROY SOMER R438 A V R 1 2 PMG excitation system alternator winding As a result the machine veer has a short circuit current capacity and This excitation system consists of a PMG l permanent magnet generator This is fitted a e to distortions generated by a Ea i Mac e an 1 The AVR monitors and corrects the alterna The PMG supplies he Ae with constant pebeta voltage by adjusting the excitation E y current voltage which is independent of the main 50 60 Hz selection via the ST3 jumper STATOR 6 wires marked T1 to T6 MAIN FIELD STATOR 12 wires marked T1 to T12 PMG SYSTEM T3 WES lO x2 21x1 22 E ov 10 220 380 o pa 4 x holes 5 8 x 175x 115 mm Slow fuse F1 250V 8A Ola ST5 ty ue m A witALAM without LAM CIA _ gt ST3 T I I T m da Frequency U50Hz 60Hz STS ra a of ID ST10 a E t LAM 13 25 J dh ra P p P1 Excitation EP53 ceiling pS ST4 Option F Y open External potentiometer ST 1 1 knee point 65 Hz for adjusting the voltage Response FA normal ST2 time ra fast A K P3 Stability N 1 3 SHUNT or separate excitation system A V R can be operated with SHUNT supply with a transformer secondary 50V or a 48V battery L
2. S6S in line type fuel injection pump left view Air inlet Water pump oon l Fuel injection nozzle coolant inlet Fuel injection pump Fuel feed pump Fuel inlet Fuel return pipe Oil level gauge Oil drain plug Fig 2 9 Engine left view S6S in line type fuel injection pump right view Oil filler Oil filler Thermostat case i aoil a E o U I e IA ORR 40 CO eke Front hanger Exhaust outlet Coolant outlet li ON aan Lf i n at fect Alternator Belt Fig 2 10 Engine right view 2 5 100 202 Chapter 2 NAME OF PARTS S6S distoributor type fuel injection pump left view Fuel inlet Magnetic valve stop solenoid Air inlet Fuel filter Fuel injection nozzle Fan Fuel return port SN A EN 11h Bl ZAS J yay a coolant nie nl zen EN SP gt Hee ae AQUA gt Id To HO Fuel injection pump Water pump E Oil filter Flywheel Oil level Oil drain plug iia ea Fig 2 11 Engine left view S6S distoributor type fuel injection pump right view Oil filler Oil filler n Front hanger Exhaust outlet Coolant outlet p Rear hanger Thermostat case 1 ak i 2 4 gt A Q Pea Elfo ONOS o 9 TO Y he Or Flywheel housing go hg w w A Alternator Fig 2 12 Engine right view 2 6 101 202 Chapter 2 NAME OF PARTS S6S T distributor type fuel injection pump left view Magnetic valve Fuel injection nozzle St
3. cccccoccocccncnccnnononononononos 11 8 Table 11 9 Low engine oil pressure occccco 11 8 Table 12 1 Main specifications cccccconnnncccnncc 12 1 Table 12 2 Main specifications ccccccononncccnnccn 12 2 86 202 CONTENTS 5 87 202 Chapter 1 BASIC SAFETY PRECAUTIONS Fire and explosions Keep flames away Do not use flames near the engine in the engine room Fuel vapor or other gas can catch fire and produce dan gerous situations Wipe off spilled fuel oil and LLC immediately and thoroughly Spilled fuel oil and LLC may ignite and cause a fire Store fuel and engine oil in a well ventilated area Make sure that the caps of fuel and engine oil contain ers are tightly closed Keep engine surrounding area tidy and clean Do not leave combustible or explosive materials such as fuel engine oil and LLC near the engine Such substances can cause fire or explosion Remove dust dirt and other foreign materials accu mulated on the engine and surrounding parts thor oughly Such materials can cause fire or the engine to overheat In particular clean the top surface of the battery thoroughly Dust can cause a short circuit Care for fuel oil and exhaust gas leakage If any fuel oil or exhaust gas leakage is found imme diately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exh
4. 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 Exciterfied 5 Rh 50 Q 300 W Diode 1A 12 V battery Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation power of the machine see the 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 1 for the rated excitation level the machine is in good working order The fault therefore comes from the AVR or its
5. Engine oil deterioration mechanisms Engine oil deteriorates due to natural deterioration and due to the contamination The natural deteriora tion of oil has two primary causes oneis the degrada tion caused by oxidation reaction or thermo decomposition of base oil and additives and the other is the degradation in the performance due to con sumption of additives during use Contaminants such as fuel and combustion products soot water vapor or oxidation products that intrude into oil have critical influence on oil quality Soot ad heres to the oil film of cylinder wall and is scraped off the cylinder wall by the piston rirg Such soot increas es the rate of insoluble substances in the engine oil and can cause the wear of piston rings and cylinder walls 119 202 Abrasion powder in the engine oil also accelerates deterioration as it can catalyze oxidation reaction Dust and dirt entered from outside deteriorate the en gine oil as well Contamination and deterioration pro cess accelerates with operation time Deterioration products and contaminants in the en gine oil if it is a small amount are harmless as they can be dispersed in oil However if it is a large amount they become harmful Since such products and contaminants flow out of the oil pan and start to accumulate inside the piston and in the oil system they eventually lead to serious problems such as pis ton ring sticking and bearing scuffing Sulfur c
6. Never mix different brands of engine oil Mixing different brands of engine oil may cause a chemical reaction of additives in the engine oil that could degrade the engine oil quality When handling oil in greater than the legally specified quantities be sure to have the work performed by a service station in compliance with the law When removing oil from the engine or oil can use an oil pump Do not suck oil with the mouth to siphon it Be sure to close the cap on the oil can after use Keep oil in a well ventilated area and out of direct sunlight Be sure to obtain the MSDS of the engine oil used and follow the instructions of the MSDS 5 1 118 202 Chapter 5 ENGINE OIL Engine oil performance requirements Engine oil requires the following performances Excellent dispersion performance the ability of oil to disperse sludge in the oil at high temperature that prevents engine oil deterioration due to sludge accu mulation and soot contamination Excellent acid neutralizing performance that prevents oxidative degradation due to fuel sulfur content Excellent high temperature oxidation stability that en dures continuous operation under prolonged high load Sufficient viscosity concentration to maintain the cold start performance and lubrication performance at high temperature Good rust and corrosion resistance to water Good foam resistance to prevent the lubricating qual ity from lowering due to oxidation
7. gt a flashing pictogram appears on the LCD screen gt message on graphic display example representing the circuit affected by the fault and the associated indicator if present FAULT example FAULT Oil Pressure lo lt 25 12 05 15 30 OK HELP Faults have priority over alarms Faults are displayed in the descending order of their appearance from the most recent to the oldest 6 3 4 2 Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed examples below FAULT FAULT ALARM FAULT Low coolant Level Emergency Stop 06 10 06 10 30 06 10 06 15 30 OK HELP Esc RESET OK HELP Press OK on the scrolling and selection wheel to access the help message if it is available example below Check the level fuel Esc EXIT If the alarm is no longer active it is reset automatically cause disappears Press Esc to reset a fault reset acknowledged if the cause of the fault has been removed reset not performed if the cause of the fault is still present 57 202 6 3 4 3 Activation of an alarm and a fault The appearance of an alarm and a fault causes gt The yellow and red LEDs to flash gt the related screen to be displayed example below FAULTS 1 2 Emergency Stop If several faults are present the number of faults is 25 12 05 15 30 displayed at the top of the screen Esc RESET OK LIST The faults list can be accessed by pressing OK
8. 52 202 AIR PREHEATING 10 seconds 24 08 2005 Generating set started Operating phase air preheating prior to starting generating set Countdown for air preheating delay Date and time depending on settings AVAILABLE POWER G8 75 cides O i screen 24 08 2005 AUTOMATIC STOP IN PROGRESS LOAD SUPPRESSION 1 min 30 sec 24 08 2005 13 12 AUTOMATIC STOP IN PROGRESS COOLING DOWN 1 min 30 sec 24 08 2005 Operating phase generating set in operation stable voltage and frequency Available power Date and time depending on settings Operating mode operation in Auto Mode Opening of power supply device motorised circuit breaker or source changeover switch controlled by TELYS Countdown for the mains return delay OR the load test delay Date and time depending on settings Operating mode operation in Auto Mode Generation set cooling in progress Countdown for Engine Stop delay cooling OR Gradual Stop delay Coolant temperature OR Overload Gradual Stop delay OR OFF load test delay Date and time depending on settings 53 202 Generating setstop OFF Generating set stop in progress IN PROGRESS Date and time depending on settings 24 08 2005 Operating mode changeover switching from Manual Mode to Auto Mode following auto start demand Start Demand AUTO Do you wish to change to Auto Mode Operating mode operation in Manual Mode WARNING AUTOMATIC start demand Im
9. Test piece Solder Copper External of test piece after the Not corrosion on surface excluding between examination test piece and spacer Discoloration is OK Circulation metallic causticity 7 0to 9 0 98 2 C 208 36 Fl pH change 1 0 1000 Hr Pre alkalinit o ke y change 15 30 vol E G Properties of 50 vol P G liquid after the Precipitation 1 0 vol examination NE Not remarkable discoloration separation External of liquid and gel Density Fe Cu Al Zn Pb 6 3 124 202 Chapter 6 COOLANT Table 6 2 LLC specification Property Standard Test piece Brass 0 30 mg cm Circulation metallic causticity 0 30 mg cm 8843 C External of test piece after the Not corrosion on surface excluding between do examination test piece and spacer Discoloration is OK 30 vol E G IL 6 5 to 11 0 Properties of liquid after the pH change Maximum 1 0 examination Not remarkable discoloration separation and gel Condition of Pump seal Not trouble while the examination parts Inside of pump case and blade Not remarkable corrosion Tensile strength change 60 to 0 Elongation change 40 to 20 Silicon Volume change O to 40 Hardness change 20 to 10 External of liquid Tensile strength change 0to 10 Rubber o adaptability Acrylonitrile Elongation change 15 to 15 30 vol butadiene 115 C 239 F rubber Volume change 0 to 40 ee Hardness change 10 to 0 T
10. Working hours counter Engine speed Battery voltage Fuel Level Air Preheating Standard specifications Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage 14 202 EN 2 2 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 l2 10 2 1 7 3 14 16 17 GROWPE ELE PLAQUE CONSTR CTROGENE GENERATING SET CTEUR MANUFACTURER PLATE PRESSION ACOUSTIOUE SOUND PRESSURE 50 HZ CE 61 TERE 78 6756 64 Execution Version Masse Kg i T maa GR Bo NO ATP te PUISSANCE ACOUSTIQUE SOUND POWER E mitten EL 200014 O Lwa 91 dB 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 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
11. gt T3 220 V gt T2 SERIAL CONNECTION PARALLEL CONNECTION Not possible with LSA 44 2 T3 T4 Voltage 50 60Hz R 251 voltage sensing 0 gt T1 110 V gt T2 Parallel connection AREP or PMG excitation J Single phase dedicated SHUNT version R 251 AVR no connection for 2000 2 wire output without terminal block LEROY 8 SOMER 176 202 LSA 43 2 44 2 4 POLE ALTERNATORS 3 3 2 Schema de connexion des options R 791 T interference suppression kit standard for CE marking Voltage potentiometer Connections OOO OW LSA 43 2 44 2 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 output as close 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 If 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 cu
12. 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 N m Grille screws M6 5 N m Cover screws M6 5 N m 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 Disconnect the 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 Remove the ball bearing 70 using a screw puller 3 aay gl ATS wy 1 Bee 4 6 5 2 Reassembly Heat the inner
13. DE shield Terminal block Air outlet grille Voltage regulator AVR Shield on exciter end AVR damper seal Tie rod Terminal block Cover front panel PMG housing Cover rear panel Adaptation shaft ae aS S Ss Ss OD OS Cover top panel Magnetic rotor Fixing screws Stator Air intake grille Fixing screws Inspection door Tie rod DE bearing Cable gland washer nut Bearing retainer fixing screw End plate Cable gland washer 43 2 only Hub 44 2 only Circlips Diode bridge assembly Inner bearing retainer lt AR a SC CC Ce Ce 349 Surge suppressor O ring 18 410 kh LEROY SOMER 186 202 End shield LSA 43 2 44 2 4 POLE ALTERNATORS SE 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 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 CEl 60034 1 et 60034 5 ISO 8528 3 Reciprocating internal combu
14. Drain After the engine has stopped drain engine oil from the engine oil drain port Note Draining by suction should be avoided mii a oil drain plug Fig 8 13 Engine oil drain plug 8 8 137 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine oil Refill 1 Make sure that the oil drain plug is tightened 2 Remove the oil filler cap 3 Fill the engine oil pan with specified engine oil to the specified level Note For engine oil refer to ENGINE OIL 5 1 For engine oil capacity refer to MAIN SPECIFICA TIONS 12 1 4 Check the oil level in the oil pan as follows 5 Pull out the oil level gauge and wipe it with a waste cloth 6 Insert the oil level gauge fully into the oil level gauge guide then pull out the gauge again 7 The proper oil level is between the high and low marks on the oil level gauge If the oil level is low add engine oil of the specified type 8 Check the oil pan and other area for oil leakage Repair any oil leakage found 9 Runthe engine with starter for approx 10 seconds while pulling the stop lever and feed engine oil to all parts of engine Stop the operation for 1 minute then repeat the operation two or three times Cir culate engine oil to all parts of the engine Note Prepare for the Cooling system 10 Check the oil level with the oil level gauge again and add oil to the specified level Oil filler Oil level gauge KG Hig
15. If the voltage oscillates use P3 to make ad justments try both directions observing the voltage between E and E approx 10V D C LEROY SOMER 9 197 202 LEROY SOMER R438 A V R The best response times are obtained at the limit of the instability If no stable position can be obtained try disconnecting or repla cing the ST2 jumper normal fast h Check LAM operation 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 value Adjustments in parallel operation Before any intervention on the alterna tor make sure that the speed droop is identical for all engines k Preset for parallel operation with C T connected to S1 S2 Potentiometer P1 quadrature droop in centre position Apply the rated load cos y 0 8 inductive The voltage should drop by 2 to 3 If it in creases check that V and W and also S1 and S2 have not been reversed I The no load voltages should be identical for all the alternators intended to run in pa rallel Couple the machines in parallel By adjusting the speed try to obtain 0 KW power exchange By altering the voltage setting P2 on one of the machines try to cancel or minimise the current circulating between the machines From now on do not touch the voltage set tings
16. LLC amine tye oreren aa 6 6 Pitting Of iron parts oooocccccnncccncnnnnconconancnnnonaness 6 6 Corrosion of aluminum Parts cccceeeeeeeees 6 6 Pitting and clogging of the radiator 6 6 Chapter 7 MAINTENANCE SCHEDULE How to use the maintenance A 7 1 Maintenance schedule 7 2 CONTENTS Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic engine iiitvecie des eenidaeieuaaweeeacenk 8 1 Belt and belt tension Inspect and Adjust 8 1 FUCL SS 8 2 Fuel tank Drain watter ccccseccceeeeceeeeeeees 8 2 Fuel filter Drain Water ccccceceeeeeeseeeeeaees 8 3 Fuel system in line type fuel injection pump A e eee 8 4 Fuel system distributor type fuel injection pump Bleed alf ooooccccocccnncccccnncononcnnnnnonos 8 5 Fuel filter in line type fuel injection pump PIC DIACC IPIOPOCPOPU OO0U0o o 8 6 Fuel filter distributor type fuel injection pump PURE DIAC S sarioa a 8 7 Lubricating SYStEM ccccseeeeseeeeees 8 8 Engine oil and Oil filter Replace 8 8 Cooling SySteM ccccoconccncccccnccconcnnonons 8 11 Coolant Change occccccoccnnccconcnnccnoncnnnnnnnnnnnnnns 8 11 Radiator fins Check and Clean 8 13 Inlet and exhaust systems 8 14 Air cleaner ChecCk ccooocccccococcccconccoccononanonos 8 14 Turbocharger InSpect occcccconcnccccoccnnn
17. 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 Particular attention must be paid to the tightness of the wheels on new vehicles Warming Lights signalling 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 Front reflective devices white Red rear lights direction indicators stop lights Rear reflective devices red triangle 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 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 Release the tow vehicle 000000 Engage the handbrake 30 202 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 L
18. 2 Output decreas aaa 11 2 Exhaust smoke is white or blue 11 4 Exhaust smoke is black or charcoal 11 5 Fuel consumption is high ooocccocccncnoo 11 6 Engine oil consumption is high 11 7 Overeating acia dd 11 8 Low engine Oil pressure ecceeeeeeeeeeeee ees 11 8 When fuel has run OUt occcccccc o 11 9 Chapter 12 MAIN SPECIFICATIONS Main specificatiONS oocccooccooo 12 1 CONTENTS 3 CONTENTS List of illustrations Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 D412 2 13 2 14 2 15 2 16 2 17 2 18 2 19 2 20 2 21 2 22 2 23 3 1 3 2 3 3 3 4 3 5 3 6 4 1 5 1 5 2 6 1 8 1 8 2 8 3 8 4 8 5 Engine left view cccccssseeeeseseeeeeees 2 1 Engine right Vie W ooocccnccncnccnncononcnnos 2 1 Engine left view ooccccoconcncccoonnnnns 2 2 Engine right ViOW cccccsesseeeeseeseeeeees 2 2 Engine left ViOW ccccccseeeeeesseseeeeees 2 3 Engine right ViOW cccccsseeeeeeseeeeeeeees 2 3 Engine left view cccccseseeessseseeeeees 2 4 Engine right ViOW cccccsssseeesssseeeeees 2 4 Engine left ViOW ccccccsese
19. 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter Drain water When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Drain water for the fuel filter if the warning of water draining for fuel filter is occurred 1 Place a drip tray under the drain hose 2 Loosen the drain plug and drain water from the fuel filter 3 Feed fuel by pushing down on the priming pump about seven strokes to facilitate draining 4 After draining tighten the drain plug securely 5 After drain the fuel filter bleed the fuel system For bleeding air from fuel system refer to Fuel system distributor type fuel injection pump Bleed air 8 5 Priming pump Fig 8 4 Fuel filter Drain water 2 8 3 132 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system in line type fuel injection pump Bleed air When fuel overflow from the air vent plug wipe thor xy While depressing turn coockwise Turn counter Move cap u oughly with a cloth Spilled fuel causes fire hazard clockwise and down After bleeding lock the priming pump securely lf the cap is not locked tightly the priming pump can be damaged causing a fuel leakage that could lead to a fire Tighten the priming pump before closing the air vent Lock release Priming plug Do not close all air vent
20. 4 to 13 F The validity term of the quality that provides with this specification is 2 years after it delivers with the indoor normal temperature keeping Chapter 6 COOLANT LLC specification LLC shall examine according to JIS K2234 section 7 examination methods and satisfy this specification General matters and the sample to the examination is shown in JIS K2234 Table 6 2 LLC specification Property Standard External Not precipitation Densit Minimum 1 112 g cm 69 4199 lb ft y 20 20 C 68 68 F Stock solution Water content Maximum 5 0 weight Stock solution 30 vol Maximum 14 5 C 6 F Frozen temperature l 50 vol Maximum 34 0 C 29 F Boiling temperature Minimum 155 C 311 F Stock solution pH 7 0 to 11 0 30 vol 30 vol Maximum 4 0 ml Bubbling character T e ane ASTM D 3306 01 5 aximum ml Disappearance of bubble l SPE VOL within 5 sec Hard water adaptability Maximum 1 0 50 vol Test piece Brass 0 15 mg cm Metallic causticit 1 Ar El External of test piece after the Not corrosion on surface excluding between 33642 Hr examination test piece and spacer Discoloration is OK 30 vol E G 50 vol P G Bubbling while examination Not bubbling overflow Properties of pH change 1 0 liquid after the precipitation Maximum 0 5 vol examination a Not remarkable discoloration separation External of liquid and gel Aluminum Cast ae E iron Steel Brass 0 30 mg cm
21. A tata 34 5 Preparation before operating INe Set iii A A A A ti A A dives 35 5 1 a anette r ae ee veceee erect 35 52 Checks after starting the generating Set cccccsssscccccessececcceeeceesceueeceeeeeeeeeeeeseueeeeesaueeceesseaeeeeessaaaeeeeeesaeaeceessuaeeeeessaeeeeeeseas 35 1 202 6 USING Meg enerator SEE assess e nd ds e Ie na aise Rene Sarton a uct ace hee o 36 6 1 Prestar Inspector A A goede raat ds 36 6 2 Generator set with NEXYS control panel ooccccnncccoccnnccnnnccccnnonnnnnnnnonononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnmnnnenoss 39 6 21 COMO panel presenta MOM ir iii 39 6 2 1 1 INTOdUCHON TO PISO Sic E E gekenceseuen 40 652 2 Waal Sta necia te tt e on de td ll tdo de e de do le e R 41 D 2 3 WENNO Ol aaa liinda E E 42 6 24 Alarms ana TAUS cirat a a a a e O E aaa tana S EE 42 6 2 3 Faults ana alarms DetallS saosna aA AEE N N 42 6 3 Generator set with TELYS Gono Pane iii E A tt at desea 44 63 PP CONIPOL Panel PreSenlalOMnissegst eet siete a de a capes e o ath 44 6 3 1 1 View ofthe font DA O A deed ork acer tend We cena tes eseears ea a Coates 44 6 3 1 2 DSSCHIDUON OL AMG SCE IV asst a odad 46 6 3 1 3 Description of the pictograms in zone Turina 47 6 3 1 4 Description Of the pictograms in ZONE 2 ccccccseececceeeeeceeeeeecaeeceeaaeeeeceueeeessueeeeaeueeesseueeesaueeessaueeeeessaeeeesaueeesseeeeesaaeees 48 6 3 1 5 Description orte pictograms IT ZONC Jene a a a ENSA 49 6 3 1
22. CE standard marking e g GOSSTANDART 7 Rated power factor 17 Sound pressure 8 Maximum altitude of the site above sea level m 18 Sound power for the rated power Figure 2 2 Example of generating set identification plate 15 202 2 3 Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Diagram 2 3 Fluid retention container The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers via the drain port v Note Never allow these fluids to drain onto the ground ensure they are collected in a designated container 2 4 Fuel and consumables All specifications product features are given in the engine maintenance manuals attached to this manual Fuels The specifications refer to European or international standards Fuels complying with the standards indicated in the engine maintenance manuals can be used without any contraindications Only these fuels may be used Consumables In addition to the specifications in
23. Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 8 6 8 7 8 8 8 9 8 10 8 11 8 12 8 13 8 14 8 15 8 16 8 17 8 18 8 19 8 20 8 21 8 22 8 23 8 24 8 25 8 26 8 27 8 28 8 29 8 30 8 31 8 32 10 1 10 2 Fuel filter Bleed air 8 4 Fuel injection pump Bleed air 8 4 Fuel filter Bleed air 1 8 5 Fuel filter Bleed air 2 8 5 Fuel filter Replace ooocccc o o 8 6 Fuel filter oooooonnccccccnnnnccocononnnnnnn oo 8 6 Fuel filter Replace cocoooo 8 7 Engine oil drain plug oooonccccnccc 8 8 Engine oil Refill 8 9 Oil filter Ghan E eaa 8 10 Ol TING ani ds ca 8 10 Radiator filler Cap 8 11 Coolant drain cock radiator 8 11 Coolant drain plug engine 8 12 Radiator coolant leve l 8 12 Reserve tank 2 0 eeeeseeeeeeeeesseeeeeeeees 8 12 Radiator fins Clean eseese 8 13 Air cleaner Check cceeeeeeeeees 8 14 Turbocharger INSpeCt ccee 8 14 Pre cleaner Clean cccccceeeeeeeees 8 15 Air cleaner element Remove 8 16 Air cleaner element Clean and A a wantatie 8 16 Air cleaner Check c cccccceeeeeee 8 16 Ba
24. Heavy Industries Ltd Increase clearance of sliding part Consult a dealer of Mitsubishi Heavy Industries Ltd 159 202 Chapter 11 TROUBLESHOOTING When fuel has run out When fuel runs out while engine is running and the engine has stopped restart the engine as described below 1 Return the starter switch to the OFF position 2 Add fuel to the fuel tank For filling fuel tank refer to Fuel tank oil level Check 3 2 3 Bleed air from the fuel system For bleeding fuel system refer to Fuel system in line type fuel injection pump Bleed air 8 4 or Fuel system distributor type fuel injection pump Bleed air 8 5 4 Restart the engine For starting the engine refer to Starting 3 4 11 9 160 202 Chapter 12 MAIN SPECIFICATIONS Main specifications Table 12 1 Main specifications ltem Specifications Engine model S4S DT Type 4 cycle water cooled turbocharged lesel engine diesel engine No of cylinders arrangement 4 cylinder in line Cylinder bore x stroke 94 x 120 mm 3 70 x 4 72 in Displacement 3 331 L 0 9 U S gal Conbustion type Direct injection system Compression ratio ed vary sce ee aestiens Firing order 1 3 4 2 Direction of rotation Counterclockwise as viewed from flywheel side Sess Cx WH SEB Dry weight 250 kg 551 Ibs Fuel Diesel fuel equivalent for JIS K 2204 Fuel injection pump In line type or distributor type VE type Fuel filter Cartridge type pape element with water sep
25. Insoluble includes acid products of engine oil imper fect combustion products sludge or soot metal abra sive particles and dust Insoluble is an indication of degradation contamination of oil Dispersant detergent which is an additive in engine oil absorbs sludge particles and disperses them as fine particles in oil Total insoluble density and remain ing dispersibility can be obtained by measuring insolu ble and coagulated insoluble using chemical specialities to stop action of disperse detergent and to collect the sludge dispersed in oil by which piston ring seizure or premature wear can be prevented before it occurs 5 3 Chapter 5 ENGINE OIL Service Limits of engine oil Engine oil degrades through the use and by lapse of time To determine the timing of engine oil replacement analyze the used oil and understand the condition of oil deterio ration and oil defacement It is also required to compare the oil analysis results and the engine analysis results including inside contamination and wear condition of engine and to consider the engine operating condition The engine oil affects the engine oil quality to use the engine operating condition and the quality of fuel Analyze the used oil and understand the condition of oil deterioration and oil defacement To determine the timing of engine oil replacement the stabiration of engine is required Refer to the following table for the determination of engine oil performance
26. Mitsubishi Heavy Industries Ltd tem Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries Ltd Check and clean radiator and radiator filler cap Refer to P8 13 Faulty radiator operation Check fuel injection pump rack stroke Control system Increase in load Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Low engine oil pressure Table 11 9 Low engine oil pressure Cause Remedies Check amount of engine oil and lubrication system Insufficient amount of engine oil Refer to P3 2 Faulty engine oil property viscos Analyze oil property Use appropriate engine oil ity Refer to P5 1 Lubricating l Check coolant system system Oil temperature too high o Consult a dealer of Mitsubishi Heavy Industries Ltd Oil filter clogged Inspect and replace oil filter Refer to P8 8 Faulty oil pump operation Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty relief valve operation Consult a dealer of Mitsubishi Heavy Industries Ltd Control Check control system and wire system Faulty pressure unit operation Consult a dealer of Mitsubishi Heavy Industries Ltd Check control system Increase in load Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine anaes Rapid wear of sliding parts Consult a dealer of Mitsubishi
27. Please note that depending on specifications items described in this manual may differ from those on your engine in shape or may not beinstalled on your engine Please contact a dealer of Mitsubishi Heavy Indus tries Ltd if you need more information or if you have any questions elf you lost or damaged this manual obtain a new copy at a dealer of Mitsubishi Heavy Industries Ltd as soon as possible Mitsubishi Heavy Industries Ltd recommends the engine owner to install an hour meter on the engine due to monitor correct running intervals and to per form the maintenance at the appropriate timing FOREWORD Warning indication The following means are used to call the attention of the operators and maintenance personnel to potential dangers of the engine Warning statements in the manual Warning labels affixed on the engine Warning statements The warning statements in this manual describe potential danger in operating inspecting or maintaining the engine using the following 5 classifications to indicate the degree of potential hazard Failure to follow these directions could lead to serious accidents which could result in personal injury or death in the worst case Understand the directions well and handle engines with following directions Indicates an immediately hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not av
28. Retighten i Every 1500 service hours Nozzle tip Clean Even 000 series fours Fuel injection nozzle Check and Clean Turbocharger Inspect 8 14 Every 2 years Coolant Change 8 11 As required Pre cleaner Clean Inspect and Replace 8 15 Air cleaner element Clean Check and Replace 8 16 Fuel filter Drain water 8 3 Fuel system in line type fuel injection pump Bleed air 8 4 Fuel system distributor type fuel injection pump Bleed air 8 5 Specific gravity of battery electrolyte Check 8 17 129 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic engine Belt and belt tension Inspect and Adjust If defects such as cuts or surface separations are found during inspection replace the belt Keep oil and grease away from the belt They may cause the belt to slip and shorten the service life Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt Adjust the belt tension accurately by following the procedures below Belt Inspect 1 Inspect the belt visually for separation or damage If any abnormality is found replace the belt with a new one 2 Inspect belt tension deflection Push the belt downward at the midway between pulleys If the deflection is 12 mm 0 47 in the tension is correct Belt pushing force Approx 98 N 10 kgf 22 Ibf If the deflection of belt is not within the standard adjust the belt tension Belt tension Alternator si
29. When running it indoors by necessity discharge the exhaust gas to outside and thoroughly ventilate the room Make sure the exhaust gas is not discharged directly to surrounding buildings plants or living passersby Exhaust gas from the engine contains carbon monox ide and other harmful substances Operating the engine in an poorly ventilated area can produce gas poisoning Be careful of falling down A During lifting process keep the engine in a well bal Lift engine carefully To lift the engine use slings capable of supporting the weight of the engine Attach the wire rope to the hangers provided on the engine using a cor rect sling anced position by taking the center of gravity of the engine into consideration Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident If the wire rope contacts the engine directly place a cloth or other soft padding to avoid damage to the engine and wire rope Do not climb onto the engine Do not climb onto the engine nor step on any engine parts located on the lateral sides To work on parts located on the upper section of engine use a ladder stool etc that was firmly secured Climbing on the engine may not only damage engine parts but also cause falling down from the engine and result in personal injuries Alwa
30. act vehicle restriction ordinance and other pertinent laws Chapter 2 NAME OF PARTS Engine external diagrams The external diagram is for the standard type of the engine The installed equipment and shapes differ according to the engine type S4S in line type fuel injection pump left view Enri PEA Fan Water pump coolant inlet Fuel injection pump l Fuel feed pump Crankshaft pulley Fuel inlet No drain plug Fig 2 1 Engine left view S4S in line type fuel injection pump right view Exhaust outlet Oil filler lo Rear hanger Flywheel housing Fig 2 2 Engine right view 96 202 Fuel injection nozzle Stop solenoid Air inlet Front hanger Coolant outlet p Thermostat case S ieee Belt Oil pan 2 1 Chapter 2 NAME OF PARTS S4S DT in line type fuel injection pump left view Fuel filter Governor S Stop solenoid Fuel injection nozzle Water pump coolant inlet a a He A HA ewig ii a ud i l ZLA a ot a Fuel return port Fuel injection pump Fuel feed pump Crankshaft pulley Fuel inlet Flywheel Oil drain plug Fig 2 3 Engine left view S4S DT in line type fuel injection pump right view Air inlet Turbocharger exhaust outlet Oil filler miee Front hanger Coolant outlet Rear hanger Thermostat case Flywheel housing A SF i LF lA a __ y Alternator Fig 2 4 Engine right view 2 2 97 202 Chapter
31. but also the distance between the batteries and the set voltage drops on the line 3 5 Protection for individuals and equipment 3 5 1 Earth connection 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 a galvanised steel earthing rod embedded vertically into the ground generating set earth socket 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 An Maximum resistance value of the earth socket R Q according to the differential unit operational current operation time should not be longer than 1 second An Earth R Earth R differential Q Q Ul 50 V Ul 25 V The Ul value 25 V is required for work site installations and livestock buildings etc 24 202 EN 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 Thick arable land IS 1 moist compact ballast Lean arable land 4 Gravel coarse ballast AATE E E To obtain an equivalent length you can use several earthing rods y a 3 6 connected in parallel a
32. connections Faulty AVR Speed too low when on load or LAM set too high Voltage between E and E Voltage correct Run at no load and check SHUNT lt 20 V AREP PMG lt 10 V Check the speed or LAM set too high at no load and the voltage between E Voltage between E and E Faulty rotating diodes 10 OW WC On ane OMe SHUNT gt 30 V AREP PMG gt 15V Short circuit in the main field Check the resistance load Faulty exciter armature Caution For single phase operation check that the sensing wires coming from the AVR are correctly connected to the operating terminals Voltage Check the AVR the surge The voltage does not return to the rated Exciter winding open circuit disappears suppressor the rotating value Faulty exciter armature during operation diodes and replace any Faulty AVR defective components Main field open circuit or short circuited Caution Internal protection may be activated overload open circuit short circuit LEROY SOMER 11 179 202 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 eje Cathode LSA 43 2 44 2 diode bridge O 0 0 000 G C C AAA 1 i FETS C GC C
33. dealer of Mitsubishi Heavy Industries Ltd Observe safety rules at work site Observe the safety rules established at your work place when operating and maintaining the engine Do not operate the engine if you are feeling ill inform your supervisor of your condition Operation of the engine with reduced awareness may cause improper operation that could result in accidents When working in a team for two or more people use specified hand signals to communicate among work ers Work clothing and protective gear Wear a hardhat face shield safety shoes dust mask gloves and other protective gear as needed When handling compressed air wear safety goggles a hard hat gloves and other necessary protective gear Works without wearing proper protective gear could result in serious injuries Never break seals To ensure proper engine operation the fuel control linkage is sealed to prevent accidental change of the injection volume and rotation speed settings Operat ing the engine without these seals in place can cause problems described below and also invalidates the warranty Rapid wear of sliding and rotating parts Engine damage such as seizing of engine parts Considerably increased consumption of fuel and lu bricating oil Degradation of engine performance due to improper balance between fuel injection volume and governor operation or overrunning of the engine which could result in a serious accident
34. each country in question and with the neutral system sold v 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 Korte v 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 v 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 eS 8 202 EN Protection aga
35. gt Description Terminal block support AREP Rotor assembly Terminal block Fan Voltage regulator AVR Fixing screws 44 2 only AVR damper seal Earth terminal Terminal block DE shield PMG housing Air outlet grille Adaptation shaft Shield on exciter end Magnetic rotor Tie rod Stator Cover front panel Fixing screws Cover rear panel Tie rod A A A dada da Ss O dd o d Cover top panel Cable gland washer nut oo IN Fixing screws End plate Air intake grille Hub 43 2 L7 amp 44 2 only Inspection door Coupling disc NDE bearing Fixing screws Preloading wavy washer Clamping washer 43 2 S1 to L6 Exciter field Spacer shim 43 2 L7 amp 44 2 only Exciter field fixing screw Diode bridge assembly Exciter armature Surge suppressor A nh Aj da Ss Ul Diode crescent support LEROY SOMER 185 202 O ring 17 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3434 en 2010 10 i 5 4 2 Two bearing LSA 43 2 44 2 Stator assembly N 5 Z NI SAY ANS Description PMG option Description Exciter field Rotor assembly Exciter field fixing screw Fan Exciter armature Fixing screws 44 2 only Diode crescent support Earth terminal Terminal block support AREP
36. knocks contact the transporter you may able to claim on their insurance and after a visual check turn the machine by hand to detect any malfunction 1 3 Identification The alternator is identified by means of a nameplate 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 e LSA Name used in the PARTNER range e M Marine C Cogeneration eT Telecommunications e 43 2 Machine type e M45 Model oJ Excitation system C AREP J SHUNT or PMG E COMPOUND e 6 4 Winding number number of poles 1 3 1 Nameplate So that you can identify your alternator quickly and 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 90 the machine insulation can drop very rapidly to just above zero at around 100 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
37. less Fed 791B 446 F 48 hrs at 180 C Aromatics substances by HPLC 35 by volume or less total of aromatic components Polycyclic aromatic content 8 by volume or less oe Asphaltene 0 1 weight or lower 115 202 Chapter 4 FUEL Table 4 1 Recommended limit and use limit of fuel property Properties Recommended limits Test method Foreign materials JIS B 9931 2000 foreign materials at engine fuel 5 0 mg liter or less ISO 4405 inlet Lubricity MWSD Measured mean 460 um 0 02 in or less a iene calculated wear scar diameter at ISO 12156 1 WS 1 4 kPa 0 0143 kgf cm 0 2031 psi perature BDF quality shall meet JIS K 2390 JIS K 2390 2008 EN14214 or ASTM D6751 FAME for aire peed FAME Fatty BDF blending of 5 by volume or less is approved mixture y Except in cases the value is specified ASTM D 6751 by the emission control EN 14214 Note When using fuel less than use limits white smoke worsening start up or unstable rotation may occur 4 3 116 202 117 202 Chapter 5 ENGINE OIL Recommended engine oil CAUTION Use only the engine oils recommended in this manual Never use other oils The use of inappropriate or inferior oils will result in sticking of piston rings seizure between piston and cylinder or premature wear of bearings and moving parts and significantly shortens the service life of the engine Many oil standards which are established through special engine tests are a
38. m Apply the available load the setting is only correct if a reactive load is available By altering the speed match the kW or di vide the rated power of the units proportionally By altering the quadrature droop potentiome ter P1 match or divide the currents 3 2 2 Max excitation setting excitation ceiling Depending on Main the mains frequency 50 60 Hz supply A Max excitation 50Hz 60Hz Field 5 ohms R 438 gt ST4 Voltage Static adjustment of the current limit potentiometer P5 factory setting 7 5 A fuse rating 8 A 10 seconds The maximum factory setting corresponds to that of the excitation current required to obtain a 3 phase short circuit current of approximately 3 IN at 50 Hz for industrial power unless otherwise specified A static method can be used to reduce this value oradaptthe Isc to the actual operating power derated machine which is safer for the alternator and the installation Disconnect power supply wires X1 X2 and Z1 Z2 and the voltage reference 0 110V 220V 380V on the alternator Connect the mains power supply using a transformer 200 240V as indicated X1 X2 48V Install a 10A D C ammeter in series with the exciter field Turn P5 fully anti clockwise and activate the power supply If there is no output current from the AVR turn potentiometer P2 voltage clockwise until the ammeter indicates a stable current Switch the power supply off t
39. of the valve to evacuate any accumulated dust particles Check the air filter clogging indicator B If the indicator is red clean the air filter 37 202 e Checking the fuel filters A When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Drain water for the fuel filter if the warning of water draining for fuel filter is occurred O Placea drip tray under the drain hose Loosen the drain plug and drain water from the fuel filter Feed fuel by pushing down on the priming pump about seven strokes to facilitate draining O After draining tighten the drain plug securely After drain the fuel filter bleed the fuel system For bleeding air from fuel system Priming pump For bleeding air from fuel system O Loosen the air vent plug on the fuel filter about 1 5 turns Apply a cloth to the air vent plug Repeat pumping until the fuel flow from air vent plug becomes free of bubbles O Tighten the air vent plug and clean Priming pump Air vent plug 38 202 6 2 Generator set with NEXYS control panel 6 2 1 Control panel presentation OSOQOOVWOOHAOOoON O MICS a og mas 300 Fig 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 startin
40. of viscosity index improver in oil decrease the viscosity and degrade the performance of viscos ity which will cause insufficient lubrication and friction wear of engine parts Total base number Total base number TBN shows the ability to neutral ize acids such as organic acid due to engine oil oxida tion or sulfurous or sulfuric acid due to the sulfur content of fuel Because TBN indicates the amount of dispersant detergent in oil it can be used to estimate consump tion of basic dispersant detergent The ability to dis perse sludge declines as dispersant detergent is used Up Total acid number The total acid number in oil increases as the organic acid is being derived by the engine oil oxidation or sulfurous acid or sulfuric acid derived by the combus tion of sulfur content of fuel or the oil becomes con taminated with imperfect combustion products An increase in the total acid number will result in cor rosion or wear of the inner parts of the engine such as cylinder liners or metal due to sulfur content and piston ring seizure due to sludge 120 202 Water content Water in oil promotes corrosion wear and decreases lubricity in sliding parts Flash point The flash point is lowered by contamination with fuels Flash point is measured to check the dilution of fuel The dilution of fuel reduces oil film and causes insuffi cient lubrication that will cause friction or wear of engine parts Insoluble
41. outlets in use e fthe generating set s residual current device is adjustable located upstream this must be above those devices located downstream terminal circuits this means that continuity on clean circuits will be maintained in the event of a fault on one of the terminal circuits Example Generating set 300mA Generating sets residual i current device Residual current device Residual current device Residual current device SOMA Terminal circuit 1 30mA Terminal circuit 2 30MA Terminal circuit 3 Any change to the setting on the generating set s residual current device could pose a risk to personal safety The user will be held liable any changes must only be made by trained qualified engineers When the generating set is disconnected from an installation after use the general residual current device must be restored to factory settings by a qualified engineer who can then check this 26 202 N 3 5 5 Adjusting the genset differential protection Before adjusting the settings on the generating set s residual current device the following two parameters must be taken into account the sensitivity of the current threshold and the activation time The generating set s residual current device must have in relation to the downstream device terminal circuit a sensitivity three times greater a longer cut off time Type A AC Time setting potentiometer Current threshold adjustmen
42. panel provided for this purpose After operational testing replace all access panels or covers LEROY SOMER 9 177 202 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE 3434 en 2010 10 i 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 cannot be 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 approximately 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
43. plugs and cocks before lock Fig 8 5 Priming pump Handle ing the priming pump as the priming pump will not return to the original position due to internal pres sure Bleed air at fuel filters and then at the fuel injection pump Bleeding from upstream to downstream is effective for this job Fuel filter Bleed air If air vent plugs the thread portion of the bracket or sealing washers are damaged replace them with new ones 1 Loosen the air vent plug on the fuel filter about 1 5 Fuel filter turns N Turn the priming pump counterclockwise to unlock and prime the fuel filter A When the fuel from the air vent plug becomes free from air bubbles stop priming and tighten the air Fig 8 6 Fuel filter Bleed air vent plug to the specified torque Fuel injection pump Bleed air 1 Loosen the air vent plug on the fuel injection pump by rotating about 1 5 turns 2 Move the priming pump up and down When the fuel flow from the air vent plug becomes free of bubbles push and turn the priming pump clockwise to lock 3 Tighten the air vent plug on the fuel injection pump Fig 8 7 Fuel injection pump Bleed air 8 4 133 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system distributor type fuel injection pump Bleed air WARNING When handling fuel make sure there are no open flames or other fire hazards near the engine When fuel overflows from the air vent plug
44. removing the air cleaner or pre cleaner immediately cover the opening inlet port of air cleaner port in body for pre cleaner with plastic sheet or similar means to prevent foreign materials from entering the engine Clean the pre cleaner periodically The pre cleaner clogging can cause insufficient intake air or increasing in the exhaust temperature lf the engine is equipped with a dust indicator con duct maintenance when the clog warning sign ap pears 1 8 95 202 Use of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace them with new tools Avoidance of prolonged time of starter operation Do not use the starter for more than 10 seconds ata time If the engine does not start wait for at least 1 minute before cranking again Continuous operation of the starter will drain the bat tery power and cause the starter to seize Do not turn off the battery switch during operation Do not turn off the battery switch during operation If the battery switch is turned OFF when the engine is running not only various meters will stop working but also the alternator may have its diode and transistor deteriorated Cautionary instructions for transporting the engine When transporting the engine on a truck consider the engine weight width and height to ensure safety Abide by road traffic law road vehicles
45. sets some engines may be fitted with specific electrical wiring different to that described in the engine documentation 3 202 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 Warning danger Warning risk of electric shock Warning toxic materials Warning pressurised fluids Warning high temperature risk of burns Warning rotating or moving parts risk of getting caught in the machinery Publications delivered with the generating set must be referred to Protective clothing must be worn Your eyes and ears must be protected Periodic maintenance must be carried out Battery level must be checked Lifting point required Figure 1 1 Pictograms and their meanings 4 202 Warning risk of explosion Naked flames and unprotected lights prohibited No smoking Entry prohibited to non authorised persons Jet washing prohibited Warning corrosive product IN OUT Battery isolating switch ie External fuel connections Retention container drainage Fuel drainage Inspection hatch Oil drainage Oil filling Coolant filling Coolant drainage Forklift
46. supercharger systems E Charged air cooling systems 3 Exhaust gas recirculation EGR system A EGR valve body and carburetor spacer if applicable B EGR rate feedback and control system 4 Air injection system A Air pump or pulse valve B Valves affecting distribution of flow C Distribution manifold 5 Catalyst or thermal reactor system A Catalytic converter B Thermal reactor C Exhaust manifold 6 Particulate controls A Traps filters precipitators and any other devices used to capture particulate emissions B Regenerators oxidizers fuel additive devices and any other device used to regenerate or aid in the regeneration of the particulate control device C Control device enclosures and manifolding D Smoke puff limiters 7 Advances oxides of nitrogen NOx controls A NOx absorbers B Lean NOx catalysts C Selective catalyst reduction D Reductant urea fuel containers dispensing systems 8 Positive crankcase ventilation PCV system A PCV valve B Oil filler cap VI 77 202 FOREWORD 9 Miscellaneous items used in above systems A Vacuum temperature and time sensitive valves and switches B Electronic control units sensors solenoids and wiring harnesses C Hoses belts connectors assemblies clamps fittings tubing sealing gaskets or devices and mount ing hardware D Pulleys belts and idlers E Emission control information labels F Any other par
47. 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 INS _ALTERNATEURS 2 121 11 19 77 ALTERNATORS LsA date N Lz Min 1 R P M JProtection Cos P F Cl ther Th class R gulateur A V R Altit _ m Masse Weight Rit AV D E bearing RItAR N D Ebearingl Graisse Grease Valeurs excit Excit values en charge full load L vide at no load PUISSANCE RATING Tension Voltage 400 AO eG E IE A LEROY 4 SOMER 172 202 LSA 43 2 44 2 4 POLE ALTERNATORS 2 TECHNICAL CHARACTERISTICS 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 Interfere
48. the low level marker Important O Pull out the oil level gauge and wipe it clean using a waste cloth 9 insert the oil level gauge fully into the oil level gauge guide then pull out the gauge again The proper oil level is between the high and low marks on the oil level gauge If the oil level is low add engine oil of the specified type 4 Install the oil filler cap after refilling O Check the oil pan and other area for oil leakage Oil filler s j E Oil level gauge High b ii Improper Proper Low L Improper mel level i 5 ey O aa ee Y 36 202 e Checking the coolant level over the cap and loosen the cap about a half turn or stand the lever to the upright position to release internal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it A Remove the radiator filler cap only after the engine has cooled to room temperature Place a waste cloth Turn the cap about Stand the lever to half a turn the upright position AIDA a a NAT SS O Open the radiator filler cap and check the coolant level if the coolant level is low add coolant to the speci fied level Check for leaks in the cooling circuit e Checking the air filter A clogged filter element limits the engine s air intake and a reduced air supply to the engine Important If the air filter is fitted with a dust control valve A press the tip
49. the vehicle in which the engine is installed is registered in the state of California a separate California emission regulation also applies vis free from the defects in material and workmanship which will cause the engine to fail to meet these regulations within the warranty period Then its warranty period is The emission warranty period is shown below However if your engine warranty period is longer than the emission warranty period the emission warranty period extends to same as the engine warranty period Below warranty period shall begin on the date the engine is delivered to the first owner If your engine is certified as Then its warranty period is er speed or constant E or 2 years whichever Constant speed la or 2 years whichever Constant speed Seda ee or 5 years whichever Variable speed sited a or 5 years whichever ae speed or constant 3000 hours or 5 years whichever Warranted parts Mitsubishi Heavy Industries Ltd warrants the parts which will increase the emission of pollutants when they become defective The followings are examples Inlet Exhaust manifold Crankcase ventilation system Fuel system Fuel injection nozzle LIMITED WARRANTY Refer to LIMITED WARRANYT 74 202 FOREWORD California emission control warranty statement your warranty rights and obligations IMPORTANT The following warranty applies to the engines that are approved of the emission regulation of the California Air Resour
50. time as a fault 6 2 5 Faults and alarms Details List of faults which will cause the generating set to stop and generate a pictogram Associated pictogram E lt E Lid Oil pressure fault Indicates that the oil pressure is incorrect Associated pictogram Engine temperature fault Indicates that the engine temperature is too high Associated pictogram Non starting fault Indicates that there have been three consecutive unsuccessful starting attempts Associated pictogram O Sa e ri Overspeed fault Indicates an excessive generating set ltt running speed Associated pictogram Sad Low fuel level fault Indicates the need to top up the fuel 42 202 EN List of faults which will cause the generating set to stop and generate a fault code Associated message Low coolant level fault indicates that the level of coolant is low in the radiator linked to a two second time delay Or Overload or short circuit fault optional with the circuit breaker SD contact closing overload or short circuit the generating set switches off immediately also causing the main circuit breaker to be triggered Additional fault linked to message opposite is displayed in the following two cases Associated message gt Differential fault 1 gt insulation fault 2 EONA E 1 Differential fault optional with a differential fault LI causing the activation of the differential r
51. up start of a cycle comprising 3 attempts to start up the engine v The following screen appears 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 41 202 6 2 3 Switching off O trigger the circuit breaker located at the base of the centre console Let the motor run under no load for 1 to 2 minutes to allow it to cool press the STOP button to stop the generating set O switch off the MICS Nexys module by switching the key to OFF without forcing it 6 2 4 Alarms and faults The appearance of a fault or an alarm causes the following O a ai screen to be displayed one or more pictograms or a fault El ef Lt pa code along with the SOS message are displayed A O Tm LA ILI AUT A o A The user can access the following screens by pressing the key O 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
52. 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 Y 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 v Be sure to evacuate exhaust gases outdoors v Provide appropriate ventilation so that personnel present are not affected 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
53. ventilation guards are corroded or scratched 4 2 3 Bearings The bearings are permanently greased approximate life of the 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 6000 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 Regreasing interval 10 000 hrs 4 2 4 Electrical servicing Cleaning product for the windings CAUTION Do not use trichlorethylene perchlorethylene trichloroethane or any alkaline products Certain 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 cle
54. volatile corrosion Prevention of rust in air intake system inhibitor Maintenance during storage Charge the battery once a month First check the battery electrolyte for proper level and then charge the battery 9 1 148 202 Chapter 9 LONG TERM STORAGE Using the engine after storage 1 Remove the cover from the engine 2 Connect a fully charged battery 3 Remove the covers from the starters and alternator 4 Adjust the tension of belt Note Inspect and adjust V belt tension Refer to Belt and belt tension Inspect and Adjust 8 XX 5 Remove sealing tapes from the openings of the engine 6 Connect pipes Note For engine oil refer to ENGINE OIL 5 1 7 Fill the fuel tank with fuel and bleed the fuel system Note For bleeding fuel system refer to Fuel system in line type fuel injection pump Bleed air 8 4 or Fuel sys tem distributor type fuel injection pump Bleed air 8 5 8 Inspect the entire engine 9 Remove the rocker covers and lubricate the valve mechanisms 10 Run the engine with starter for approx 10 seconds while pulling the stop lever Stop the operation for approx 1 minute then repeat the operation two or three times 11 Make sure the engine oil pressure rises 12 Conduct a warm up operation for a sufficient duration Note For starting the engine refer to Starting 3 4 13 Apply load and increase the engine speed to the rated speed Storing the e
55. wipe thoroughly with a cloth Spilled fuel can ignite and cause a fire After replacing fuel filter or draining water from fuel fil ter or when running out of fuel bleed the fuel system as follows 1 Loosen the air vent plug on the fuel filter about 1 5 turns 2 Apply a cloth to the air vent plug 3 Repeat pumping until the fuel flow from air vent plug becomes free of bubbles 4 Repeat pumping until the fuel flow from air vent plug becomes free of bubbles Priming pump Fig 8 9 Fuel filter Bleed air 2 8 5 134 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter in line type fuel injection pump Replace When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Clean the area around the fuel filters Place a fuel tray under the fuel filter Using a filter wrench remove the fuel filters a 2 MPS Wipe off fuel on the fuel filter cartridge mounting surface of the filter bracket with a waste cloth 5 Check new fuel filters for proper seating of the gas ket Do not use a filter with the dented case Fillter dam age or fule leakage may occur and it can cause fire hazard 6 Apply clean fuel to the gasket on the new fuel filter 7 Install the fuel filter to the filter bracket Do not use a filter wrench to install the fuel filter Do not dent or scratch the
56. 02 Reset button Fig 8 23 Air cleaner Check Turbocharger Fig 8 24 Turbocharger Inspect Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Pre cleaner Clean Inspect and Replace A CAUTION Never service the pre cleaner while the engine is running Servicing the air cleaner while the engine is running can cause particles of foreign matter to enter the engine and result in rapid wear of parts leading Wash v2 Rinse to a shorter service life of the engine NX The pre cleaner is equipped to the silencer of the tur pa SN Install bocharger to prevent foreign items from sucking and Dry keep the engine clean for optimum performance Be sure to clean the pre cleaner as described below Fig 8 25 Pre cleaner Clean 1 Remove the pre cleaner from the silencer and hand wash the pre cleaner with a mild detergent Rinse the pre cleaner with fresh water After drying thoroughly inspect the pre cleaner for defect If any defect are found replace the pre cleaner with a new one oN 4 After cleaning inspecting or changing the pre cleaner reinstall it to the silencer 8 15 144 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air cleaner element Clean Check and Replace When handling compressed air wear safety goggles a dust mask a hardhat gloves and other necessary protec tive gear Works without wearing proper protective gear could result in serious injur
57. 1 22 to 1 26 Charged Charge 7 Fig 8 30 Specific gravity of battery electrolyte Check 8 17 146 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Starter Inspect Visually check the starter for damage If the starter is dusty blow dirt using compressed air Note If the starter is defective consult a dealer of Mit subishi Heavy Industries Ltd Alternator Inspect Visually check the alternator for damage If the alternator is dusty blow foreign material using compressed air Alternator Remove the belt and check that the movement is smooth when rotating the pulley by hand Note If the alternator is defective consult a dealer of Mitsubishi Heavy Industries Ltd 8 18 147 202 Fig 8 32 Alternator Inspect Chapter 9 LONG TERM STORAGE Long term storage The following describes how to store the engine in a non operable condition for 3 months or more and in an opera ble condition for 3 months or more If the engine has been left unattended for 3 months or more the internal engine parts can rust and that may cause damage to the engine When storing the engine for an extended period of time be sure to follow the directions below Storing the engine in a non operable condition for 3 months or more ig ple for storage Drain the engine oil in use pour new oil Prepare a fuel mixture containing 50 rust preventive oil NP 9 and fill the fuel tank with it Operate under non load
58. 2 50 0 50 0 70 2 0 Oo 80 8 OO 95 4 0 95 4 0 120 2250MCM 22 202 3 4 3 Power connections Disconnect the battery leads or use the battery isolating switch before carrying out any operations on the generating set To disconnect the battery disconnect the negative lead first Warning Open the access hatch to the power section Feed the power cables through the access hatch on the genset control unit Connect the power cables to the bars N LO L1 L2 L3 or N2 R2 S2 T2 Connect the power cables to the installation ensuring the live and neutral wires are correctly connected SA Acces hatch s a N LO L1 L2 L3 or or or or N2 R2 S2 T2 USE Ensure that the direction of rotation of the phases is identical on the genset and the installation Our gensets are factory set with a conventional direction of phase rotation 23 202 EN 3 4 4 Battery installation 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
59. 2 NAME OF PARTS S4S distoributor type fuel injection pump left view Fuel inlet ae Fuel injection nozzle F uel filter Air inlet Fan IC Fuel return port Water pump E Sl S coolant inlet aa er Magnetic valve EN EOS OSADO stop solenoid A OoOo Ae a D E O A LIE COX y Coolant drain plug Crankshaft pulley LS A Oil level gauge Fuel injection pump well Ex Flywheel Oil filter Oil drain plug Fig 2 5 Engine left view S4S distoributor type fuel injection pump right view Exhaust outlet Front hanger Oil filler Coolant outlet Rear hanger N AL Thermostat case DO a ere ZO maf Alternator e ps lo 4 2 E Flywheel housing 62 TN sm SS US L JO kig gt m tt ail Y a z Va 5 Et r O O Belt LM Fig 2 6 Engine right view Oil pan 98 202 2 3 Chapter 2 NAME OF PARTS S4S DT distoributor type fuel injection pump left view Fuel inlet Fuel injection nozzle Fuel filter DA Y A N E J Water pump H Ih coolant inlet Magnetic valve stop solenoid Crankshaft pulley Fuel injection pump Oil drain plug Fig 2 7 Engine left view S4S DT distoributor type fuel injection pump right view Turbocharger Exhaust outlet AIEE Front hanger Oil filler mv Coolant outlet co O in i h JIO j Rear hanger A Thermostat case ln AE O 3 Flywheel housing Fig 2 8 Engine right view 2 4 99 202 Chapter 2 NAME OF PARTS
60. 4 POLE ALTERNATORS Installation and maintenance 169 202 LSA 43 2 44 2 4 POLE ALTERNATORS 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 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 WARNING SYMBOLS
61. 5 Cautions when operating ccccccoccnccccccnnncnnnoo 3 5 Inspection during operation 00 ceeeeeeeeees 3 5 SIP pd did 3 6 Inspection after StOppinNQ occcococnnccccnnccnncnnnnno 3 6 Chapter 4 FUEL Recommended fuel o ooo 4 1 Handling Melia iaa aaa 4 1 Chapter 5 ENGINE OIL Recommended engine oil 9 1 Selection of Oil vViSCOSItY 5 1 Handling engine Ol oo o o 5 1 Engine oil performance requirements 5 2 Engine oil deterioration mechanisms 5 2 Definition of properties of engine oil 5 3 MISCO urinarias 5 3 Total Dase numMbDer cionconioinicacos ataca snacadcincins 5 3 Totallacid Numbers da ate eee 5 3 Water Content etica 5 3 cn eeteaas 5 3 INSOlUIDlScnactntas aii elo il iicala lis 5 3 Service Limits of engine 0il 5 4 CONTENTS 2 83 202 Chapter 6 COOLANT Recommended water for coolant 6 1 Long life coolant LLC 6 1 Genuine LLC scsi ote iciisda 6 1 Other brand BEC Stcserat das 6 2 Standard for other brand LLC 6 2 General demands of LLC neccen 6 2 LECFSpociica lO Naci rs 6 3 Maintenance of LLC accenn 6 5 Replacement intervals of LLC ee 6 5 LEC CONCONtT Alec 6 5 Importance of LLC cooccccconcccccnncnnnnnn os 6 6 Characteristics of LLC additive and Important notes ccccoccnccnccncnnoninnnns 6 6 Examples of abnormalities caused by
62. 500 V compatible with parallel operation Disconnect ST1 to connect the module set the voltage via the module po tentiometer R 734 module detection of 3 phase current and voltage for parallel operation on unba lanced installations imbalance gt 15 R 726 module 3 functions mounted exter nally P F regulation 2F and voltage sensing cir cuit before paralleling 3 F Control through DC voltage used monito ring apply to the terminals for connection of a potentiometer DC voltage e internal impedance 1 5 kQ e 0 5V enable a voltage setting of 10 LEROY SOMER 196 202 LEROY SOMER R438 A V R 3 INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wi ring diagram Check that the ST3 frequency selection jumper is on the correct frequency setting Check whether the ST4 jumper or the re mote adjustment potentiometer have been connected Optional operating modes e ST1 jumper open to connect the R 7310r R 734 3 phase sensing module e ST2 jumper open if rapid response time used e ST5 jumper open to suppress the LAM function 3 2 Settings The machine is tested and set at the fac tory When first used with no load make sure that the drive speed is correct and stable see the nameplate After opera tional testing replace all access panels or covers The only possible adjustme
63. 6 Display ol Messages Zone dt A EEE DA ARS AT aE 51 A A A ee 55 AS A icaise acc aeoe acata cute teacecscenasaanestasce desma cadnaens ecsecudaeunseacee N 56 034 Alas and tall sd sa 56 6 3 4 1 VI WINO AlAMMNS ana taula oi s 56 6 3 4 2 ACUV ATOM aia 57 6 3 4 3 ActiVation or an alarm anda la A A tau sad et 58 6 3 4 4 Emo ine tault codes dis Plain is 59 6 3 4 5 PONTIO A ee re tet ree et PRC POR ETO Cele EE OOO RRC a een eT ree er ee ee 60 Ta MealMtenancesschequlS pegia ea ii ideo 60 7 1 REMINaer Ol US tt E A dre lts 60 72 Maintenance safely TAS CIO a een eel aks 60 7 3 Table of Maintenance Opera br a aa A AA A sere 61 7 4 A A eZee ree 62 7 5 NG load and under load testera a linda eE 62 SBAEN cr E E E I E EE E E 63 8 1 Storage and anspor nas e eo lt a a la Ll date a Bile OA 63 8 2 Battery setting INTO SANMIC epastboaenneteanedulnseanmcananonedcake 64 8 3 TNS CN A A neta a 64 8 4 Mole Moi r2 110 AAA a aa a a aa 65 8 5 aS eG e medie S oere a a a a a a 66 o A 67 9 1 Appendix A Engine user and maintenance Manual cccccssccccceeeecceeececceuseecceeeecsaucesseueeecseeeessaseesessaueeessaueeessaeeesseeees 67 9 2 Appendix B Alternator user and maintenance Manual occccoccncoccnccccncconcncnnnncnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnninnncns 165 2 202 1 Preface 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been desi
64. 94 202 Perform all specified pre opera tion inspections and periodic inspections Conduct the pre operation inspections and periodic inspections as described in this manual Failure to conduct the specified inspections may cause various engine problems damage to parts and serious accidents Break in the engine To break in new engines or overhauled engines oper ate the engine at a speed lower than the rated speed in a light load condition during the first 50 hours of operation Operating new engines or overhauled engines in a severe condition during the break in period shortens the service life of the engine Warm up the engine before use After starting the engine run the engine at low idling speeds for 5 to 10 minutes for warm up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lubricated before they are subjected to heavy loads Warm up operation circulates lubricants in the engine and contributes to a longer service life and economi cal operation Do not conduct warm up operation for prolonged period of time Prolonged warm up operation causes carbon build up in the cylinders that leads to incom plete combustion Never operate the engine in an overloaded condition If the engine shows an overloaded condition such as black exhaust smoke reduce the load immediately to operate the engine at an appropriate outp
65. Air Resources Board 2 Free from defects in materials and workmanship which cause the failure of a warranted part to be identical in all material respects to the parts as described in Mitsubishi Heavy Industries Ltd s application for certifi cation for a period of 5 years or 3 000 hours of operation whichever occurs first In the absence of a device to measure hours of use the engine shall be warranted for a period of 5 years For all engines rated less than 19kW and for constant speed engines rated under 37 kW with rated speeds higher than or equal to 3 000 min the period of 2 years or 1 500 hours of operation whichever occurs first shall apply In the ab sence of a device to measure hours of use the engine shall be warranted for a period of 2 years c The warranty on emission related parts shall be interpreted as follows 1 Any warranted part which is not scheduled for replacement as required maintenance in the written instruc tions required by Subsection e shall be warranted for the warranty period defined in Subsection b 2 If any such part fails during the period of warranty cove rage it shall be repaired or replaced by Mitsubishi Heavy Industries Ltd according to Subsection 4 bebw Any such part repaired or replaced under the war ranty shall be warranted for the remaining warranty period 2 Any warranted part which is scheduled only for regular inspection in the written instructions required by Sub section e shal
66. CroppPed ccccceeeeeeceeeseeeseees 1 4 Be careful when handling fuel engine OOM Sado 1 5 Use only specified fuel engine oil and LLC 1 5 Handle LLC carefully occoocccocncccnccocnno 1 5 Proper disposal of waste oil LLC and A Gene 1 5 When abnormality OCCUFS 1 5 82 202 Do not add coolant immediately after a sudden stop due to OverheatinQ ccooccoccocccocnnoncncnnnnons Avoid immediate restart after abnormal stop 1 5 Avoid continuous engine operation at low oil DIOS SURG ad ali 1 5 If belt breaks stop engine immediately 1 5 Service battery ooocccocccocccnonocononos 1 6 Handle the battery correctly o 1 6 Other CAU ION Sisi dliti 1 7 Never modify engine occcoccccccccocccccnconncnanonnns 1 7 Observe safety rules at work site 1 7 Work clothing and protective gear 1 7 Never break seals occooccocooccocioccconionionnns 1 7 Perform all specified pre operation inspections and periodic InSpectiONS occooccoccconccnnnocnnnno 1 7 Break in the engine ooocooccccccncccoconcncononononcnnnns 1 7 Warm up the engine before US e o 1 7 Never operate the engine in an overloaded 610 6 hi IM lc ee ean 1 7 Conduct cooling operation before stopping the engine Protection of the engine against water entry 1 8 Properly maintain the air c
67. Fuel consumption is high Cause Remedies Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Improper fuel property Use appropriate fuel Refer to P4 1 Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Check radiator Refer to P8 13 Cooling o led eCheck control system system E Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Insufficient amount of air Refer to P8 16 n and Check intake air pressure and leakage of intake air se Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd 157 202 Chapter 11 TROUBLESHOOTING Engine oil consumption is h
68. IS AS E 4 8 6 Dedicated single phase LSA 44 2 4 pole SHUNT excitation 60 Hz only Resistances at 20 C 0 LSA 44 2 Stator L N Armature VS3 0 0194 0 5 VS45 0 0194 0 5 S7 0 0140 0 5 M95 0 0088 0 5 Field excitation current i exc A 240 V 60 Hz i exc excitation current of the exciter field LSA 44 2 no load on load VS3 0 44 1 18 VS45 0 44 1 25 S7 0 43 1 2 M95 LSA 43 2 0 55 4 9 Table of weights Total weight kg 1 28 Rotor kg S1 220 76 15 220 220 76 240 2 0 80 90 M45 L65 290 102 LSA 44 2 Total weight kg Rotor kg VS3 405 140 VS45 405 140 S7 460 165 S75 460 165 M95 515 185 L12 LEROY SOMER 183 202 570 210 15 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 Designation LSA 43 2 44 2 SHUNT Code AVR R 250 AEM 110 RE 019 R 251 AEM 110 RE 021 Diode bridge assembly LSA 4329100 ALT 432 KD 001 Surge suppressor LSA 4321 13 AEM 000 RE 126 AVR fuse Designation 250 V 8 A slow blow LSA 43 2 44 2 AREP 4 P Code AVR R 438 AEM 110 RE 017 D
69. KAGE 9 o d i 5 ee a a SD Ga YOKE 3 LINKAGE CASING STOP ae 12 A SETTING SCREW 8 ___ AUTOMATIC BACKWARD JAW WM SIMPLE JAW E RETRACTOR Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 32 202 EN 4 7 Faults and repairs Faultobserved Origin ____ Soltions ____ Braking too weak the towing vehicle are in the same horizontal plane eii Remove the dust Damage to slide guide rings Replace the rings and possibly the slide and grease Faulty shock absorber Replace the shock absorber Cross bar s not balanced Adjust the cross bar s Jerky braking Different brake setting on the two sides Adjust the brake settings Trailer tending to swerve upon braking Cables damaged or incorrectly fitted data ee parts Poor load distribution Check the load distribution Damage to slide or to guide rings Replace the faulty parts and grease Slide corrosion Remove the corrosion and grease When starting the trailer holds back the Tie rod damaged Mep are E iene ARE AOSE NE settings towing vehicle Linkage damaged or incorrectly set pepe oe A aja 9 9 y the settings 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 Parking braking too weak Notched sector damaged 33 202 EN 4 8 Electrical connection dia
70. LI Option R731 3 ph detection Ni in 3 ph detection ST1 open Single phase detection LEROY SOMER 193 202 LEROY SOMER R438 A V R 2 R438A V R 2 1 Characteristics Storage 55 C 85 C Operation 40 C 70 C Standard power supply AREP or PMG Rated overload current 8A 10s Electronic protection overload short cir 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 e 0 110 V terminals 95 to 140 V e 0 220 V terminals 170 to 260 V e 0 380 V terminals 340 to 520 V Voltage regulation 1 Normal or rapid response time via ST2 jumper see below Voltage adjustment via potentiometer P2 other voltages via adapter transformer Current sensing parallel operation C T 2 5 VA cl1 secondary 1 A optional Quadrature droop adjustment via potentio meter P1 Max excitation current adjustment via P5 see below 2 1 1 Configuration jumpers function Delivrery config Open Closed ST1 45h Open for module pn installation tri detection ST2 Fast Response time ST3 50 ou 60 Hz Frequency selection External ST4 potentio meter ST5 Without with LAM Others P
71. MG Uno Potentiometer LAM voltage drop amplitude U f function bend position 13 or 25 2 1 2 Setting potentiometers function Delivrery position NE Quadrature droop operation with C T Voltage S tability xcitation current ceiling 2 2 Frequency compared with voltage without LAM Voltage A Bend 57 5 Hz 48 HZ 4 4 100 U UN 50 Hz A 60 Hz Frequency Hz 60 Hz 2 3 LAM Load Acceptance Module characteristics 2 3 1 Voltage drop The LAM system is integrated in the R 438 AVR as standard Role of the LAM Load Adjustment Mo dule On application of a load the rotation speed of the generator set decreases When it passes below the preset frequency thres hold the LAM causes the voltage to drop by approximately 13 or 25 and conse quently the amount of active load applied is reduced by approximately 25 to 50 until the speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its dura tion for a given applied load or to increase the applied load possible for one speed va riation turbo charged engine To avoid voltage oscillations the trip thres hold for the LAM function should be set ap proximately 2 Hz below the lowest frequen cy in steady state LEROY 6 SOMER 194 202 LEROY SOMER Installation and maintenance R438 A V R LAM action eli
72. ROUBLESHOOTING Output decrease Table 11 3 Output decrease Cause Remedies Improper fuel property Use appropriate fuel Refer to P4 1 Inspect and replace fuel filter Refer to P8 6 or Clogged fuel filter Refer to P8 7 Gauze filter Clean Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Check fuel injection pump rack stroke Improper amount of injected fuel O l Consult a dealer of Mitsubishi Heavy Industries Ltd Check fan and radiator en Overheat overcooled Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Insufficient amount of air Refer to P8 16 Inlet and Check intake air pressure and leakage of intake air ee Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Hea
73. TORS 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 torque and check that ther
74. TURE SUITABILITY e Provides good conditions for thermal exchange e Perfect stability at high temperatures e GenCOOL PC 26 is specially adapted for engines with high power densities LONG LASTING PROTECTION e High alkaline reserve stability and longevity of corrosion inhibitors Maintains its technical properties during prolonged use at high temperatures neutralisation of acids e 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 18 202 EN PACKAGING STORAGE e GenCOOL PC 26 is supplied in 210 metallic barrels with smooth interior linings e t can be stored for 2 years in its original container and packaging e Avoid zinc coated containers RECOMMENDATIONS FOR USE e Compatible with the original fluid e It is recommended that the cooling system is completely drained when replacing the fluid R 15 602 1 pa 2 t0 88 NE T 78 103 NF T 78 101 R 15 602 4 NF T 78 102 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 cm2week 0 17 R 15 602 8 3 Installation Connections 3 1 Unloading 3 1 1 Safety during unloading To unload electrical generating sets from their transport supports with optimum safety and efficiency
75. User and maintenance manual for generating sets ie e ESMO _ hental bompact O COM ad R44C3 33504024301NE_0_1 o O O eait ieee 3 LE General ECO MIME HOGI OMS rennan odon 3 ESA atole led os A i ete teen Peder nr eee eer ener er er eee ne et eee eee 4 1 3 INSTRUCTIONS and sale regulation ia tancias 6 E REEE A A E este e de eae ee T AE eee E E 6 1 3 2 Risks related to exhaust gases and Tel Sxxce ctee ieee ade etl deltas ena io 7 13 3 Risks related to toOxXIC DOCS ii A A A AA A A eagle es A Se aes 7 314 RISicornires Duras ana explosion ad dci 8 1 3 5 Risks related to electrical networks moria tc tilda 8 1 3 6 Dangers presented by electric currents first aid ccccccsssseccecseeeeeeeceeseeeeecaaaseceesaueeeeesseaeeeeseeuueeceessuaeeeesseaeeeessuaeeeeessaaaeeess 9 137 RISKS related 10 MOVING NE Sd aa 9 13 9 RISKS ealed to NOISE ie E ETE O E E 9 2 General desci puo a a a aa a Meds a cea coadeeneeedacda tate 10 Zils Technical SOCCIMNCANOMS tt e 13 2 2 o ner rr Ov ried ne Cer tro ee ee ree er ee eee ee rene ener he 15 2 3 A A A 16 2 4 UCI ANG CONS UIA CS nenna ro nea O yeas eel ised E 16 PA AS DCC IICAUOMS rats temseceu tee hecent A tata en tandecauvenanatuceanace wescee E E A E E E E 17 Bales OA o ee tenaenanss yaaa onctn esd vedta ios 17 ZAI Speolicalons Ol COOL AIS dl id oon beach ee 18 Fe MSA AUG A Connections eii 19 3 1 UTI A nn E T R i cela Lyla oe es 19 3 kFoaeyradurmg Un O Mg aaa ena
76. We would like to draw your attention to the following two safety measures that must be complied with a During operation do not allow anyone to stand in front of the air outlet guards in case anything is ejected from them b Do not allow children younger than 14 to go near the air outlet guards 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 SOMER 170 202 LSA 43 2 44 2 4 POLE ALTERNATORS 1 RECEIPT 4 SERVICING MAINTENANCE 1 1 Standards and safety measures 008 4 4 1 Safety Measures occcccocccccoconcoocnonocanoconanononos 10 a o A teat 4 4 2 Regular MaintenanCe occcocccccncccononccnncnnnnnnos 10 gles ew Co 1 gid lero ici diri 4 4 9 Fault GClCCUON misc okie 10 tAr Ol OMAOE eru 4 4 4 Mechanical defectS ccccccoooncccnnnccnononnnnnnss 11 1 ADICON Sii ii 4 4 0 El
77. a displayed Fuel level indicator Alarm Fault Alarm Fault lt low fuel level high fuel level Coolant level temperature indicator Alana High fa Cay No preheating Ef Low level a level fault a fault lus fault lt alarm NA A doy fault alarm Battery Min battery pp mm oh ae este Battery charge voltage ON indicator flashing DAY voltage flashing INN flashing bars Oil pressure temperature indicator High or low oil High or low oi Oil pressure level ps temperature Alarm Fault y Alarm Alarm Fauli AS Fault Emergency stop Emergency stop fault Overload or short circuit Tripping of circuit breaker following an overload or short circuit Engine speed Underspeed fault Non starting fault 48 202 EN 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 Fuel Level Indicator Indication of Temperature of High Temperature coolant HT units according to settings menu Indication of Battery Voltage Indication of Oil Temperature units according to settings menu Engine Speed Indication Indication of Temperature of High Temperature coolant units according to settings menu Indication of Oil Pressure units according to settings Indication of Oil Temperature uni
78. ailer on axle stands O 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 Pull the 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 gt Check the transmission setting after 180 miles 800 km running in period and if necessary adjust the gap J1 using the tensioner Parking gt The lever 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 gt 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 The 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 31 202 NUT 5 COMPENSATING TENSIONER6 CROS5 BAR7 BRAKECABLE _ SPRING 5 SLIDE 2 LIN
79. aning product run into the slots Apply the productwitha brush sponging frequently toavoid 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 that the 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 containing soap or detergent in the case of greasy dust Petrol or chloroethylene can also be used After cleaning the alternator it is essential to check the winding insulation see sections 3 2 and 4 8 4 3 Fault detection If when commissioned the alternator does not work normally the source of the malfunction must be identified To do this check that the protective devices are fitted correct
80. anty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the heavy duty off road engine owner you should however be aware that Mitsubishi Heavy Industries Ltd may deny you warranty coverage if your heavy dutyoff road engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with California s emissions requirements You are responsible for initiating the warranty process The Air Rexources Board suggests that you present your heavy duty off road engine to a Mitsubishi Heavy Industries Ltd dealer or distributor dealer as soon as problem exists The warranty repairs should be completed by the dealer or distributor as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact Mitsubishi Engine North America at 1 630 268 0750 75 202 FOREWORD Warranty coverage a The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser b Mitsubishi Heavy Industries Ltd warrants to the ultimate purchaser and each subsequent purchaser of the en gine registered in the state of California that the engine is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the
81. arator Fuel injection nozzle Hole type Initial fuel injection pressure 17 65 MPa 180 kgf cm 2560 psi Lubrication method Forced circulation pressure feed by oil pump Lubrication oil Class CF or CH 4 oil API service classification Whole engine Approx 10 L 2 6 U S gal Engine oil capacity Oil pan Approx 9 L 2 4 U S gal Oil filter Cartridge type paper element I Water cooled multi plate Cooling method Forced water cooling by centrifugal pump Approx 5 5 L 1 5 U S gal Approx 5 L 1 5 U S gal Coolant capacity basic engine only basic engine only Starting system Electric motor starting Starter DC 12 V 2 2 kW or DC 24 V 3 2 kW Alternator DC12V 50A orDC 24 V 25A Turbocharger Mitsubishi TDO4H Note a The specifications above are subject to change without prior notice b The specifications above are described for the standard model The special model specifications may differ from those of standard model 12 1 161 202 Chapter 12 MAIN SPECIFICATIONS Table 12 2 Main specifications ltem Specifications Engine model S6S DT Type 4 cycle water cooled turbocharged lesel engine diesel engine No of cylinders arrangement 6 cylinder in line Cylinder bore x stroke 94 x 120 mm 3 70 x 4 72 in Displacement 4 996 L 1 3 U S gal Conbustion type Direct injection system Compression ratio sala vary E A Firing order 1 5 3 6 4 2 Direction of rotation Counterclockwise as viewed from flywheel side D
82. arm up the engine Checking engine oil pressure During warm up operation check if the oil pressure is in the range of standard value 0 15 MPa 1 5 kgf cm 21 psi or more Also make sure the oil pressure gauge is operating properly Note The oil pressure gauge may indicate a higher level than normal level immediately after the en gine starts due to the low oil temperature The pressure gradually lowers to the normal level as the oil temperature rises External inspection during warm up Visually check the external view of the engine for fuel engine oil and coolant leakage or exhaust gas leak age from joints 3 4 111 202 Chapter 3 OPERATION Operation Cautions when operating Do not approach rotating parts during operation Entanglement by rotating parts can cause serious injury Do not touch any hot part of the engine such as exhaust pipes during operation or immediately after shut down A hot engine can cause burns Always provide adequate ventilation in the engine room If air supply to the engine room is not sufficient the room temperature rises and can affect engine output and performance For the first 50 hours operate the engine under a light load for break in operation Operating the engine under heavy load or severe conditions during the break in period can shorten the service life of the engine Do not turn the battery switch to OFF position when the engine is running Turning off th
83. associated wiring ie sensing auxiliary windings Variac 6 Exciter field 5 Diode 1A DC 12 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 in an 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 LEROY 12 SOMER 180 202 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 ET 14 1 120 and T30 TORX bit 1 puller eg Facom U35 1 puller eg Facom U32 350 4 6 2 Screw tightening torque IDENTIFICATION screwQY Torque N m Field terminal block screw M4 4 N m Field screw M6 10 N m Diode bridge RP M6 5 N m Diode nut M5 4 N m
84. at gloves and other necessary protective gear Works without wearing proper protective gear could result in serious injuries Check the radiator fins for holes and cracks To clean the radiator fins blow compressed air from the opposite direction of the normal air flow Fig 8 22 Radiator fins Clean 8 13 142 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet and exhaust systems Air cleaner Check Checking procedure described below is a commonly used procedure Some application may be equipped with different air cleaner 1 Check the air cleaner indicator for the element clog 2 Ifthe element is clogged the red signal mark is vis ible 3 Immediately clean or replace the air cleaner ele ment when the signal turns red Note For cleaning of the air cleaner element refer to Air cleaner element Clean Check and Re place 8 16 Turbocharger Inspect Check the turbocharger when the engine is cold Also make sure that the compressor wheel is not rotating before inspecting the turbocharger If the color of the exhaust gas is abnormal also inspect the turbocharger Disconnect the pipe from the air inlet side Hold the compressor wheel nut by hand and turn the wheel to check for looseness or abnormal noise Replace the turbocharger if looseness or abnormal noise is found Note When removing and inspecting turbocharger contact a dealer of Mitsubishi Heavy Industries Ltd 143 2
85. ations ensure that the equipment is clean or clean it if necessary Ns Ss NS OS 60 202 7 3 Table of maintenance operations 10h 20 000 h OPERATIONS 2 years ee AAA MAME EEE EA Generator set S E S S S S S y O __ Check the general condition D T e poo jp e Check the tightening torques Ce f d f Check the absence of leaks J o o ST e Check the condition of battery charge l d e f pp Clean the battery terminals Z O o o o To o Toe poo poo oo pp electrical equipment IEA NP O E contactors w _ _ _ ___ e Check engine oil and coolant level e e Check fuel filter Water bowl e o po e n AA mA IE oA e Replace engine oil and oil filter inspect belt and adjust and belltension 1 JT e Check and Clean radiator fins e pp ESE TO EEE o pump ES OI O q AH AE A Inspect starter OO ed S Inspectaltemator OO Oe Cd Retighten bolts and nuts on the engine e0 OO Clean mozzte tip OO Check and Clean fuel injection nozzle Pe To Inspectturbocharger f T T Te So Change coolant O f f T T T Te oo O y y y s e e e e Wema SSS y e e e S S o e Check the various electrical connections of the installation Grease the bearings d oe After the first 50 service hours for a new or overhauled engine a 61 202 N 7 4 Fault finding Refer to the user manual and engine and alternator main
86. aust gas to contact flammable materials possibly leading to personal injury and or damage to equipment Use explosion proof lighting apparatus When inspecting fuel engine oil coolant battery elec trolyte etc use a flameproof light An ordinary light ing apparatus may ignite gas and cause it to explode Prevent electrical wires from short circuiting Avoid inspecting or servicing the electrical system with the ground cable connected to the battery Otherwise a fire could result from short circuiting Be sure to dis connect the battery cable from the negative termi nal before beginning with the work procedure Short circuits possibly resulting in fire may be caused by a loose terminal or damaged cable wire Inspect the terminals cables and wires and repair or replace the faulty parts before beginning with the ser vice procedure Keep fire extinguishers and a first aid kit handy Keep fire extinguishers handy and become familiar with their usage Keep a first aid kit at the designated place where it is easily accessible by anyone at any time Establish response procedures to follow in the event of fire or accident Provide an emergency evacuation route and contact points and means of communication in case of emergency 1 1 Chapter 1 BASIC SAFETY PRECAUTIONS Stay clear of all rotating and moving parts WARNING Install protective covers around rotating parts Make sure the protective covers of t
87. bicle relays The alternator has been connected with the busbar separating the terminals as shown in the terminal connection diagram ao ja The equipotential earth links have been implemented correctly cross section and continuity of the earths Voltage adjustment by remote potentiometer Thermistor PTC temperature 130 C Ca NH pn 150 Black NS Haiphg 180 Red white 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 Setting 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
88. cation There are no strict rules governing the choice of location other than the proximity of the electrical supply panel and the disturbance caused by the noise However it is important to take into account the fuel supply the evacuation of burnt gases the direction of these gases and evacuation noises The choice of location will therefore be the result of a carefully considered compromise Examples of problems that may be encountered q Incorrect ventilation and exhaust Building or terrain too rough Generating set incorrectly seated E Impossible to fill with fuel Impossible to open enclosure doors Figure 3 1 Examples of problems that may be encountered Ensure that the generating set is placed on a flat surface 3 3 Moving the genset Whenever the generating set is moved the appropriate equipment must be used sling forklift etc and you must know the parts of the generating set which enable it to be moved see below gt a A iat a O Central lifting ring Forklift pockets Drawbars 21 202 EN 3 4 Connections 3 4 1 Connections general information As with low voltage electrical installations use and maintenance is governed by standard NFC 15 100 France or by the standards in the relevant country based on international standard IEC 60364 6 61 They must also adhere to the regulations in the NFC 15 401 application guide France or to the regulations and standa
89. ces Board CARB The California Air Resources Board CARB is pleased to explain the emission control system warranty on you 2008 or later engine In California new heavy duty off road engines must be designed built and equipped to meet the State s stringent anti smog standards Mitsubishi Heavy Industries Ltd must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mitsubishi Heavy Industries Ltd will repair your heavy duty off road engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2008 and later heavy duty off road engines are warranted for the Warranty Period If any emission related part on your engine is defective the part will be repaired or replaced by Mitsubishi Heavy Industries Ltd OWNER S WARRANTY RESPONSIBILITIES As the heavy duty off road engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Mitsubishi Heavy Industries Ltd recommends that you retain all receipts covering maintenance on your heavy duty off road engine but Mitsubishi Heavy Industries Ltd cannot deny warr
90. ch The starter switch key must be kept by the person who performs inspection and maintenance during the work Keep engine stopped during servicing Be sure to stop the engine before proceeding to inspection and service procedure Never attempt to make adjustments on the engine parts while the engine is running Rotating parts such as belt can entangle your body and cause serious injuries Always restore engine turning tools after use Be sure to remove all turning tools used during main tenance and inspection work Remember also that the turning gear must be returned to the operating condi tion before starting the engine Starting the engine with the turning tools inserted or with the turning gear in engagement can lead to not only engine damage but also personal injuries Changing the engine speed set ting is prohibited Never change engine speed setting Tampering with the setting can cause the engine and its coupled machine to operate at excessive speeds and result in accidents Chapter 1 BASIC SAFETY PRECAUTIONS Be careful of exhaust fume poisoning Operate engine in a well venti lated area enclosed area and the exhaust gas amp If the engine is installed in an is ducted outside ensure that there is no exhaust gas leakage from duct joints When using the engine as portable generator set do not run it in doors such as a warehouse or tunnel or in an poorly ventilated area near the shielding
91. citficalMalllSsue a 11 1 6 Contra indications tO USE occcccoccccccncnnonoconnnns 4 4 6 Dismantling reassembly oooooncccoccccnccccooc 12 4 7 Installation and maintenance of the PMG 14 2 TECHNICAL CHARACTERISTICS 4 8 Table of characteristics coooccccconcnnccoonnos 14 2 1 Electrical characteristics ooo ccconicnconnom 5 4 9 Table Of weights cccooccccoconococonococonononos 15 2 2 Mechanical characteristicS ooo mmm 5 5 SPARE PARTS 3 INSTALLATION COMMISSIONING 5 1 First maintenance parts ocooccccccccccccconcnnnnnns 16 3 ASS e ce 6 5 2 Bearing designations occcoooccnnccccnconaninnnnnoo 16 3 2 Inspection prior to first USE occooncconcconncooo 6 5 3 Technical Support ServiC8 ooccccoccccccccccncnncnno 16 3 3 Terminal connection diagrams ooccccnccco 7 5 4 Exploded view parts liSt oooccoo 17 3 4 COMMISSIONING occcoooccnccnncnccnnnnnnnnncnononencnnanonos 9 AS Sects toni tee S 9 EC DECLARATION OF INCORPORATION 19 LEROY SOMER 3 171 202 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
92. coooonccncocccccnncnnoncnnononcononnnnnnnnonnnnnnononrnnnonancennos 5 DISS ANV R ii a ia 6 Ale A nn A 6 2 2 Frequency compared with voltage without LAM ooooccococccnccconcnnconoooconononncncnnonconnonnnons 6 2 3 LAM Load Acceptance Module characteristiCS o occcoooccccnccooncnnonnonononnnanoncnnonons 6 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only T 2 5 R438 A V R Options rro ninas M 3 INSTALLATION COMMISSIONING c0occcoooccocconcccccnncnnccononnconnnanoronnnnnnrrnnnnnrrrrnannnrrrnananennanas 8 3 1 Electrical checks on the AV Parranda dieta ne dd A 8 gA EEUN eere A 8 du 010 62 aU ea E roce 11 TA SPARE PARES sitiada iii taa 12 4 1 Designation A e E ON specs 12 4 2 Technical support service ra 12 All such operations performed on the A V R should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components The R438 is an IPOO product It must be installed inside a unit so that this units cover can provide IP20 minimum total protection it must only be installed on LS alternators in the ap propriate location so that when viewed externally it has a higher degree of protection than IP20 Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered a
93. corro sion ionization of engine parts in contact with the coolant LLC loses its effectiveness by hours of use as well as lapse of time Moreover if the chemicals in LLC are not maintained certain chemicals in the LLC become rapidly used up and result in dissolution of metals instead of protecting metals from corrosion Consequently other corrosion preventing chemicals react with dissolving metals and accelerate corrosion This condition generates more severe corrosion than when plain soft water is used This is a typical problem caused by the use of inap propriate LLC 6 6 127 202 Examples of abnormali ties caused by LLC amine type Pitting of iron parts Amines are generally effective in suppressing the rust ing of ferrous metals but they are said to cause prob lems for copper parts Dissolved copper copper corrosion in the cooling system deposits on iron parts and the copper deposits cause corrosion and then pitting on iron parts that have a high ionization characteristics due to galvanic or local cell action Corrosion of aluminum parts Silicate is highly effective in protecting aluminum against rusting However it is unstable in a solution in which the pH is 9 or lower and can turn to gel and pre cipitate in the solution For this reason the pH is usu ally specified to be about 10 to ensure a high alkaline level This means after silicate is used up the high alkalinity causes chemical attacks on alu
94. ctogram will flash The following information is displayed If the motor is not fitted with an air preheating system or once the am Spend otroiaion preheating delay has elapsed p the engine starts up start of a as cycle comprising 3 attempts to Coolant temperature start up the engine 6 Oil Temperature 55 202 EN 6 3 3 Switching off Open the circuit breaker gt manually OR gt by selecting menu 12 CONTROL LOAD The following display will disappear supply stopped ny EP FP F PE F O Press the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24 08 2005 Switch TELYS off by turning the key to OFF without forcing it to the OFF position 6 3 4 Alarms and faults 6 3 4 1 Viewing alarms and faults Alarms and faults are displayed as follows O Alarms All alarms will cause gt the yellow LED to flash General alarm In conjunction with this LED gt aflashing pictogram appears on the LCD screen gt message on graphic display example representing the circuit affected by the alarm and the associated indicator if present FAULT example ALARM Low Fuel Level 25 12 05 15 30 OK HELP 56 202 2 Faults All faults will cause gt the generating set to stop immediate or gradual stop coolant temperature and overload or short circuit gt the red LED to flash General fault In conjunction with this LED
95. de Adjust 1 Remove the belt cover 2 Loosen all retaining bolts of the alternator and ad justing plate 3 Move the alternator to adjust the belt tension 4 After adjusting the belt tension tighten all retaining bolts of the alternator and adjusting plate 5 Install the belt cover Fig 8 1 Belt and belt tension Inspect and Adjust 8 1 130 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system Fuel tank Drain water When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not remove the strainer when filling the fuel For fuel to be used refer to FUEL 4 1 Bleeding water procedure described below is a commonly used procedure Some application may be equipped with different fuel tank If fuel gets mixed with particles of foreign materials such as dust dirt or water it can cause not only decrease of output but also malfunctions of the fuel system To avoid such a problem drain fuel tank as described below 1 Place a fuel tray capacity of 2 L 0 5 U S gal or Drain cock more under the drain cock of fuel tank 2 Open the drain cock of fuel tank and drain fuel at least 1 to 2 L 0 3 to 0 5 U S gal 3 Make sure that water and particles of foreign mate rials discharged with fuel Close the drain cock Fig 8 2 Fuel tank Drain water 8 2 131
96. degradation If any of the following devi ate the limit replace the engine oil with new oil Table 5 1 Engine oil properties Properties Standard Test method als JIS K 2283 2007 Viscosity 100 C 21 gt F 15 or more Of New oil ie Se 2 0 or more with hydrochloric acid HCL method JIS K 2501 2003 Total base number mgKOH g 1 2 of new oil or more with perchlo ISO 3771 ric acid PCA method Total acid number mgKOH g Up to 3 0 of new oil ee d JIS K 2265 2007 Flash point open cup C F 180 356 or higher ISO 3769 ISO 2719 ulate mm s in s 5 4 121 202 Chapter 6 COOLANT Note In this operation manual the word coolant represents the liquid combined water and LLC Recommended water for coolant Use soft water for the engine cooling system The water quality must meet the requirements in the Table below Basically the water quality should be within the recommended value however up to the limit is acceptable Table 6 1 Water quality standards Chemical Recommend ae pH 25 C 77 F yee 6 5t08 0 6 51085 alee an tae Electrical conductivity Corrosion and rust scale Total hardness Scale formation M alkalinity Scale formation Chlorine ion Corrosion and rust Sulfuric acid ion Corrosion and rust Total iron Scale formation Silica Scale formation Residue from evaporation ppm lt 250 lt 400 Scale formation Note Figures in parentheses are the standard value In addition to the item
97. des 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 and E SHUNT gt 30V AREP PMG gt 15V Faulty rotating diodes Short circuit in the main field Check the resistance Faulty exciter armature Caution For single phase operation check that the sensing wires coming from the AVR are correctly connected to the operating terminals Voltage disappears during operation Check the AVR the surge suppressor the rotating diodes and replace any defective components The voltage does not return to the rated value Exciter winding open circuit Faulty exciter armature Faulty AVR Main field open circuit or short circuited Caution Internal protection may be activated overload open circuit short circuit 12 Warning after operational testing replace all access panels or covers LEROY SOMER 200 202 LEROY SOMER R438 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 017 4 2 Technical support service Our technical support service will b
98. dicated in the engine maintenance manuals the consumables mentioned in the section entitled Specifications are recommended 16 202 2 4 1 Specifications 2 4 1 1 Oil grades Al John Deere PLUS 50 rel GenPARTS GENLUB TDX 15W40 MITSUBISHI GenPARTS GENLUB TDX 15W40 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 v Particularly suited to more modern engines with or without turbochargers intercoolers or sophisticated injection systems e g HEUI injector pumps v All types of use can cope with the most demanding applications v Depolluted engines complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel especially ecological diesel with low sulphur content PERFORMANCE ACEA E3 API CH 4 v Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition ADVANTAGES 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 viscosity at 100 C 14 1 mm2 s cSt Viscosity index Values gi
99. e Do not remove the strainer when filling the fuel tank For fuel to be used refer to FUEL 4 1 Make sure the fuel tank is full If the fuel level is low refill the tank to the FULL level line Fig 3 2 Fuel tank oil level Check Engine oil level Check For engine oil to be used refer to ENGINE OIL 5 1 1 Pull out the oil level gauge and wipe it clean using Oil fill il filler a waste cloth E A a Oil level gauge 2 Insert the oil level gauge fully into the oil level gauge guide then pull out the gauge again 3 The proper oil level is between the high and low l l l mA Do F High k Improper marks on the oil level gauge If the oil level is low q aff EE g add engine oil of the specified type Proper 4 Install the oil filler cap after refilling L a ae uN Improper 5 Check the oil pan and other area for oil leakage Fig 3 3 Oil filler and Oil level gauge 3 2 109 202 Chapter 3 OPERATION Coolant level Check Remove the radiator filler cap only after the engine Turn the cap about Stand the lever to half a turn the upright position has cooled to room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it 1 Open the radiator filler ca
100. e a fuel specified in this manual only Do not refill the fuel tank more than the specified level as it may Diesel fuel result in a fire Z equivalent Use a diesel fuel equivalent for JIS K 2204 diasel for fuel It is necessary to use a fuel that has a pour point suit JIS K2204 able for the ambient temperature Fig 4 1 Recommended fuel Handling fuel When using fuel stored in a storage tank leave it to sit for more than 24 hours so that dust and water can settle at the bottom Then use the upper clean fuel Fill up the fuel tank or service tank after each operation This prevents water from mixing with fuel in the tank and also gives time for dust and water to separate and settle at the bottom of the tank Before refilling clean the areas around the caps thoroughly and remove the caps from the drum and tank Also clean your hands and the hose before refueling When using a hand operated pump be careful not to pump water or sediment accumulated at the bottom of the storage tank Be sure to use a Strainer when filling fuel tank For a complete filtration it is recommended to use a clean lint free cloth together with the strainer 4 1 114 202 Chapter 4 FUEL Table 4 1 Recommended limit and use limit of fuel property Properties Recommended limits Test method JIS K 2265 2007 Flash point 50 C 122 F or higher 45 C 113 F ISO 3769 ISO 2719 Initial boiling point 170 C 338 F or higher Distillat
101. e battery switch during operation not only stops the instrument opera tions but also may deteriorate the alternator diode and regulator Never turn the key to the START position during operation The starter may be damaged When operating the engine with a 30 of rated load or lower limit each operation to an hour Prolonged warm up operation causes carbon build up in the cyl inders that leads to incomplete combustion Operate the engine with a 30 of rated load or more for over 5 minutes after continuous operation for an hour to prevent causing carbon build up 112 202 Inspection during operation Carefully check the exterior of engine such as piping joints for leaks Check for abnormal engine noises or vibrations such as knocking Check the color of exhaust gas from the exhaust muf fler Check the instruments and gauges for proper opera tion and make sure they indicates normal values Table 3 1 Standard values at rated speed Item Standard 0 29 to 0 49 MPa 3 to 5 kgf cm 43 to 71 psi 70 to 90 C 158 to 194 F Engine oil pressure Coolant temperature Note a When the oil pressure drops below 0 15 MPa 1 5 kgf cm 21 psi in normal operation or below 0 05 MPa 0 5 kgf cm 7 psi at low idling stop the engine immediately Be sure to locate the cause of problem and correct it before restarting the engine b When the thermo switch is activated in nor mal run idle the engine in low gear immed
102. e hangers To prevent wire ropes from contacting the engine use a cloth or other soft padding Rear hanger Front hanger L g C o D Wu Y The center The center of gravity of gravity Fig 10 2 Engine s center of gravity standard specification 10 1 150 202 151 202 Chapter 11 TROUBLESHOOTING General precautions Contact a dealer of Mitsubishi Heavy Industries Lid for repair service Repairing a malfunctioning engine may require special equipment or involve potentially dangerous work except for relatively simple procedures such as the change and addition of fuel engine oil and coolant In the event of the engine failure contact a dealer of Mit subishi Heavy Industries Ltd Considerations before work Before troubleshooting consider possible causes of the problem and try to find out if the same problem has occurred in the past Check the parts that may be causing the problem in the most efficient order When disassembling a component pay close atten tion to the disassembly sequence so that you can reassemble the component in reverse order of disas sembly 152 202 Cautions against contamination Dust and foreign materials are the most common cause of rapid wear of parts When disassembling a component take measures to prevent dust and foreign materials from entering the component being disassembled Cautions regarding parts han d
103. e happy to provide any information you require When ordering spare parts you should in dicate the complete machine type its serial number and the information indicated on the nameplate Part numbers should be identified from the exploded views and their description in the parts list Our extensive network of service stations can dispatch the necessary parts without delay To ensure 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 201 202 13 LEROY SOMER R438 NOTES LEROY 14 SOMER 202 202
104. e 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 1 mm 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 Insert a clamp ammeter to m
105. e requested to read this Oper ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance Never operate the engine or conduct maintenance work with out completely understanding this manual MITSUBISHI gt HEAVY INDUSTRIES LTD Pub No 99610 29120 71 202 INTRODUCTION This operation and maintenance manual contains detailed operation inspection and maintenance information for engines from Mitsubishi Heavy Industries Lid Please read this manual thoroughly before proceeding with operation inspection and maintenance work for correct use and servicing Failure to follow directions in this manual may result in serious accidents 72 202 FOREWORD Limited warranty Mitsubishi Heavy Indusiries Lid will repair or replace parts returned to us when we judges that the parts are defec tive in material and or workmanship after conducting inspection Mitsubishi Heavy Industries Ltd s warranty is limited to the compensation work of repair or replacement of parts The warranty coverage Is effective for the original purchaser only Those to whom ownership is later transferred are not provided with the warranty Mitsubishi Heavy Industries Ltd s makes no warranties either expressed or implied except as provided in this manual including but not limited to warranties as to market ability merchantability fitness for a particular purpose or use or against i
106. eeeeseeeeeeens 2 5 Engine right ViOW ccccccsseeeeeeeeeeeees 2 5 Engine left view cccccssseeessesseeeeees 2 6 Engine right ViOW 0 cccccseeeeeeeseeeeees 2 6 Engine left view cccccsssseessssseeeeees 2 7 Engine right VIeW oocccccoocccnccconcnnccnnnnos 2 7 Starner Wi Deo 2 8 Preheat indicator oooooooccccccincccccnncccnnnno 2 8 Water temperature meter and thermo aaa ist caidas 2 9 AMOO areni 2 9 HOU Mel nia 2 9 Stop Solenoid cnc ae 2 10 Oil pressure switch ooccnccnnccncnno 2 11 Thermo switch occccccoocnccccnccnnnnnccnnnnnnos 2 11 Air cleaner indicator 2 11 Battery electrolyte level Inspect 3 1 Fuel tank oil level Check 3 2 Oil filler and Oil level gauge 3 2 Radiator filler Cap oocccccccco 3 3 Radiator coolant level 3 3 Reserve tank coolant level 3 3 Recommended fuel cccceeeeeeeees 4 1 Recommended engine olil 5 1 Selection of oil viscosity 5 1 GLASSY SLLGC cai tilde 6 1 Belt and belt tension Inspect and A O A 8 1 Fuel tank Drain water 8 2 Fuel filter Drain water 1 8 3 Fuel filter Drain water 2 8 3 Priming pump Hanadle 8 4 CONTENTS 4 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig
107. eek 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 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 v Dry batteries do not require any servicing v Batteries ready for use must be recharged at the latest when the acid density drops below 1 20 8 1 Storage and transport v Batteries ready for use must be stored in a cool and dry place frost free protected from the sun self discharge v Batteries must be transported and stored vertically risk of acid spillage v Leave the terminal cover on the positive terminal 63 202 EN 8 2 Battery setting into service Batteries filled with acid have a density of 1 28 g ml and are charged Inthe 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 Tempera
108. elay the sr generating set stops immediately also causing the main circuit breaker to be tripped 2 Insulation fault optional with an insulation fault causing the activation of the control unit performing insulation the generating set stops immediately Associated message Underspeed fault indicates an incorrect rotation speed below 1000 rpm Associated message Emergency stop or external emergency stop fault Associated message STOP fault activated if the STOP button is pressed whilst the AUT LED is flashing to indicate that the generating set is operating in automatic mode List of alarms associated with a pictogram Associated pictogram A Bar Low fuel level alarm Indicates the need to fill up with fuel Associated pictogram Alternator charging fault alarm indicates a problem affecting the alternator charging rate 43 202 6 3 Generator set with TELYS control panel 6 3 1 Control panel presentation 6 3 1 1 View of the front panel CLIT eee en o Phd Fig 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
109. ely after the engine stops If the cap is opened when the coolant is at operating temperature steam and hot coolant may blow out and result in burns Do not touch high pressure injection fuel If fuel leaks or sprays out from the high pressure injec tion pipe do not touch the fuel Fuel in the fuel injection pipes is under high pressure and if the fuel contact your skin it goes into deep tis sues and may result gangrene Refill coolant only after the coolant temperature dropped When refilling of coolant perform it after coolant tem perature drops not immediately after the engine is stopped Otherwise you are scalded with hot coolant Chapter 1 BASIC SAFETY PRECAUTIONS Be careful when handling fuel engine oil or LLC Use only specified fuel engine oil and LLC Use fuel oil and LLC specified in this manual and handle them carefully Use of any other fuel oil or LLC or improper handling may cause various engine problems and malfunc tions Obtain the MSDS issued by the fuel oil and LLC sup pliers and follow the directions in the MSDSs for proper handling Handle LLC carefully When handling LLC always wear rubber gloves and a protective face mask If LLC or cooling water contain ing LLC comes into contact with your skin or eyes or if it is swallowed you would suffer from inflammation irritation or poisoning Should LLC be accidentally swallowed induce vomit ing immediately and seek medical att
110. ensile strength change O to 10 Ethylene Elongation change 30 to 0 propylene diene monomer Volume change 0 to 10 Hardness change 10 to 0 Storage stability vol 30 vol room temperature 6 Hr Maximum 0 3 6 4 125 202 Chapter 6 COOLANT Maintenance of LLC CAUTION Should coolant or LLC be accidentally consumed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention LLC is toxic Never dispose of coolant containing LLC drained from engine into regular sewage For disposal of used coolant consult LLC distributor Replacement intervals of LLC Be sure to renew LLC at the intervals specified in the maintenance schedule of this manual Failure to renew LLC may cause malfunctions due to performance degradation of preventing rust and cavitation The coolant mixed with LLC which Mitsubishi Heavy Industries Ltd recommended expires in 2 years Be sure to change coolant at least once every 2 years LLC concentration Keep the LLC concentration of 30 GLASSY and 40 PG GLASSY on any temperature conditions LLC of less than 30 concentration does not provide sufficient corrosion protection If the LLC concentration is lower than 10 it may accelerate corrosion When adding coolant do not add plain water Always use coolant with the same LLC concentration Table 6 3 Recommended LLC concentration Lowest ambient temperat
111. ention Should LLC enter your eyes flush them immediately with plenty of water and seek medical attention If LLC splashes onto your skin or clothing wash it away immediately with plenty of water Keep flames away from LLC The LLC can catch flames causing a fire Coolant containing LLC drained from the engine is toxic Never dispose of coolant into regular sewage Abide by the applicable law and regulations when discarding drained coolant Proper disposal of waste oil LLC and coolant Do not discharge waste engine oil LLC and coolant into sewerage river lake or other similar places Such a way of disposal is strictly prohibited by laws and reg ulations Dispose of waste oil LLC and coolant and other envi ronmentally hazardous waste in accordance with the applicable law and regulations 92 202 When abnormality occurs MA CAUTION Do not add coolant immediately after a sudden stop due to over heating If the engine stops suddenly or if you have no choice but stop the engine suddenly due to overheating do not add coolant immediately Adding water while the engine is hot can damage parts such as cylinder heads due to a sudden drop of temperature Add coolant gradually after the engine has completely cooled Avoid immediate restart after abnormal stop If the engine stops abnormally do not restart the engine immediately If the engine stops with an alarm check and remedy the cause of the problem before restar
112. er 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 PID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard PPID Parameter Identifier SPN PPID corresponds to PID but is only used by VOLVO This represents the type of fault that has occurred This may be an electrical FMI Failure Mode identifier mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combination Terminology used by JOHN DEERE SPN Suspect Parameter This represents the system or component at fault for example SPN 100 Number indicates an oil pressure problem or a problem with the oil pressure sensor This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault FMI Failure Mode identifier 59 202 In the event of a fault the screen will display the following message Engine fault code ALARM Pressing OK will display fault finding information ENGINE GENERAL 110 18 In addition appendix D indicate the meaning of the 25 12 2005 15 30 code The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation OK HELP For JOHN DEERE JD and VOLVO VO engines the c
113. eration at standstill Frequency starting Sustained voltage on overload LEROY SOMER 11 199 202 LEROY SOMER R438 3 3 Electrical faults Action A V R Effect Check Cause No voltage at no load on start up Connect a new battery of 4 to 12 volts to terminals E and E respecting the polarity for 2 to 3 seconds The alternator builds up and its voltage is still correct when the battery is removed Lack of residual magnetism The alternator builds up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to the AVR Faulty diodes Armature short circuit The alternator builds up but its voltage disappears when the battery is removed Faulty AVR Field windings disconnected Main field winding open circuit check the resistance Voltage too low Check the drive speed Correct speed Check the AVR connections AVR may be faulty Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the AVR voltage pot P2 before running at the correct speed Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Voltage oscillations Adjust AVR stability potentiometer If no effect try normal fast recovery mo
114. ernator 2 and 4 poles 50 Hz 60 Hz Winding n 6 and M or M1 connected in dedicated single phase 400 V for the excitation values The voltage and current values are given for no load operation and operation at rated load with separate field excitation All values are given 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 LSA 43 2 Stator L N S1 0 155 0 23 15 0 155 0 23 25 0 155 0 23 35 0 128 0 23 M45 0 105 0 23 L65 0 083 0 23 L8 0 063 0 23 Armature Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 43 2 no load on load S1 0 5 133 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 LSA 43 2 S1 15 25 S35 M45 L65 L8 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 43 2 no load on load S1 2 6 S15 3 S25 3 2 S35 3 6 M45 l 3 2 L65 E 3 2 L8 l 3 2 LEROY 14 SOMER 182 202 LSA 43 2 44 2 4 POLE ALTERNATORS 4 8 3 Ded
115. es 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 result in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables remove the cable from the negative terminal first When reconnecting the battery connect the positive lead first Charge the battery in a well ventilated 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 If electrolyte comes into contact with your eyes rinse immediately with plenty of water and s
116. es when operating maintain ing and inspecting the engine When the engine is used by individuals whose native language is not English thecustomer is requested to provide thorough safety guidance to the opera tors Also add safety caution and operating signs that describe the original warning label statements in the native language of the operators The engine must be operated maintained and inspected only by qualified persons who have thor ough knowledge of engines and their dangers and who also have received risk avoidance training viii 79 202 To prevent an accident do not attempt to carry out any operation other than those described in this man ual and do not use the engine for any unapproved purpose When the ownership of the engine is transferred be sure to provide this manual with the engine to the new owner Also inform Mitsubishi Heavy Industries Ltd of the name and address of the new owner of the engine This manual is copyrighted and all rights are reserved No part of this manual including illustra tions and technical references may be photocopied translated or reproduced in any electronic medium or machine readable form without prior written con sent from Mitsubishi Heavy Industries Ltd The contents in this manual are subject to change at any time without notice for improvement of the engine Pictures or illustrations of the product in this manual may differ from those of product you have
117. ess the reset button on the top of air cleaner indica tor and restore the signal after cleaned the air cleaner indicator or replaced with a new one Fig 2 23 Air cleaner indicator 2 11 106 202 107 202 Chapter 3 OPERATION Preparations for operation CAUTION Should an engine abnormality be observed during operation stop the engine and correct the problem or contact a dealer of Mitsubishi Heavy Industries Ltd Always conduct the following inspection before starting the engine Engine external Inspect Be sure to keep combustible materials away from the engine especially from the hot engine parts such as exhaust manifolds or the battery Check for fuel and oil leakage Clean the top surface of the battery A fire can be caused by combustible materials placed near hot engine parts If any abnormality is found be sure to repair it or contact a dealer of Mitsubishi Heavy Industries Ltd Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure that the engine and battery are clean If combustible materials or dust are found near the engine or battery remove them N Check the electrical wiring for such components as the starter and alternator for looseness a Check the entire engine for fuel leakage engine oil or coolant If leakages are found repair or contact a dealer of Mitsubishi Heavy Industries Ltd 4 Make sure the
118. etermine the most appropriate service intervals Feel free to consult a dealer of Mitsubishi Heavy Industries Ltd regarding service intervals Service the items at multiples of the original requirement For example at 1000 service hours also service those items listed under every 250 service hours and every 50 service hours ltems marked with in the maintenance schedule require special tools or large equipment For the servicing of those items contact a dealer of Mitsubishi Heavy Industries Ltd 7 1 128 202 Chapter 7 MAINTENANCE SCHEDULE Maintenance schedule Table 7 1 Maintenance schedule Interval and Service item Page a N Fuel tank Drain water Every 50 service hours Air cleaner Check 8 14 First 50 service hours for Engine oil and Oil filter Replace a new or overhauled engine Bolts and nuts on the engine Retighten T Co gt Co Engine oil and Oil filter Replace T oo Belt and belt tension Inspect and Adjust Every 250 service hours Radiator fins Check and Clean 8 13 Add grease to link joints etc Fuel filter in line type fuel injection pump Replace 8 6 Fuel system distributor type fuel injection pump Bleed air 8 5 Every 500 service hours Valve clearance Inspect i Cleaning the fuel tank Every 500 service hours or Every 1 years Checking glow plug i Starter Inspect 8 18 Every 1000 service hours Alternator Inspect 8 18 Bolts and nuts on the engine
119. feria 19 SEZ AMSILICHONS TOK UI OAG ING erica si ta 20 32 A O ee ee er ee 21 2a Moving the Jense inrita a e a a a a a a e a a a a e aA 21 3 4 A te ue rire relive am elas eels bie te ea et clean has 22 3 4 1 Connections General InfOnmatl OMe faces S elect aleb A A e das 22 Bid FOWE CADIS a eiii iia 22 SES RO WE IMIS ONS da do e dl dd 23 a o O A deacandencedsate 24 3 5 Protection TOF Individuals ANG equi tits A li 24 A A a eget atiua het ng eal Gin Laie 24 3 5 2 Earning STE DANCE ais 25 A act eta cea et ac el a a tsa a a lc gc acc Seah cate ate ac Ota ett 26 3 5 DiITEneMilal POU CUO Meadas tale taladrar lace seso dolia odio 26 3 5 5 Adjusting the genset differential protection ccccccccssseecccceeeeceecceeueeeeeesuuseeeseaseceeessaueeeeessaaeeeeeeesseaeeeessauaeeeesseageeeessaeeeeseaas 27 3 6 Connection SUMA iia 28 37 Speciallaiangements isa as 29 A A te ee EANA E ee aR EE EEE aa ee eee oe ae 29 4 1 O A 29 4 2 As A ee eee eee reer re eee ee nee 29 4 3 Opera asta iii ia oi ecos 30 4 4 Unhlchnd NETANE psa tino vi Someta tre ac ooo atrae ee Teenie tr ere ern 30 4 5 Implementation Tor TMstallal Mi e a a tenadndeqsude hatedavecuvatecesdcgee N aE A T EEE 31 4 6 Brea transmission adjustment cesset noocoet concn settee etch smash ot sateott o lo 31 4 7 Eo aO nee eee et Re rare rae nr Ore PRR cee E eR eee Peter eee eer eee 33 4 8 Electrical Cconnecio n alada tenia 34 4 9 Complete wheels technical Itorma ON and
120. following valves plugs and cocks are open or closed tightened properly Fuel feed valve Open Coolant drain cock plug Closed Tightened Oil drain valve Closed Battery electrolyte level Inspect If battery electrolyte is spilled on your skin or clothes flush immediately with plenty of water If battery electrolyte get into your eyes flush them immediately with plenty of water and then get medical attention Do not use open flames or other fire hazards near the battery When handling the battery be careful of soarks gen erated by accidental shorting For other cautions in handling the battery refer to Service battery 1 6 Battery electrolyte evaporates during use and the electrolyte level gradually decreases Proper electro lyte surface level is between the LOWER LEVEL and UPPER LEVEL lines apli 394 to 0 591 in For the battery without level lines proper electrolyte surface level is about 10 to 15 mm 0 394 to 0 591 in above the top of the plates ee If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water pour in carefully 10 to 15 mm Fig 3 1 Battery electrolyte level Inspect 3 1 108 202 Chapter 3 OPERATION Fuel tank oil level Check When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fir
121. fuel filter surfaces 8 After installing the new fuel filter bleed the fuel sys tem Note For bleeding fuel system refer to Fuel filter in line type fuel injection pump Replace 8 6 9 Start the engine and let it idle for several minutes 10 Make sure that there is no fuel leakage during the engine operation If fuel leakage is found loosen the fuel filter and check the gaskets for damage If there is no damage retighten the fuel filter 135 202 Air vent plug Filter bracket F uel filter Fig 8 10 Fuel filter Replace Apply fuel to gasket Fig 8 11 Fuel filter Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter distributor type fuel injection pump Replace When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire 1 Clean the area around the fuel filters 2 Disconnect the fuel filter level sensor from its con nector 3 Place a fuel tray under the fuel filter 4 Loosen the drain plug and drain fuel from the fuel filter 5 Remove the level sensor from the fuel filter 6 Remove the fuel filter element N Wipe off fuel on the fuel filter element mounting surface of the fuel filter body with a waste cloth 8 Check new fuel filter elements for proper seating of the gasket Do not use a filter with the dented case Fillter dam age or fule leaka
122. g up shutting down the module and RESET function Electronic card protection fuse Screen scroll button press successively to access the various screens which are available STOP button press to switch off the generating set START button press to switch on the generating set Normal operation LEDs and alarm and fault warning LEDs Slot reserved for panel fascia options Mounting bolt LCD for displaying alarms and faults operating states electrical and mechanical quantities 39 202 aa a lic LA A Fig 6 2 Description of the LEDs A lit LED indicates Module being supplied green lights up and remains lit Emergency stop activated control panel or external emergency stop red lights up and remains lit Visualisation of starting phase and speed voltage stabilisation flashing and generating set operating OK or set ready to generate green lights up and remains lit General alarm orange flashing General fault red flashing OO 000 6 2 1 1 Introduction to pictograms The pictograms are as follows Operating temperature Symbols for electric and mechanical sizes Overspeed Non starting fault ee Starting on external command g gt Battery Preheating __ gt Air intake K A Delay Oil pressure Fig 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 pressu
123. ge may occur and it can cause fire hazard 9 Install the fuel filter element to the filter body Do not dent or scratch the fuel filter surfaces 10 Using new O ring install the level sensor to the fuel filter element 11 After installing the new fuel filter bleed the fuel sys tem Note For bleeding fuel system refer to Fuel system distributor type fuel injection pump Bleed air 8 5 12 Start the engine and let it idle for several minutes 13 Make sure that there is no fuel leakage on mount ing sureface of fuel filter element If fuel leakage is found loosen the fuel filter and check the gaskets for damage If there is no damage retighten the 136 202 fuel filter Drain plug Element she torque 1543N em 1 53 0 3kgf m 11 06 2 21 bf ft Fig 8 12 Fuel filter Replace 8 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubricating system Engine oil and Oil filter Replace When draining oil or changing the oil filter wear gloves Hot engine oil and parts may cause burns Do not dump waste oil It is forbidden by law For disposal of waste oil consult a dealer of Mitsubishi Heavy Indus tries Ltd Change engine oil and the oil filter at the same time Also checking and analyzing the oil properties is recommended when changing the engine oil Do not reuse the oil filter element as it is a paper type When replacing filters always replace gasket with new ones Engine oil
124. gine is hot and the coolant is pressurised due to risks of burns v 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 or other mobile equipment without a prior study taking into account the various specific features of using the generating set SON KAS 1 3 5 Risks related to electrical networks v The electrical equipment supplied with the generating set complies with standard NF C15 100 France or with the standards of the countries in question v The earth connection must be installed in accordance with the standards in force in
125. gned 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 This symbol draws attention 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 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 cond
126. gram 2 white side lights on 2 two coloured gp flexible support side marker lights 2 x 6 function rear lights depending on model depending on model depending on model EE a L 7 metal pin male plug A po 2 x 2 conductor cables 2 plate lights Metal socket D connector PS _ conductor cable 2 x 2 conductor cables depending on model 2 x 2 conductor cables depending on model Figure 4 6 Electrical connection diagram 4 9 Complete wheels technical information w M S hy N TYRES COMPLETE WHEELS Dimensions Indices Diameter mm Cross section Radius under Load Pressure mm load Kg bar mm a 550 800 850 195R14C 106P eee 198 32 0 4 5 195 50x10_ 98N 450 19 HO Wheel with 4 holes Wheel with 5 holes 34 202 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 e Check that the general recommendations from section Installation ventilation exhaust connections etc are followed Carry out level checks oil coolant diesel battery Ensure that the generating set is correctly eart
127. h Improper Proper Improper O Oil level gauge O LUS JL AA Ce Fig 8 14 Engine oil Refill 8 9 138 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil filter Change Do not use a dented filter cartridge Filter damage or fule leakage may occur while engine is running and it can cause fire hazard To avoid damage to the filter do not use a filter wrench when installing Tighten the filter by hand 1 Clean around the oil filters 2 Place a drip pan under the oil filter 3 Using a filter wrench remove the oil filter Note Check the element of the oil filter that has been removed If metal particles are found consult a dealer of Mitsubishi Heavy Industries Ltd gt Thoroughly wipe off oil on the mounting surface of oil filter with a waste cloth Check the new oil filter for proper seating of gasket Apply clean engine oil to gasket Do Install the oil filter When the filter gasket contacts the mounting surface of filter tighten the filter with specified torque Fig 8 16 Oil filter 8 10 139 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system Coolant Change Remove the radiator filler cap only after the engine Turn the cap about Stand the lever to half a turn the upright position has cooled to room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position t
128. h the starting component an explosion may occur in the inlet tube causing bodily injury v Do not touch the lighting column lights when they are switched on Maintenance v Follow the maintenance table and its instructions v 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 v Fit only original parts v 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 v Clean off any trace of oil fuel or coolant using a clean cloth v Do not use a soapy solution containing either chlorine or ammonia as these two chemicals prevent bubble formation v Never use petrol or other inflammable substances to clean the parts Use only approved cleaning solvents v Do not use a high pressure cleaner for cleaning the engine and equipment The radiator hoses electrical components etc may be damaged v Avoid accide
129. haft 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 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 does not reach the rated value when AVR the battery is removed Faulty diodes Armature short circuit No Connect between E and voltage E a new battery of 4 to at no load 12 volts respecting on start up the AVR polarities for 2 to 3 seconds The alternator builds up but its voltage Faulty AVR disappears when the battery is removed Field windings disconnected Main field winding open circuit Check the resistance Check the AVR connections AVR may be faulty Field windings short circuited Correct speed Rotating diodes burnt out Voltage too low Check the drive speed Main field winding short circuited Check the resistance Increase the drive speed Speed too low 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
130. hases and obtain the periodic full loads necessary to unchoke the engine Finally when operating under load we advise vigilance towards the oil breather circuit and more particularly towards engines which have the crankcase vent connected to the turbocharger inlet risk of oil or oil vapour absorption and accelerated engine speed On load tests It is recommended to conduct an on load test on the generating set monthly for a period of around 1 hour after stabilisation of the parameters The load must be greater than 50 of nominal power ideally 80 to ensure unchoking of the engine and to obtain a decent picture of the generating set operation Off load test no load This test is not recommended it must not exceed 10 minutes and must not be repeated without a monthly on load test This test only allows you to check for correct engine start up It does not allow you to check that the generating set is working properly 62 202 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 flam
131. he engine are correctly installed Repair any damaged or loose covers Never remove the covers such as damper cover camshaft cover or rocker cover that enclose the revolving parts during operation When the engine is coupled to driven equipment be sure to provide protective covers over the parts such as the connecting belts and couplings that are exposed Never remove protective covers Check work area for safety Before starting the engine make sure no one is near the engine and tools are not left on or near the engine Verbally notify persons within the immediate area when starting the engine When the starter device is posted with a sign that pro hibits startup operation do not operate the engine Stay clear of moving parts while engine is running Do not approach rotating or sliding day CF If any part of the clothing or outfitting is caught by a parts of the engine while the engine is running Keep objects likely to be caught by rotating parts away from such parts rotating part serious bodily injuries could result 1 2 89 202 Lockout and tagout Be sure to lockout and tagout before starting inspec tion and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to OFF position and attach a Do Not Run or similar caution tag to the starter swit
132. hed earthing rod Ensure that the electrical connections have been made properly Ensure that the fuel connection has been made properly valve position if the generating set is equipped with the three way valve option enabling external supply 5 2 Checks after starting the generating set e Carry out the mechanical checks oil pressure water temperature absence of noise etc e Carry out the electrical checks voltage current frequency rotary field etc e Carry out the safety checks emergency shutdown oil pressure coolant temperature etc e Carry out the check on Normal Emergency Inverter switching or coupling if fitted 35 202 6 Using the generator set 6 1 Pre Start Inspection e Inspecting the engine compartment gt Make sure there is no combustible material near the engine or battery Also check to make sure that the engine and battery are clean lf combustible materials or dust are found near the engine or battery remove them gt Check the electrical wiring for such components as the starter and alternator for looseness gt Check the entire engine for fuel leakage engine oil or coolant If leakages are found repair gt Make sure the following valves plugs and cocks are open or closed tightened properly v Fuel feed valve Open Y Coolant drain cock plug Closed Tightened v Oil drain valve Closed e Checking the engine oil level A Do not top up the oil if the oil level is not below
133. hen on again turn P5 clockwise until the required max current is obtained no more than 8 A LEROY 10 SOMER 198 202 LEROY SOMER R438 A V R Checking the internal protection Open switch D the excitation current should increase to its preset ceiling remain at that level for 10 seconds and then drop to lt 1A To reset switch off the power supply by ope ning switch A Note After setting the excitation ceiling as described adjust the voltage again see section 2 1 1 In some countries itis a legal requirement to have a short circuit current of 3 IN so as to offer selective protection 3 2 3 Special type of use WARNING Excitation circuit E E must not be left open when the machine is running AVR damage will occur 3 2 3 1 R438 field weakening SHUNT The exciter is switched off by disconnecting the AVR power supply 1 wire X1 or X2 Contact rating 16 A 250V A C 3 2 3 2 R438 field weakening AREP PMG The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxi liary winding contact rating 16 A 250V A C Connection is identical for resetting the AVR internal protection In case of using the de excitation pro vide a forced excitation 3 2 3 3 R438 field forcing 400V 10A pg Diode Exciter field Forced excitation Time Guaranteed voltage build up Parallel operation de energized Parallel op
134. hes 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 7 202 1 3 4 Risk of fire burns and explosion N 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 v Make sure not to create sparks or flames and not to smoke near the batteries as the electrolyte gases are highly flammable especially if the battery is charging Their acid also poses a risk to the skin and in particular to the eyes Y 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 v Do not touch hot parts such as the exhaust pipe or put combustible materials on it Y Keep all flammable or explosive materials e g petrol oil cloth etc out of the way when the set is running v 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 Y Do not remove the radiator cap if the en
135. i ately until the engine temperature becomes normal Then perform cooling operation for 5 or 6 minutes before stopping the engine Be sure to locate the cause of problem and cor rect it before restarting the engine 3 5 Chapter 3 OPERATION Stopping CAUTION Stopping the engine abruptly while engine parts are hot due to high speed operation can be a cause for heat up of the engine parts and shorten the engine life Before stopping the engine idle the engine in low gear immediately until the engine temperature becomes normal except in an emergency Then perform cooling operation for 5 or 6 minutes before stopping the engine and inspect the whole engine Never accelerate the engine immediately before shutting it down Do not restart the engine immediately after abnormal shut down When the engine stops with alarms be sure to locate the cause of the problem and correct the problem before restarting the engine After restarting the opera tion inspect the whole engine for any abnormalities again If the engine has an abnormality repair it immediately Engine stopping method may differ depending on the specifications Follow the instructions according to the specifications of the equipment Inspection after stopping Inspect the engine for fuel oil or coolant leakage If any leakage is found repair the leakage or contact a dealer of Mitsubishi Heavy Industries Ltd 113 202 Chapter 4 FUEL Recommended fuel _ WARNINGS Us
136. icated single phase LSA 43 2 4 pole SHUNT excitation 60 Hz only Resistances at 20 C Q LSA 43 2 Stator L N Armature S1 0 058 0 23 S25 0 058 0 23 S35 0 046 0 23 M45 0 037 0 23 L65 0 027 0 23 L8 0 019 0 23 Field excitation current i exc A 240 V 60 Hz i exc excitation current of the exciter field LSA 43 2 no load on load S1 0 59 1 44 S25 0 59 1 68 L65 L8 4 8 4 3 phase LSA 44 2 4 pole SHUNT excitation Resistances at 20 C Q LSA 44 2 Stator L N Armature VS3 0 046 0 5 VS45 0 046 0 5 S7 0 036 0 5 S75 0 036 0 5 M95 0 024 0 5 L12 0 019 0 5 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 44 2 no load on load VS3 0 5 1 8 VS45 0 5 2 1 S7 0 5 1 9 S75 0 5 2 1 M95 0 6 2 L12 0 5 1 9 4 8 5 3 phase LSA 44 2 4 pole AREP excitation Resistances at 20 C Q LSA 44 2 Armat VS3 0 5 VS45 0 5 S7 0 5 S75 0 5 M95 0 024 L12 0 019 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field no toad LSA 44 2 VS3 7 q E a M95 DOC
137. ies Never service the air cleaner while the engine is running Servicing the air cleaner while the engine is running can cause particles of foreign material to enter the engine and result in rapid wear of parts leading to a shorter service life of the engine Never knock or hit the element Cleaning inspecting and replacing procedure described below is a commonly used procedure Some application may be equipped with different air cleaner Remove the air cleaner cap and wing bolt Remove the air cleaner element from the body Blow compressed air 0 69 MPa 7 kgf cm 100 psi or lower onto the inside surface of the element to remove foreign materials Wing 4 To remove dust stuck on the air cleaner element blow dry compressed air onto the outside surface S Air cleaner from a distance s element Blow compressed air on the inside surface toward the outside along the pleats Then blow com pressed air on the outside and inside surface again 5 After cleaning hold the air cleaner element near a light bulb to illuminate the inside to check for de fects such as cuts pinholes or local wear 6 If any defect is found replace the air cleaner ele ment with a new one 7 Reassemble the air cleaner element as it is If defects such as cuts pinholes or local wear are found in the element or if the air cleaner indicator shows a red sign soon after the cleaned element is installed change it for new one After cleaning or rep
138. igh Table 11 7 Engine oil consumption is high Cause Remedies Fuel system Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd _ Check oil leakage Oil leakage to the outside of engine a l Consult a dealer of Mitsubishi Heavy Industries Ltd Engine oil viscosity too low Use appropriate oil viscosity Refer to P5 3 Check amount of engine oil and lubrication system Refer to P3 2 Check oil cooler and oil thermostat Lubricating system Engine oil temperature is high Consult a dealer of Mitsubishi Heavy Industries Ltd Check radiator Refer to P8 13 Cooling eCheck control system Overheatin system i Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd ee Check oil leakage to the turbocharger Inlet and Spread oil to intake part te exhaust Consult a dealer of Mitsubishi Heavy Industries Ltd eii Wear of valve operating system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Control Check control system Increase in load o system Consult a dealer of Mitsubishi Heavy Industries Ltd 11 7 158 202 Chapter 11 TROUBLESHOOTING Overheating Table 11 8 Overheating Cause Remedies Check coolant leakage Check coolant level Refer to P3 3 Low coolant level Cooling sys Faulty water pump operation Consult a dealer of
139. inst electric shocks is ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications If the protective plates blanking covers need to be removed to 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 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 thei
140. iode bridge assembly LSA 4329100 ALT 432 KD 001 Surge suppressor LSA 4321 13 AEM 000 RE 126 AVR fuse 5 2 Bearing designations Ref Designation Qly 60 Bearing on exciter end 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 LSA 43 2 Bearing on shaft extension end 1 6312 2RS C3 RLTOGOETO0O7 63152RS C3 RLTO75ET004 1 6307 2RS C3 RLTO35ETO0O30 63092RS C3 RLTO45ETO30 250 V 8 A fast blow Code LSA 44 2 CAUTION Part numbers should be identified from the exploded views and their description from the parts list Our extensive network of service centres can dispatch the necessary parts without delay Toensurecorrectoperationandthesafety ofourmachines 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 SOMER 184 202 16 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3434 en 2010 10 i 5 4 Exploded views parts list 5 4 1 Single bearing LSA 43 2 44 2 Description Stator assembly wW D A ss
141. ion 90 Y di till t rs distillate A o 3405 temperature 330 to 380 C 626 to 716F Pour point PP 6 C 42 8 F or lower than ambient temperature o Cloud point CP Below ambient temperature ei JIS K 2288 2000 Cold filter plugging point CFPP 3 C 37 4 F or lower than ambient temperature IP 309 96 JIS K 2270 2000 Carbon residue 10 bottom oil 0 1 weight or lower 0 4 weight or lower ISO 6615 ISO 10370 JIS K 2280 1996 Cetane number 45 or higher 40 or higher ISO 5165 Cetane index new type 45 or higher 40 or higher a a 2 0 mm s 0 0031 in s or more at 30 C 86 F JIS K 2283 2000 8 0 mm s 0 0124 in s or more at 30 C 86 F ISO 3104 JIS K 2541 2003 The content Kinematic viscosity 0 2 weight or lower should be as Sulfur content Except in cases the value is specified low as the by the emission control diesel fuel ISO 4260 ISO 8754 p JIS K 2275 1996 Water content and sediment 0 1 volume or lower ISO 3733 E a JIS K 2272 1998 Ash content 0 01 by mass or less 0 03 weight or lower ISO 6245 Copper corrosion _ JIS K 2513 2000 3 hrs at 50 C 122 F Color change Copper plate No 3 or less ISO 2160 0 83 to 0 87 g cm 0 80 to 0 87 g cm JIS K 2249 1995 Density at 15 C 59 F 49 9424 to 54 3123 Ib ft3 49 9424 to 54 3123 lb ft8 ISO 3675 24 hrs at 250 C 482 F 75 carbonization or less 80 carbonization or less Caulking nrs at 230 C 55 carbonization or
142. ircuits protected set to 30 mA to the terminal terminal circuits protected set to circuit output s 30 mA to the terminal circuit output s Connect to the power supply Earth the generating set 28 202 N 3 7 Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 4 Trailer 4 1 Trailer linkage Before attaching the trailer check the trailer hook on the tow vehicle it should fit the trailer ring perfectly accidents Also check no incipient fractures or excessive wear on the hitching system locking system is operating properly Trying to tow a trailer with a non matching device bar wires cords etc could lead to serious To hitch the trailer proceed as follows Lock the wheels to stop the trailer from moving Lift up the rear trailer supports and lock them Release the parking brake Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook Hitch the trailer remove the locks on each side of the wheels then lift up the front wheel fully using its handle Connect the electrical circuit of the trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook
143. itions 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 staff to carry out maintenance parts replacement and even total reconditioning of generating sets Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance include the start up and shutdown procedures for the engines Some user and maintenance manuals for the engines fitted to generating sets cover control units and A 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 Important In addition according to the manufacturing criteria of the generating
144. 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 1 3 8 Risks related to noise Important Dangerous noise Risk of hearing loss Prolonged exposure to a noise level above 80dB A can lead to permanent hearing damage Therefore it is recommended that ear defenders are used when working in close proximity to a generating set which is in operation 9 202 2 General description Overview en Figure 2 1 1 General description of the generating set Acces to maintenance area Acces to control unit Lifting ring Acces to power connections Forklift grooves 6 Drawbar S 10 202 Figure 2 1 2 General description of the generating set Protective grille Alternator 2 Battery isolating switch External fuel supply combined tap optional Starter battery 6 Charging alternator 11 202 Control gi Hom oh bs Te 7 as E 3 ri pl 4 E ia 1 E de a ie j h om t Figure 2 1 3 General description of the generating set O Control unit Working hours counter Emergency stop Power circuit breaker Socket control panel 6 Connection terminal block Note Photo presented with the Nexys control unit 12 202 2 1 Technical specifications Range Generating set type RENTAL POWER R44C3 Weights and Dimensions Dimensions with high aut
145. l be warranted for the warranty period defined in Subsection b 2 A statement in such writ ten instructions to the effect of repair or repla ce as necessary shall not reduce the period of warranty coverage Any such part repaired or replaced under the warranty shall be warranted for the remaining war ranty period 3 Any warranted part which is scheduled for replacement as required maintenance in the written instructions required in Subsection e shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or re placed by Mitsubishi Heavy Industries Ltd accordi ng to Subsection 4 below Any s uch part repaired or replaced under warranty shall be warranted for the remainder of the period prior to the first scheduled re placement point for the part 4 Repair or replacement of any warranted part under the warranty provisions shall be performed at no charge to the owner at a warranty station 5 Notwithstanding the provisions of Subsection 4 above warranty services or repairs shall be provided at all Mitsubishi Heavy Industries Ltd distribution centers that are franchised to service the subject engines 6 The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station 7 Mi
146. lacing the air cleaner element press the reset button to reset the indicator Fig 8 28 Air cleaner Check 8 16 145 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical system Battery Inspect If battery electrolyte is spilled on your skin flush immediately with plenty of water If battery electrolyte enters the eyes flush them immediately with lots of fresh water and seek medical attention at once Do not use open flames or other fire hazards near the battery When handling the battery be careful of sparks gen erated by accidental shorting Battery electrolyte level Inspect Battery electrolyte evaporates during use and the f electrolyte level gradually decreases The proper elec trolyte surface level is between the LOWER LEVEL and UPPER LEVEL lines For the battery without level lines the proper electro lyte surface level is about 10 to 15 mm 0 394 to 0 591 in above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water pour in carefully Specific gravity of battery electrolyte Check If the specific gravity measured at 20 C 68 F is lower than 1 22 then charge the electrolyte a s Electrolyte Table 8 1 Specific gravity of electrolyte surface Specific gravity amp UA Glass tube Less than 1 22 Discharged Charge LZ From 1 26 to 1 28 Fully charged eee 3 From
147. lant LLC GLASSY long life coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type be sure to use the LLC which meets specification in Mitsubishi Heavy Industries Ltd The quality and performance of commercially avail able LLCs as well as their component variations are the responsibility of LLC suppliers Before purchasing commercial LLC be sure to dis cuss the suitability of LLC with the LLC supplier Use only all season LLC non amine type Do not use antifreeze alone instead of LLC 6 2 123 202 Standard for other brand LLC When using other brand LLCs by necessity be sure to use the LLC that meets following specification Mit subishi heavy industries Ltd disclaim the warranty claim concerning malfunctions caused by the use of LLC that does not meet the following specification General demands of LLC LLC shall be a homogeneous liquid Engine cooling system shall not receive troubles such as corrosions and precipitation products etc by LLC when the LLC is diluted to 30 to 60 density LLC shall be mixed with other LLC that satisfies this specification and shall not separate elements each other and shall not decrease the performance each other LLC shall not allow the container to be corroded and shall not has precipitation products etc even if LLC is left in the container for 6 months LLC shall not has extraction products etc even if LLC is kept in 20 to 25 C
148. lated area Make sure the cable clamps are securely installed on the battery terminals A loose cable clamp can cause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the battery switch to the Open OFF position or remove the plug from the negative terminal to cut off the electrical current Battery electrolyte contains dilute sulfuric acid Care less handling of the battery can cause the loss of sight and or skin burns Also do not consume the battery electrolyte Wear protective goggles and rubber gloves when working with the battery when adding water charg ing etc lf battery electrolyte is spilled onto the skin or clothing immediately wash it away with lots of water Use soap to thoroughly clean The battery electrolyte can cause the loss of sight if splashing into the eyes If it gets into the eyes imme diately flush it away with plenty of clean water and seek immediate medical attention lf the battery electrolyte is accidentally consumed gargle with plenty of water then drink lots of water and seek immediate medical attention 1 6 93 202 Chapter 1 BASIC SAFETY PRECAUTIONS Other cautions Never modify engine Unauthorized modification of the engine will void our warranty Modification of the engine may not only cause engine damage but also produce personal injuries If there is a need to modify the engine contact a
149. lean 1 1 Care for fuel oil and exhaust gas leakage 1 1 Use explosion proof lighting apparatus 1 1 Prevent electrical wires from short circuiting 1 1 Keep fire extinguishers and a first aid kit A Na 1 1 Stay clear of all rotating and moving A A 1 2 Install protective covers around rotating Pa rin 1 2 Check work area for safety coooccocncconon 1 2 Stay clear of moving parts while engine is NNN O eea 1 2 Lockout and taQout nna 1 2 Keep engine stopped during servicing 1 2 Always restore engine turning tools after use 1 2 Changing the engine speed setting is PrONIDIOA prsni reolennel lo tenes 1 2 Be careful of exhaust fume POISONINO ssicsvinsnicumanidonpeccniariaos 1 3 Operate engine in a well ventilated area 1 3 Be careful of falling down 1 3 Lift engine Carefully oocccconccocncocncncnnos 1 3 Do not climb onto the engine o oocooo 1 3 Always prepare stable scaffold 1 3 Protect ears from noise 0eceeee 1 4 Weal ar DIUGS iii 1 4 Be careful of burns ccceeeee ees 1 4 Do not touch the engine during or immediately after OPeratiOn cccssccsseccseecseecseeeeeeeceeeeaees 1 4 Do not open the radiator filler cap when the engine 1S NO lisa 1 4 Do not touch high pressure injection fuel 1 4 Refill coolant only after the coolant temperature
150. leaner and DIG ClO america 1 8 Use of tools optimum for each work 1 8 Avoidance of prolonged time of starter ODAO Maramara a E 1 8 Do not turn off the battery switch during ODETrAUON rra ea a a ieee veies 1 8 Cautionary instructions for transporting the NOMS tots ies bsos 1 8 Chapter 2 NAME OF PARTS Engine external diagrams 2 1 Equipment and instrument 2 8 Starter Switch ara 2 8 Preheat indicator annsin ran ra 2 8 Water temperature meter and thermo unit 2 9 AMME a lio 2 9 HOUR Mel cs cid oca 2 9 Stop solenoid occoonooocconconconocconenacinaronnonanins 2 10 Engine protection devices 2 11 Oil pressure SWITCH occcoccccccccccccncncncnoncnnnno 2 11 Thermo SWITCNirta oiiie 2 11 Air cleaner indicator cooccoccoccccnconconcccnonnns 2 11 CONTENTS 1 CONTENTS Chapter 3 OPERATION Preparations for operation 3 1 Engine external Inspect oooccccccccnnccccccccnncccns 3 1 Battery electrolyte level Inspect 3 1 Fuel tank oil level GhecCk oooooncccinncnncccncccccnccs 3 2 Engine oil level Check cccoooccccccconoconononnns 3 2 Coolant level Check c coonccncccconcocococconnononoo 3 3 SLANG escri tek 3 4 Warm Up Operation cccccceseeeeeeees 3 4 Checking engine oil preSSUre cccceeeeees 3 4 External inspection during warm Up 65 3 4 Operalla 3
151. ler of Mitsubishi Heavy Industries Ltd mechanical locked The starter cranks but the engine does not start Table 11 2 The starter cranks but the engine does not start Cause Remedies l Inspect fuel tank supply fuel bleed air Refer to P8 2 Run out of fuel blocked pipe eCheck fuel pipes valves fuel i Use appropriate fuel Refer to P4 1 mproper fuel proper ue lid Remove dust water impurities Refer to P8 2 Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system l Inspect and replace fuel filter Refer to P8 6 or Refer to P8 7 Clogged fuel filter l Gauze filter Clean Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injecti eCheck the rack movement aulty fuel injection pum i Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd iri Clean inspect and replace pre cleaner Refer to P8 15 Air intake Insufficient amount of air l P P j l system Clean inspect and replace air cleaner element Refer to P8 16 Fuel control link Check Control Faulty governor o system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Low compression pressure Consult a dealer of Mitsubishi Heavy Industries Ltd 11 2 153 202 Chapter 11 T
152. ling Handle parts carefully When replacing parts use only genuine parts by refer ring to the parts catalogue Work safety Be sure to use wrenches of the correct size Using a wrench of the wrong size not only damages nuts but can also cause the personal injury Use correct tools and perform work with utmost cau tion Be sure to accurately estimate the weight of the part being dismounted If theremoved part is much heavier than you have estimated it may fall down during lifing and can result in the damage to the parts or personal injury 11 1 Chapter 11 TROUBLESHOOTING Troubleshooting The starter does not crank or cranks slowly resulting in start failure Table 11 1 The starter does not crank or cranks slowly resulting in start failure Cause Remedies Check the DC fuse Faulty wire connection Check wiring connection between battery starter and starter switch Check alternator Refer to P8 18 Insufficiently charged battery Electrical Check and adjust belt Refer to P8 1 system Check specific gravity of battery electrolyte Refer to P8 17 Faulty battery Charge battery Change battery Faulty starter or starter relay Consult a dealer of Mitsubishi Heavy Industries Ltd Oil viscosity too high Use appropriate engine oil Refer to P5 1 ECOS Check amount of engine oil and lubrication system system Excessive oil Refer to P3 2 Engine Rapid wear of sliding parts or Consult a dea
153. ly 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 LEROY 10 SOMER 178 202 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 vibration Defective mounting or play in coupling Vibration Rotor balancing fault Excessive vibration and humming noise Alternator operating in single phase mode single phase load or faulty coming from the machine contactor or installation fault Stator short circuit System short circuit Mis paralleling Alternator damaged by a significant impact Possible consequences Abnormal noise followed by humming and vibration Broken or damaged coupling Broken or bent s
154. ly returns to the ON position Preheat indicator The preheat indicator shows the condition of the glow plugs As soon as the glow plugs are heated the preheat indicator turns red Fig 2 16 Preheat indicator 2 8 103 202 Chapter 2 NAME OF PARTS Water temperature meter and thermo unit The engine coolant temperature detected by the thermo unit is displayed by the water temperature meter When the water temperature meter shows 95 C 203 F idle the engine in low gear until the tempera ture becomes normal After the temperature becomes normal perform cooling operation for 5 or 6 minutes and then inspect the cooling system Ammeter It indicates the battery charging condition while the engine is running When the battery is charged the pointer swings to the positive side When the battery is discharged the pointer swings negative side Hour meter It indicates the operating time of the engine When performing the periodic inspection and mainte nance check the time interval with this meter 104 202 Thermo unit Fig 2 17 Water temperature meter and thermo unit Fig 2 18 Ammeter Q O HOUR METER Fig 2 19 Hour meter 2 9 Chapter 2 NAME OF PARTS Stop solenoid The stop solenoid operates for normal shutdown of engine operation The stop solenoid moves the rack of fuel injection pump to cut the fuel and consequently stops the engine Two types of stop solenoids are a
155. mediate start OK Esc Generating set stop request due to fault or by pressing STOP in Auto Mode Manual Mode activated Operating mode operation in Auto Mode Do vou wish to change generating set in operation A AUTO mode g Warning message for switching to Manual Mode l after the STOP button has been pressed or a fault has appeared OK Esc 54 202 6 3 2 Starting A Check that the generating set circuit breaker has triggered Connect the generating set battery O Turn the key switch to the ON position without forcing it to the ON position the ON lamp will light up if the lamp does not light up check and replace the fuse if necessary Test the Alarm and Fault LEDs menu 15 TEST LAMPS 1 ACTIONS 1 5 11 MANUAL lt gt AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS 5 OK Esc O Press Esc several times to return to the following home menu OPERATION MANUAL Press START to start 24 08 2005 O Check the battery voltage pp O Press START TI III l OOO AVAILABLE POWER AIR PREHEATING START UP 100 0 IN PROGRESS 10 seconds 24 08 2005 24 08 2005 24 08 2005 The following pictogram is displayed If the engine is equipped with an Warning the number of successive air preheating system there is a and automatic starting attempts is delay adjustable before the limited to 3 engine starts preheating activation period The following pi
156. minated by cutting the ST5 2 4 Typical effects of the LAM with jumper a diesel engine with or without a Voltage LAM U F only Underspeed and LAM ST5 disconnected UN ca ce Be cs 2 4 1 Voltage U f without LAM i 2 3 2 Gradual voltage return function During load impacts the function helps the genset to return to its rated speed faster thanks to a gradual increase in voltage ac cording to the principle If the speed drops between 46 and 50 Hz the rated voltage follows a fast gradient as it i without is restored Gl If the speed drops below 46 Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value prop N lt 46 Hz Time Load on the shaft kW Drop N gt 46 Hz LEROY SOMER T 195 202 LEROY SOMER R438 A V R 2 5 R438 A V R options Current transformer for parallel operation of 1A 5 VACL 1 Remote voltage adjustment potentiometer 470 Q 0 5 W min adjustment range 5 range limited by internal voltage potentio meter P2 Remove ST4 to connect the po ten tiometer A 1 kQ2 potentiometer can also be used to extend the adjustment range For wiring up the external potentiometer the earth wires must be isolated as well as the potentiometer terminals wires at the same voltage as the power R731 external module sensing of 3 phase voltage 200 to
157. minimum engine speed for 5 to 10 minutes BON Immediately before stopping the engine spray volatile corrosion inhibitor VCI through the inlet port to prevent rust on the air intake system With the engine stopped drain the fuel mixture from the fuel tank Apply rust preventive oil NP 3 liberally on the exposed sections of the machining Seal the air inlet exhaust outlet breather and other openings with an adhesive cloth tape 2 53 p Cover the entire engine Note a Store the engine in a well ventilated indoor area b It is not necessary to drain coolant since it contains LLC Add LLC to increase the concentration to between 30 to 60 c Post a sign at an easily noticeable place to warn that the rust preventive oil in the engine must be replaced with engine oil and the fuel tank must be filled with fuel before operating the engine for the first time after storage d New engine oil can substitute for rust preventive oil NP 10 2 of lubrication system Recommended rust preventive oil and corrosion inhibitor Table 9 1 Recommended rust preventive oil and corrosion inhibitor JIS No Recommended IES SES Application Prevention of rust on a Nippon Oil Corporation i NP 3 Anti Rust P 1600 oo machine sur K 2246 NP 9 Nippon Oil Corporation Prevention of rust in fuel Anti Rust P 2400 system NP Nippon Oil Corporation Prevention of rust in 10 2 Anti Rust P 230 lubricating system Ryoukou Kagaku Z 1519 VCI Diana ND
158. minum To prevent this problem proper maintenance of the coolant is required For case example rapid wear of mechanical seals in the water pump due to secondary effects of silicate gel formed Corrosion of aluminum parts after silicate is consumed Pitting and clogging of the radi ator When LLC deteriorates or when its concentration in the coolant is too low the anti corrosion performance of LLC lowers and results in the corrosion of met als Brass and solder tend to corrode faster than other metals and corrosion of these metals is said to cause water leakage and clogs Example Holes and clogs in radiator Chapter 7 MAINTENANCE SCHEDULE How to use the maintenance schedule Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation Be sure to conduct inspections and maintenance according to the maintenance schedule The maintenance schedule shows the standard service intervals If you notice any abnormalities such as abnormal noise black exhaust smoke white exhaust smoke extremely high temperature of exhaust gas abnormal vibration and fuel oil or exhaust gas leakage make sure to conduct the inspection and maintenance work regardless of rec ommended service intervals in the Maintenance schedule Note Appropriate service intervals vary depending on the usage and operating conditions as well as consumption of fuel oil and coolant Check the operating record of the engine to d
159. nce 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 MAIN FIELD Exiter Armature SERIES connection 2 1 3 AREP system with R 438 AVR MAIN FIELD Exiter Armature PARALLEL connection 2 1 4 PMG system with R 438 AVR MAIN FIELD Exiter Armature PARALLEL connection 2 2 Mechanical characteristics Steel frame Cast iron end shields Protected ball bearings greased for life Mounting arrangements IM 1201 MD 35 foot and flange mounted single bearing with SAE coupling disc IM 1001 B 34 double bearing with SAE flange and standard cylindrical shaft extension Drip proof machine self cooled Degree of protection IP 23 2 2 1 Options Air inlet filter Regreasable bearings only for LSA 44 2 and SHUNT or AREP version IP 44 protection STATOR 12 wires marked T1 to T12 T1 17 T2 T8 T3 T9 T4 1710 15 111 T6 T12 Power supply and voltage reference STATOR 12 wires marked T1 to T12 Auxiliary windings T1 17 T2 T8 T3 T9 T4 T10 15 111 T6 T12 Voltage reference STATOR 12 wires marked T1 to T12 T1 17 T2 Te T3 T9 T4 T10 T5 T11 T6 T12 Voltage reference LEROY SOMER 5 173 202 LSA 43 2 44 2 4 POLE ALTERNA
160. nd patents applied for LEROY SOMER 3 191 202 LEROY SOMER R438 A V R 1 SUPPLY 1 1 AREP excitation system For both AREP 8 PMG excitation systems the alternator voltage regulator is the R438 With AREP excitation the R438 electronic AVR is powered by two auxiliary windings which are independent of the voltage match circuit The first winding has a voltage in proportion AREP SYSTEM MAIN FIELD Slow fuse F1 250V 8A STs ff aie with LAM without LAM ST3 mA d Frequency 50Hz 60Hz LAM 13 25 Excitation P5 3 ceiling open knee point 65 Hz Response f 1 normal ST2 time FA fast K P3 Stability Single phase detection Aux windings 10 Yellow to that of the alternator characteristic Shunt the second has a voltage in propor tion to the stator current compound charac teristic Booster effect The power supply voltage is rectified and filtered before being used by the AVR moni toring transistor This principle ensures that regulation is not affected by distortions ge nerated by the load STATOR 6 wires marked T1 to T6 STATOR 12 wires marked T1 to T12 according voltage 4 x holes 5 8 x 175x 115 mm 200 mm pros ST9 aE Ph 1 P1 ST4 Option External potentiometer for adjusting the voltage P2 1 Option
161. nd set apart by at least their length impermeable rock Example 4 interconnected 1 metre rods separated by 1 metre Note For the United States National Electrical Code reference NFPA 70 The generating set must be earthed To do this use a copper wire with a minimum cross section of 13 3 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 2 Earthing system principle The Earthing system or SLT formerly Neutral system of the electrical facility defines the situation of the generating set neutral in relation to earth and the grounds of the electrical facility at the user end The purpose of the earthing systems is to protect personnel and equipment by managing risks posed by insulation defects For safety reasons any live conducting part of a facility must be insulated from the earth This insulation may be achieved by distance or by using insulating materials But with time insulation may deteriorate due to vibrations mechanical impacts dust etc and therefore generate an earth with dangerous potential This defect poses risks for personnel and property but also continuity of service Earthing systems are codified by two letters that define the connections v The first letter defines the neutral connection EN Insulated or earthed
162. nfringement of any patent Mitsubishi Heavy Industries Ltd will not be liable for any damages or consequential damages including but not limited to damages or other costs resulting from any abuse misuse misapplication of the engine and devices supplied from us Mitsubishi Heavy Industries Ltd will not be liable for any damages or personal injuries resulting from any modification without our written permission of the engine and devices supplied from us Mitsubishi Heavy Industries Ltd will not be liable for any damages or production losses caused by the use of fuel engine oil and or long life coolant LLC that we are not recom mended The owner of the engine is responsible for the performance of the required maintenance listed in this operation manual Mitsubishi Heavy Industries Ltd may deny the warranty coverage if the engine or part has failed due to inadequate or improper maintenance 73 202 FOREWORD Emission warranty IMPORTANT The following warranty applies to the engines that are approved of the emission regulation of the U S Environ mental Protection Agency Warranty coverage Mitsubishi Heavy Industries Ltd warrants to the first owner and each subsequent purchaser of a new non road die sel engine that the emission control system of your engine vis designed built and equipped so as to conform at the time of sales with all applicable regulation of the U S Envi ronmental Protection Agency If
163. ngine in an operable condition for 3 months or more When the engine is not operated during storage of 3 months or more internal engine parts can rust and lose oil film As a result the engine can seize when it is started after storage To prevent such a risk the engine must be oper ated periodically during storage Operating the engine for maintenance Operate the engine for maintenance at least once a month as described below 1 Run the engine with starter for approx 10 seconds while pulling the stop lever Stop the operation for approx 1 minute then repeat the operation two or three times 2 Make sure the engine oil pressure rises 3 Operate the engine about 5 to 10 minutes under no load as the maintenance operation Note For starting the engine refer to Starting 3 4 9 2 149 202 Chapter 10 TRANSPORTATION Lifting the engine o OA WARNING _Z___ To lift the engine use wire ropes shackles and slings capable of supporting the weight of the engine Attach the wire rope to the hangers provided on the engine using a correct sling Keep the engine balanced during lifting by consider ing the engine s center of gravity Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load could be imposed on the hangers and this could damage the hangers and result in a serious accident Attach wire ropes to the hangers after removing the pipe cover and the insulator near th
164. nt drain cocks and plugs 4 Pour in fresh water and operate the engine at 800 to 900 min for about 10 minutes Repeat rinsing until the draining water becomes clear and clean Coolant Refill 1 Tighten the coolant drain cocks and plugs 2 Remove the radiator filler cap and pour in undilut ed LLC Note Determine the amounts of LLC and water to be added by using the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICA TIONS 12 1 3 Pour in water soft water with minimal impurities such as tap water slowly to FULL level line 4 Check the radiator and other parts for coolant leak age If any coolant leakage is found repair it 5 When coolant reaches FULL level line close the radiator filler cap securely 6 Runthe engine with starter for approx 10 seconds while pulling the stop lever Stop the operation for 1 minute then repeat the operation two or three times to bleed the cooling system 7 Check the coolant level in the radiator If the engine is equipped with a reserve tank fill the reserve tank with coolant to FULL level line as well Always use the coolant with the same LLC concen tration 8 12 141 202 Fig 8 19 Coolant drain plug engine Fig 8 21 Reserve tank Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Radiator fins Check and Clean When handling compressed air wear safety goggles a hardh
165. ntal contact with parts at high temperatures exhaust manifold exhaust v Before any maintenance operation on a lighting column light cut the electrical power supply and wait for the bulbs to cool down Consumables v Observe regulations in force concerning use of fuel before using your generating set pump unit or lighting tower v Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit Environment v 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 v 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 v The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements v Facilities must be operated under the constant supervision of a qualified person who must regularly check that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply v Apart from the combustion devices it is prohibited to use fire in any form This restriction must be clearly displayed 6 202 SN OAS SS Spreading of waste water sludge and waste is prohibited The fuels to be
166. ntling 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 Rest the rotor on one ofits poles then slide it out Use the tube as a lever arm to assist dismantling After extraction of the rotor be careful not to 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 assembly 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 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 4 7 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 Mounting is impossible with the regreasable bearings option with the LSA 44 2 4 8 Electrical characteristics Table of average values Alt
167. nts to the machine should be made on the AVR 3 2 1 R438 settings AREP or PMG system WARNING Before any intervention on the A V R make sure that the ST9 jumper is closed with AREP excitation and disconnected with PMG or SHUNT or separate excita tion a Initial potentiometer settings see table below Remote voltage adjustment potentiometer centre ST4 jumper removed 400V 50 Hz Input O 380 V Voltage minimum fully anti clockwise Stability Nobel centre position Voltage quadrature droop Not set operation with C T fully anti O quadrature loop fully clockwise anti clockwise Excitation ceiling Limit of excitation and 10A short circuit current maximum minimum fully anti clockwise Stability adjustments in standalone operation b Install a D C analogue voltmeter needle dial cal 50V on terminals E E and an A C voltmeter cal 300 500 or 1000V on the alternator output terminals c Make sure that the ST3 jumper is positio ned on the desired frequency 50 or 60 Hz d Voltage potentiometer P2 at minimum fully anti clockwise e Stability potentiometer P3 to around 1 3 of the anti clockwise limit f Start the engine and set its speed to a fre quency of 48 Hz for 50 Hz or 58 for 60 Hz g Set the output voltage to the desired va lue using P2 Rated voltage UN for solo operation eg 400 V Or UN 2 to 4 for parallel operation with C T eg 410 V
168. o release inter nal pressure Never open the radiator filler cap while the engine is hot otherwise the steam or hot coolant spurts out and you may be scald with it Coolant containing LLC drained from the engine is toxic Never dispose of coolant into regular sewage For disposal of used coolant consult a dealer of Mit subishi Heavy Industries Ltd or a industrial waste disposer Fig 8 17 Radiator filler cap The service life of LLC is 2 years Be sure to change coolant at least once every 2 years Coolant Drain 1 When draining coolant immediately after engine operation idle the engine in low gear for 5 to 6 min o e ler ce utes until the coolant temperature drops to 70 to 80 C 158 to 176 F Open the radiator filler cap Place coolant receiving can under the drain cocks and plugs and open the coolant drain cocks and plugs to drain the coolant oN Coolant drain cock Fig 8 18 Coolant drain cock radiator 8 11 140 202 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system Clean Clean the cooling system when operating the engine first time or restarting the engine after storage with coolant drained Close coolant drain cocks and plugs 2 Pour in a cleaning solution a solution that is non corrosive to rubber and metals in the cooling sys tem and operate the engine at 800 to 900 min for about 15 minutes then drain the cleaning solution 3 Close coola
169. odes 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 the alarms and faults that appear as soon as OK is pressed 25 12 2005 15 30 7 Maintenance schedule 7 1 Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule given as a guideline N B the environment in which the generating set is operating determines this schedule If the generating set is used in extreme conditions shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel oil and coolant which conform to the specifications given in this manual 7 2 Maintenance safety instructions Before each operation please observe the following maintenance safety instructions read the safety instructions carefully chapter 1 refer systematically to the maintenance instructions the battery isolating switch must be in the open position no operations must be carried out while the motor is running wear protective equipment gloves goggles safety shoes etc before operating on a pressurised circuit ensure that the circuit pressure has been reduced atmospheric pressure after the oper
170. 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 the scrolling and selection wheel to scroll through ALARM 25 12 05 15 30 the list of faults Low Fuel Level GS OK HELP Esc Check Emerg Stop Pos Connector s Esc If the alarm is no longer active it is reset automatically cause disappears Press Esc to reset a fault reset acknowledged if the cause of the fault has been removed reset not performed if the cause of the fault is still present 58 202 EN 6 3 4 4 Engine fault codes display Certain alarms and engine faults generate specific fault codes These codes are standardised according to the J1939 and or J1587 standards Terminology used by the SAE CAN J1939 standard SPN Suspect Parameter This represents the system or component at fault for example SPN 100 Number indicates an oil pressure problem or a problem with the oil pressure sensor This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by VOLVO FMI Failure Mode identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to an assembly of components for example the injection system SID System Identifi
171. oided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Note Indicates important information or information which is useful for engine operation 80 202 FOREWORD Units of measurement Measurements are based on the International System of Units SI and they are converted to the metric system units in this manual using the following conversion rates Pressure 1 MPa 10 197 kgf cm Torque 1 N m 0 10197 kgf m Force 1 N 0 10197 kgf Horsepower 1 kW 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 75 cmHg Meter of water 1 kPa 10 197 cmH20 cmAg Engine speed 1 min 1 rom Kinetic viscosity 1 mm s 1 cSt Abbreviations standards and others API American Petroleum Institute ASTM American Society for Testing and Materials ISO International Organization for Standardization JIS Japanese Industrial Standards LLC Long Life Coolant MIL Military Specifications and Standards MSDS Material Safety Data Sheet SAE Society of Automotive Engineers 81 202 CONTENTS Chapter 1 BASIC SAFETY PRECAUTIONS Fire and explosions occooccooccoccccncoccos 1 1 Keep flames aWay ccooccoccnoconncocncncnnncnonanonanonas 1 1 Keep engine surrounding area tidy and c
172. on the tow vehicle 0000000 CORRECT CORRECT Tow vehicle Tow vehicle Trailer Trailer INCORRECT INCORRECT Tow vehicle Tow vehicle Trailer Trailer Diagram 4 1 Coupling a trailer 4 2 Check before towing Before towing check the following Tightness of the generating set enclosure bolts Wheel tightness Hitching hook locked Tyre pressure 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 SENN ON A SANS 29 202 EN 4 3 Operation On site trailer 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 itis absolutely prohibited to exceed this speed Nor are these trailers fitted with signalling lights On road use is prohibited On roaa 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 In the first few miles
173. onitor 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 6 SOMER 174 202 INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3 2 2 Mechanical checks 3 3 Terminal connection diagrams Before starting the machine for the first time check that To modify the connection change the position of the terminal the fixing bolts on the feet are tight cables The winding code is specified on the nameplate 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 shaft end phase rotation in order 1 2 3 For anti clockwise rotation swap 2 and 3 the winding connection corresponds to
174. onomy tank Dimensions x wxh 2200 mm x 1000 mm x 1528 mm ar Weight E 1150 kg dry weight 1350 kg in operating configuration BEER Hood GERD M3127 Sound pressure level at 1 m 73 dB A measurement uncertainty 0 70 Emergency 2 kW kVA 400 230 _50 3 08 5 amp 8 32 40 29 36 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 10 one hour every 12 hours is available as per ISO 3046 1 Term of use Standard reference conditions ESP PRP 40 409 Air Intlet Temp 1000m 1000m mA S L 60 relative humidity Engine data Fuel consumption 100 main power 10 4 L h Fuel type High autonomy fueltank 0 High autonomy fuel tank Engine capacity with radiator Max coolant temperature Fan power Refrigerant type Thermostat 76 5 90 GC 13 202 Alternator data e The alternator is protected against short circuits e Vacuum impregnation epoxy winding IP23 protection rating LEROY SOMER LSA43 2S159 CE AREP 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
175. ononos 8 14 Pre cleaner Clean Inspect and Replace 8 15 Air cleaner element Clean Check and A A 8 16 Electrical SyStemM oocococcccccicconncno 8 17 Siafter INSPeCliusaiani ala 8 18 Alternator INSpeCt ooccccccnncccconncocacncoconcnnnos 8 18 Chapter 9 LONG TERM STORAGE Long term storage cccoocccoccconcncnncncnncos 9 1 Storing the engine in a non operable condition for 3 months or more 9 1 Preparation for Storage cooocccccocnnccoccnccnncnnnnnos 9 1 Maintenance during Storage ccccooccnncccncccnnnn 9 1 Using the engine after storage 9 2 Storing the engine in an operable condition for 3 months or more 9 2 Operating the engine for maintenance 9 2 84 202 Chapter 10 TRANSPORTATION Lifting the engine 10 1 Chapter 11 TROUBLESHOOTING General precautiOnS coocccconcnnco 11 1 Contact a dealer of Mitsubishi Heavy Industries Ltd for repair Service 11 1 Considerations before work cccconnncccccomm o 11 1 Cautions against contamination 11 1 Cautions regarding parts handling 11 1 Work safety ccccsesceceeeeeseeeeeeeeeeeseeeesseeeeeas 11 1 Troubleshooting ccoocccoccccccnnccccnnno 11 2 The starter does not crank or cranks slowly resulting in start failure occocooncccococinccncononos 11 2 The starter cranks but the engine does not O IN A 11
176. ontent in fuel is burned and transformed into sulfurous acid gas and sulfuric gas that cause corro sive wear of cylinders and piston rings A detergent additive in the engine oil neutralizes them into harm less substances As the detergent additive is con sumed in its role of neutralizing the engine oil total base value decreases A decrease in the total base value indicates a corresponding decrease in soot dis persion ability As a result deposits on the pistons in crease Due to oxygen in the air oil temperature rise under high load continuous operation causes oxidation deg radation As oxidation degradation accelerates oxi dative products are polymerized The polymerized oxidative products cause the oil viscosity to increase which leads to the generation of sludge and varnish As a result problems such as lubrication failure and piston ring sticking occur Also acid substances gen erated by oxidation can cause problems like main bearing corrosion Chapter 5 ENGINE OIL Definition of properties of engine oil Viscosity Viscosity is a basic physical property of engine oil and is considered as the most important aspect when eval uating oil Contamination of oil by blow by gas and deterioration of oil by its natural aging in crease the viscosity and degrade the performance of viscosity which will cause the deposition of sludge inside the engine and oil filter clogging Contamination of oil by fuel and sheared molecules
177. op solenoid Oil cooler Fuel filter Water pump Coolant inlet Coolant drain plug Fuel injection pump VE Oil filter Relief valve T Oil drain plug Oil level gauge Fig 2 13 Engine left view S6S T distributor type fuel injection pump right view Turbocharger Air inlet Oil filler Exhaust outlet Coolant outlet Oil filler Rear a ti a hanger Al EL p u Thermostat case Fuel return port oo i X AGA SS l i ye por ie E di Fuel inlet SE HS gt IRE a gt BR S Alternator SS IVA TAME gE Fi cit F ro nt Damper Fig 2 14 Engine right view 2 1 102 202 Chapter 2 NAME OF PARTS Equipment and instrument The installed equipment and shapes differ on the engine type Starter switch The starter switch is used to start the engine HEAT When the key is turned to this position the glow plugs 7 START become hot and allow easy startup of a cold engine lt OFF When the key is turned to this position power supply to the electric circuits is cut off and the key can be removed and inserted at this position To sotp engine turn the key to this position ON When the key is at this position power is supplied to Fig 2 15 Starter switch the electric circuits After the engine starts the key is set to this position START When the key is turned to this position the starter cranks the engine and the engine starts When the key is released ti automatical
178. 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 symbols to alert the user to potential risks of accidents It is vital that you unders tand and take notice of the following warning symbols This A V R can be incorporated in a ma chine marked C E WARNING Warning symbol for an operation ca pable of damaging or destroying the ma chine or surround ing equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest tech nological developments The information contained in this document may therefore be changed without notice LEROY 2 SOMER 190 202 LEROY SOMER Installation and maintenance R438 A V R CONTENTS A PPP e Sy PON UA 4 1 1 AREP excitation system apsaietossineravsmiasusinesladnati onurinscedhimesiiadoiinooliateindahersandesimanniadeaanecs 4 1 2 PMG excitation SSI isso rita 5 1 3 SHUNT or separate excitation SySteM o
179. ossible in situ v The 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 v 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 v Warn personnel present to keep their distance during operation v Do not run the generating set pump unit or lighting column without refitting the protective covers and closing all the access doors v Never let a child touch the generating set pump unit or lighting column even when shut down v Avoid operating the generating set pump unit or lighting tower in the presence of animals disturbance scares etc v 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 v Never start the engine without an air filter or exhaust Y Engine with turbocharger never start the engine without fitting the air filter The compressor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage v Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact wit
180. 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 NS 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 IMMEDIATELY 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 Caution fuels and oils are dangerous to inhale Ensure proper ventilation and use a protective mask Never expose the equipment to liquid splas
181. ower the stands if fitted and lock them SBS SS 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 O After fitting the wheels on the axle turn the wheels in the FORWARD direction on all RA 2 type brakes check that the adjustment screw 8 reaches the FORWARD stop on the brake backing plate 2 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 O Tighten all the lock nuts Checking the setting tr
182. p and check the coolant level 2 Ifthe coolant level is low add coolant to the speci fied level Always use the coolant with the same LLC concen tration Note Determine the quantities of LLC based on the coolant capacity and the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICA TIONS 12 1 3 Ifa reserve tank is equipped fill the reserve tank with coolant up to the FULL level line Fig 3 6 Reserve tank coolant level 3 3 110 202 Chapter 3 OPERATION Starting The starting method changes based on the application and specifications Start the engine according to the specified procedure Before starting the engine check to make sure no one Is near the engine and that tools are not left on or near the engine In a loud voice notify people in the area when starting the engine Do not apply a load to the engine at starting Disengage the clutch if installed Continuous operation of the starter will drain the battery power and cause the starter to seize Do not use the starter for more than 10 seconds at a time When the engine does not start wait for more than one minute before cranking again Warm up operation WARNING Do not approach rotating parts during operation Entanglement by rotating parts can cause serious injury After the engine starts operate the engine in a no load condition at low idling speed for 5 to 10 minutes to w
183. 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 10 LCD for displaying alarms and faults operating statuses electrical and mechanical quantities 11 ESC button for returning to the previous selection and for default RESET function 12 MENU button for accessing the menus 13 Lighting for the emergency stop button O ON OD O a ND 44 202 Fig 6 5 Description of the LEDs A lit LED indicates 1 2 3 Alarm activated flashing yellow Fault found flashing red Module on green on continuously Fig 6 6 Close up of USB ports USB key connection HOST file transfer between USB key and TELYS and vice versa Connection for microcomputer DEVICE gt file transfer between PC and TELYS and vice versa gt main module power supply Protective cover 45 202 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 f f f IRPA eer Om e A A a A paa 0 _ gt HQ gt OM i l O fa CF A PSI i S A JN o JR Rieles t 03 a t f ee Se CF Al PSI ZBARF SERIAL No 08030010000 SOFTWARE 5 3 5 NOMINAL VOLTAGE 400V FREQUENCY 50Hz NOMINAL KW 320kW E EARTH SYSTEM TNS Fig 6 7 descrip
184. r transport support brackets under optimum safety and efficiency conditions you must ensure that the following points are observed Y v 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 its 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
185. rcoal Table 11 5 Exhaust smoke is black or charcoal Cause Remedies Use appropriate fuel Refer to P4 1 Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd oe Check exhaust smoke temperature Uneven fuel injection l o l Consult a dealer of Mitsubishi Heavy Industries Ltd eCheck turbocharger Refer to P8 14 Clean inspect and replace pre cleaner Refer to P8 15 Clean inspect and replace air cleaner element Insufficient amount of air Refer to P8 16 Inlet and Check intake air pressure and leakage of intake air oe Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 14 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Control Check control system Increase in load a l system Consult a dealer of Mitsubishi Heavy Industries Ltd 11 5 156 202 Chapter 11 TROUBLESHOOTING Fuel consumption is high Table 11 6
186. rds in the relevant country 3 4 2 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 51 100m T01 150m mm AWG 4 10 6 9 6 9 10 7 10 7 16 5 16 5 25 3 PO TORO EE DBB EE 35 2 4X 1X50 0 1 4X 1X50 0 4X 1X70 2 0 1 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 1 4X 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 1 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 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 Cable sizes OBEN mA WO 10 7 1675 25 3 25 3 35
187. re 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 YYYY 40 202 6 2 2 Manual starting A Check that the generating set circuit breaker has triggered O connect the generating set battery 2 turn the key switch to the ON position without forcing it All of the LEDs light up for 2 seconds to confirm that they are operating correctly If the LEDs do not light up check the protection fuse and replace it if necessary All the items on the screen are displayed for 2 seconds Only the ON LED remains lit to indicate that the module is powered up The following screen appears KASSA I DD ty RI The first line displays the motor speed in RPM AL Y The second line displays the battery voltage in volts V Y Check the battery voltage min 12 V O Press once briefly the green START button v If the motor is equipped with an air preheating system there is a 10 second delay before the motor starts preheating activation period v The screen appears RA l Ut IJ The third line displays the air preheating time Ja o remaining with pictograms representing a wy ls resistor and an hourglass v If the motor is not fitted with an air preheating system or once the preheating delay has elapsed the engine starts
188. rent 6A approximately 6 hours charging required KAASAS 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 battery The power of the charger must be suitable for the battery to be charged and the charging time available You need to use an automatic charger able to provide a sufficient voltage and charging current as well as a compensation voltage to handle spontaneous battery discharge 65 202 8 5 Faults and remedies Fault observed Probable origin Measures or observations Incorrect composition Cool es heats up when a new battery is correct storage ROA Prolonged storage in a damp place 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 Acid level too low Excessive charge voltage leading to Check the charger and repair if a significant accumulation of gas necessary Acid level too low Insufficient charge Recharge Short circuit in the power circuit i is Incorrect operation from start up Consumption fault Check the electrical installation Reduce the acid level by filling with Acid density too high i E do He Macia distilled water Repeat the operation if y necessary Battery empty Battery exhausted or faulty Starting problems Capacity too low Recharge the batter
189. required for Bulk tank level high lifting Rinse any splashes of acid on the skin or in the eyes using clean water Consult a doctor immediately Contaminated clothes must be washed with water During any operation on the Fuel supply selection valves batteries wear protective glasses and protective clothing Important refer to the documentation accompanying the generating set Warning emission of toxic exhaust gases Do not use in a confined or badly ventilated area Figure 1 1 continued Pictograms and their meanings 5 202 EN 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 itto 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 v The operating and safety instructions must be made known to operating personnel They will be regularly updated v 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 p
190. ry weight 355 kg 783 Ibs Fuel Diesel fuel equivalent for JIS K 2204 Fuel injection pump In line or distributor type VE type Fuel filter Cartridge type pape element with water separator Fuel injection nozzle Hole type Initial fuel injection pressure 17 65 MPa 180 kgf cm 2560 psi Lubrication method Forced circulation pressure feed by oil pump Lubrication oil Class CF or CH 4 oil API service classification Engine oil capaciy ee ete ee Oil filter Cartridge type paper element Oil cooler E Cooling method Forced water cooling by centrifugal pump Coolant capacity erie ad ie parteras acc Starting system Electric motor starting Starter DC 12 V 3 0 kW or DC 24 V 5 0 kW Alternator DC12V 50A orDC 24 V 25A Mitsubishi TDO6H Turbocharger Note a The specifications above are subject to change without prior notice b The specifications above are described for the standard model The special model specification may differ from those of standard model 12 2 162 202 July 2009 A OPERATIONS MANTEANCEMANAL SS SERIES Pub No 99610 29120 163 202 Printed in Japan Pub No 99610 29120 164 202 EN 9 2 Appendix B Alternator user and maintenance manual 165 202 166 202 User guide and maintenance manual LEROY SOMER Alternator 43 2 amp 44 2 SHUNT AREP amp PMG 3434 33522059401 6 1 01 10 2010 168 202 LEROY SOMER 3434 en 2010 10 i LSA 43 2 44 2
191. s specified above turbidity is specified to be below 15 mg liter Long life coolant LLC Should coolant or LLC be accidentally consumed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention Be sure to use Mitsubishi Heavy Industries Ltd genuine long life coolant LLC GLASSY long life coolant Ethyl ene glycol type or PG GLASSY long life coolant Non amine type as coolant When using other brand LLCs by necessity be sure to use the LLC that meets the specification in Mitsubishi Heavy Industries Ltd Mitsubishi heavy industries Ltd disclaim the warranty claim concerning malfunctions caused by the use of LLC that does not meet the following specification Genuine LLC Mitsubishi Heavy Industries Ltd recommends the use of our genuine long life coolant GLASSY long life coolant Ethylene glycol type and Eco friendly prod uct PG GLASSY long life coolant Non amine type which are most appropriate coolant for diesel engine from Mitsubishi Heavy Industries Ltd Fig 6 1 GLASSY LLC 6 1 122 202 Chapter 6 COOLANT Other brand LLCs CAUTION Never mix Mitsubishi Heavy Industries Ltd genuine LLC with other brand LLCs Mixing with other brand LLCs degrades the performance of Mitsubishi Heavy Industries Ltd genuine LLC When using LLC other than Mitsubishi Heavy Indus tries Ltd genuine long life coo
192. slipring of a new bearing by induction or ina 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 Refit the 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 Rotor NDE shield Screw rod 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 the 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 Check that 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 13 181 202 LSA 43 2 44 2 4 POLE ALTERNATORS 4 4 6 7 Accessing the main field and stator 4 6 7 1 Disma
193. stion 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 Lf Y 4152 en 12 2009 c LEROY SOMER 19 187 202 188 202 LEROY SOMER 3971 en 2010 11 f T1 T7 T4 T10 R438 A V R Installation and maintenance 189 202 LEROY SOMER R438 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your A V R you can look forward to many years of trouble free
194. t potentiometer Two types of differential relay are fitted on the generating sets Type A Differential device for which operation is guaranteed v for residual sinusoidal alternating currents v for continuous pulsed residual currents v for continuous pulsed residual currents with a continuous component of 0 006 A with or without phase check independent of the polarity Type B Device for which operation is guaranteed as in the case of type A for residual sinusoidal currents up to 1000 Hz for residual sinusoidal currents superimposed on a pure continuous current for continuous pulsed currents superimposed on a pure continuous current for residual currents which could come from rectifier circuits e three phase half wave rectifier or a three phase full wave bridge rectifier full wave bridge rectifier between phases with or without phase angle check independent of the polarity o e a Our residual current devices are factory set with an activation threshold of 30 mA and with automatic cut off Depending on the use if the residual current device is modified it is recommended to fit a seal to prevent any tampering when the generating set is being used 27 202 3 6 Connection summary Mark the type of differential protection Fixed genset differential protection Adjustable genset differential protection No operation required Add differential protection No operation required Add differential protection terminal c
195. t with the primary purpose of reducingemissions or that can increase emission during fail ure without significantly degrading engine performance e Mitsubishi Heavy Industries Ltd shall furnish with each new engine written instructions for the maintenance and use of the engine by the owner LIMITED WARRANTY Refer to LIMITED WARRANTY VII 78 202 FOREWORD Important information To avoid the potential hazard accident prevention activities must be planned methodically and con ducted continually by considering all aspect of engine operation maintenance and inspection All related personnel including managers and supervi sors should actively participate recognize their roles and organize themselves and their work to ensure a safe environment The foremost safety objective is to prevent accidents which may result in injury or death or equipment damage Always observe laws or regulations of the local or federal national government Mitsubishi Heavy Industries Ltd cannot foresee all potential dangers of the engine potential danger resulting from human error and other causes or dan ger caused by a specific environment in which the engine is used Since there are many actions that cannot be performed or must not be performed it is impossible to indicate every caution in this manual or on warning labels As such it is extremely important to follow directions in this manual and also to take general safety measur
196. tenance manuals appended Additionally in the event of an abnormal rise in engine temperature check that the radiator is clean 7 5 No load and under load tests Notes on operation at no load and under load When operating at no load or low load lt 30 of nominal power the operating conditions do not allow optimum running of the engine The main causes are as follows Y The low volume of fuel burned in the combustion chamber leads to incomplete combustion the resulting thermal energy means that the optimum engine operating temperature cannot be reached Y Overheated engines have lower compression ratios low compression ratio without turbocharging which are defined for full load and not suitable for good combustion at low load All of these factors lead to choking of the engine in particular the piston rings and valves which leads to v Accelerated wear and glazing of the cylinder liners v Loss of sealing of seats and sometimes sticking of valve stems Consequently operating any turbocharged engine at low load lt 30 can only have adverse repercussions on an engine s operation and its service life Maintenance intervals will have to be shortened to accompany harsh operating conditions Shortening draining intervals among other things will enable you to change the oil more frequently which will tend to be choked with unburnt particles and contaminated with fuel Adding a load bench is generally used to limit low load p
197. the site operating Any intervention on the alternator terminals during voltage see section 3 3 reconnection or checks should be performed with the machine stopped Connections codes L L voltage MEC EEES R 250 voltage sensing O gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 Winding 50 Hz 60 Hz 6 380 415 380 480 R 250 voltage sensing O gt T8 110 V gt T11 R 438 voltage sensing LAV o gt T3 380 V gt T2 50 Hz 60 Hz 220 240 220 240 O gt T1 110 V gt T4 T12 R 438 voltage sensing 0 gt T10 220 V gt T1 Winding 50 Hz 60 Hz 6 220 240 220 240 3 phases E 7 250 260 NN R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 Factory connection L3 W LM voltage 1 2 LL voltage LEROY SOMER E 175 202 INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 15 Winding 50 Hz a Hz Anas 110 120 3 phases Y 120 130 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 110 V gt T2 AN FOR LSA 44 2 THE COUPLING B IS NOT POSSIBLE Connection not Winding 50 Hz 0 Hz Sannacton no eS tee 220 240 a 240 250 260 R 250 voltage sensing O gt T8 110 V gt T11 R 438 voltage sensing 0
198. ting Sustained use of the engine without any remedy could result in serious engine problems Avoid continuous engine oper ation at low oil pressure If an abnormal engine oil pressure drop is indicated stop the engine immediately and inspect the lubrica tion system to locate the cause Continuous engine operation with low oil pressure could cause bearings and other parts to seize If belt breaks stop engine immediately If the belt breaks stop the engine immediately Con tinuous engine operation with the broken belt could cause the engine to overheat and thereby the coolant to boil into steam which may gush out from the reserve tank or radiator and you may be scalded with it 1 5 Chapter 1 BASIC SAFETY PRECAUTIONS Service battery Handle the battery correctly Never use flames or allow sparks to generate near the battery The bat tery releases flammable hydrogen gas and oxygen gas Any flames or sparks in the vicinity could cause an explosion Do not use the battery when the battery electrolyte level of which is below LOWER LEVEL line Sus tained use of the battery could result in an explosion Do not short the battery terminals with a tool or other metal object When removing battery always remove the plug from the negative terminal first When connecting bat tery always connect the plug to the positive termi nal first Remove all plugs then charge the battery in a well venti
199. tion of the screen example O Zone 1 in this zone the status of the generating set is displayed Zone 2 in this zone pictograms relating to dimensions measured are displayed as well as Alarm and Fault pictograms Zone 3 in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement O Zone 4 in this zone messages relating to the control of the generating set and the menus are displayed Note the information displayed on measurements alarms and faults as well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set Certain screens may therefore not be present 46 202 6 3 1 3 Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms Display Activation conditions TELYS in manual mode MANU Flach For 5 seconds when switching from g AUTO mode to MANU mode TELYS in automatic mode AUTO l Flashing For 5 seconds when switching from AUTO Mode MANU mode to AUTO mode Flashing Generating set in start up phase Generating set stabilised voltage and Fixed frequency Flashing appearance of constant The generating set is powering the movement from left to right installation 47 202 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 Dat
200. ts according to settings menu Fuel Level Indicator P3 Alternator composite Voltage Indicator Default screen in operation Total Active Power Indicator Alternator Frequency Indicator U12 Alternator composite Voltage Indicator U23 Alternator composite Voltage Indicator U31 Alternator composite Voltage Indicator Alternator Frequency Indicator 49 202 V1 Alternator single Voltage Indicator V2 Alternator single Voltage Indicator V3 Alternator single Voltage Indicator Alternator Frequency Indicator U12 Alternator composite Voltage Indicator V2 Alternator single Voltage Indicator V1 Alternator single Voltage Indicator Alternator Frequency Indicator V1 Alternator single Voltage Indicator Single phase Alternator current indicator Alternator Frequency Indicator Single phase Alternator current indicator Two phase Alternator current indicator Three phase Alternator current indicator Neutral Alternator current indicator Total Active Power Indicator Total Reactive Power Indicator Total Effective Power Indicator Total Power Factor Indicator lagging or leading 50 202 H T t f Fuel Level Indicator art Me H Indication of Battery Voltage Screen order of appearance according to network type with the generating set on P10 Order of appearance Coo G ee Change screens by using the scrolling and selection wheel When the wheel is rotated clockwise the screens scroll upwards and vice
201. tsubishi Heavy Industries Ltd shall be liabldor damages to other engine components proxmately caused by failure under warranty of any warranted part 8 Throughout the engine s warranty period defined in Subsecton b 2 Mitsubishi Heavy Industries Ltd shall maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any maintenance or repairs and must be provided without charge to the owner Such use shall not reduce the warranty obligations of Mitsubishi Heavy Indus tries Ltd 76 202 FOREWORD 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified p arts shall be grounds for disallowing a warranty claim Mitsubishi Heavy Industries Ltd shall not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part 11 The Air Resources Board may request and in such case Mitsubishi Heavy Industries Ltd shall provide any documents which describe that Mitsubishi Heavy Industries Ltd s warranty procedures or policies d Warranted parts list 1 Fuel metering system A Fuel injection system B Air fuel ratio feedback and control system C Cold start enrichment system 2 Air induction system A Controlled hot air intake system B Intake manifold C Heat riser valve and assembly D Turbocharger
202. ttery electrolyte level Inspect 8 17 Specific gravity of battery electrolyte CTC A a teats Sak aceea eae 8 17 Starter INS pClass 8 18 Alternator INSD Ct ccccsseeeeeeeeeees 8 18 Hangers eeir 10 1 Engine s center of gravity standard specification 10 1 CONTENTS List of tables Table 3 1 Standard values at rated speed 3 5 Table 4 1 Recommended limit and use limit of TUE Propecia is 4 2 Table 5 1 Engine oil properties cccoonnccccncccn 5 4 Table 6 1 Water quality standardS 6 1 Table 6 2 LLC specification oooononnnnininncnnimmm 6 3 Table 6 3 Recommended LLC concentration 6 5 Table 7 1 MAINTENANCE SCHEDULE 7 2 Table 8 1 Specific gravity of electrolyte 8 17 Table 9 1 Recommended rust preventive oil and corrosion inhibitor oooonccnncccccnc 9 1 Table 11 1 The starter does not crank or cranks slowly resulting in start failure 11 2 Table 11 2 The starter cranks but the engine GOSS NOT SIAM uta ios cel di 11 2 Table 11 3 Output decrease ccoooonccnnococcnoncccnnnnnnss 11 3 Table 11 4 Exhaust smoke is white or blue 11 4 Table 11 5 Exhaust smoke is black or charcoal 11 5 Table 11 6 Fuel consumption is high 11 6 Table 11 7 Engine oil consumption is high 11 7 Table 11 8 Overheating
203. ture when activated gt 10 C Fill with acid to the mark or about 1 cm above the edge of the plates battery becomes hot 5 to 20 mins lt 12 5 V charge 10 mins gt 125 V Fit on the set 8 3 Check Acid density Charge status Voltage when idle l 100 Above 12 60 V IN 12 54 V EEE 12 36 V From 50 recharge 12 18 V Risk of sulphation Under 11 88 V Umusable 64 202 EN 8 4 Load preconization v Highly discharged or sulphated batteries formation of whitish lead sulphate deposit on the plates which becomes hard and insoluble to acid this deposit reduce the active surface of the plates and increases their internal resistance can no longer regenerate or be charged in a generating set A A discharged battery should be recharged immediately or else it will suffer irreparable damage Important Battery charge When several batteries are connected together the following points should be checked Are the batteries connected in series Has the correct voltage been chosen 1 battery x 12 V 3 x 36V batteries Adjust the charge current to the lowest battery The power difference between the batteries must be as low as possible E ON Example of charge 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery is short 30 Ah and this must be recharged Charge factor 1 2 Ah x 1 2 36 Ah to be charged Charging cur
204. ure Ner Type External 10 C 14 F 20 C 4 F 30 C 22 F 45 C 40 F or above or above or above or above H Pears ra o s 7 Note a If the outside air temperature is 30 C or less use GLASSY b The concentration above is based on Mitsubishi Heavy Industries Ltd genuine LLC GLASSY long life coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type For determining the accurate LLC concentration refer to the instructions for the LLC used 126 202 Chapter 6 COOLANT Importance of LLC Today s trend is toward smaller and lighter engines offering greater output lower fuel consumption and lower exhaust emission levels Conditions to which engine coolant is subjected therefore are becoming severer due to longer operat ing hours higher coolant temperature and higher cool ant circulating speed Many different materials such as steel aluminum copper solder and rubber are used in the cooling sys tem and they are also subjected to the severe condi tions described above Those materials have different ionization characteristics and this difference acceler ates corrosion through the medium of engine coolant To prevent such a problem the use of LLC that con tained the additive to prevent rust is very important Characteristics of LLC additive and important notes LLC contains several chemicals in such proportions as to produce chemical reactions that suppress
205. ut and load Overloading causes not only high fuel consumption but also excessive carbon deposits inside the engine Carbon deposits cause various problems and will shorten the service life of the engine Chapter 1 BASIC SAFETY PRECAUTIONS Conduct cooling operation before stopping the engine Before stopping the engine let it idle in low gear for 5 to 6 minutes to cool down Stopping the engine immediately after high load oper ation will cause engine parts to heat up and shorten the service life of the engine During cooling operation check the engine for abnor malities Protection of the engine against water entry Do not allow rainwater etc to enter the engine through the air inlet or exhaust openings Do not wash the engine while it is operating Cleaning fluid water can be sucked into the engine Starting the engine with water inside the combustion chambers can cause the water hammer action which may result in internal engine damage and serious accidents Properly maintain the air cleaner and pre cleaner Maintain the engine with air cleaner or pre cleaner according to the following instructions Do not maintain the air cleaner or pre cleaner while the engine is running The turbocharger may suck particles of foreign materials into the engine and could result in serious accidents Remove the air cleaner or pre cleaner slowly to pre vent foreign materials accumulated on the element from falling off After
206. vailable RUN OFF ETS Energized To Stop type Not energized while the engine is running Energized by a stop signal to stop the engine RUN ON ETR Energized To Run type Energized while the engine is running and de ener gized to stop the engine 2 10 105 202 Stop solenoid ETR Fig 2 20 Stop solenoid Chapter 2 NAME OF PARTS Engine protection devices The engine protection device is a device to prevent the engine from the accident by generating the alarm when abnormality occurs Stop the engine if the protection device is activated investigate the cause of abnormality and restore it When the cause of abnormality is unknown contact a dealer of Mitsubishi Heavy Industries Ltd The installed protection devices type set value or shapes varies according to the specifications Oil pressure switch The oil pressure switch activates the alarm system or stops the engine suddenly when the engine oil pres sure becomes abnormally low Thermo switch The oil pressure switch generates an alarm when the engine coolant temperature becomes high and reaches the specified temperature Air cleaner indicator The air cleaner indicator alarms with its red signal when air cleaner elements become clogged the differ ence in pressure between front air cleaner and rear air cleaner and reaches the specified value The signal indicates only and does not generate an alarm Therefore the periodic visually inspection is needed Pr
207. vailable to determine the quality of oil depending on the engines to which they will be applied and on operating conditions Among those standards API American Petroleum Institute service classifications are mostly used to classify Class OF Class CH 4 engine oils SAE specifies the viscosity only while the oe API service classification indicates the quality level of engine oil OIL OIL API Service API Service Classification Classification For engine lubrication oil please use API service clas sification CF Fig 5 1 Recommended engine oil Selection of oil viscosity Use the following chart to select the appropriate oil viscosity according to the ambient temperature Excessively high oil viscosity causes power loss and Temperature 39 20 10 0 10 20 30 40 50 C F 121 4 14 32 50 68 86 104 122 an abnormal rise of oil temperature while excessively low oil viscosity accelerates wear due to inadequate lubrication and also causes a decrease in engine out Engine oil SABON viscosity put due to leakage of combustion gas Fig 5 2 Selection of oil viscosity Handling engine oil Before filling the engine with engine oil stop the engine and make sure there are no open flames and other fire hazards near the engine Leaked or spilled oil on hot surfaces or electrical components can cause a fire Wipe off any spilled oil immediately and thoroughly After filling securely close the filler cap
208. ven as examples only SAE 15W 40 SAE 10W 40 SAE OVW 3 J J i E a A 17 202 2 4 1 2 Specifications of coolants GenPARTS GENCOOL PC 26 C ee GenPARTS GENCOOL PC 26 C 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 tis made from antifreeze and G 48 inhibitors e t protects up to 26 C e ltis free from nitrates amines and phosphates e ltisa clear fluorescent orange liquid REFERENCES APPROVALS for the antifreeze HEAVY GOODS VEHICLE LIGHTER VEHICLES Approved by MTU MERCEDES BENZ MAN KHD Approved by BMW VOLKSWAGEN MERCEDES PORSCHE GENERAL MOTORS Conforms with VOLVO OPEL SEAT and SKODA Conforms with VOLVO IVECO VAN HOOL and STAYR specifications 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 e Protects against high temperature cavitation top of cylinder and coolant pump protection e Non corrosive for seals and hoses e 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 TEMPERA
209. 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 Data displayed 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 FREQUENCY 50Hz Alternator Nominal Frequency NOMINAL KW 320kW Nominal Active Output EARTH SYSTEM TNS Neutral Point o Bar graph indicating the display delay of the screen 51 202 Generating set stopped OPERATION MANUAL Press START Operating mode generating set in Manual Mode ready to start to start Date and time depending on settings 24 08 2005 OPERATION AUTO WARNING Operating mode generating set in Auto Mode Es os depending on settings 24 08 2005 13 12 WARNING Operating mode generating set in Auto Mode with AUTOMATIC Start programmed start Countdown to micro disconnection delay or EJP notice delay for France only Date and time depending on settings 19 min 30 sec 24 08 2005 Generating set start up START UP Operating phase generating set in starting phase IN PROGRESS Date and time depending on settings 24 08 2005
210. via an impedance device Connected to earth v The second letter defines the grounding situation of the electrical facility Connected to earth Connected to neutral E g IT Isolated Neutral Ground earthed Number of Measurement of residual current Triggering of 1 fault by RCD Triggered by overcurrent protection No measurement of residual current upon 1 fault E na IT SN 3 poles Insulation resistance measurement Triggered upon 2 fault by overcurrent protection 25 202 3 5 3 TT system Figure 3 2 TT neutral system The alternator neutral is earthed and the grounds of the user equipment have their own earth connection In the TT system automatic power cut off via a Residual Current Device RCD is obligatory at the upstream part of the facility to ensure protection of personnel with a maximum 30 mA device on outlet circuits 3 5 4 Differential protection In order to ensure that people are protected from electric shocks from the TT system the generating set is equipped with a residual current device this can be fixed or adjustable depending on the option chosen e If the generating set s residual current device is not adjustable and the activation threshold has been set at 30 mA all terminal circuits in use are protected e If the generating set s residual current device is not adjustable and the activation threshold has been set at 300 mA a 30MA residual current device must be added to each of the circuit
211. vy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd see Faulty governor control Consult a dealer of Mitsubishi Heavy Industries Ltd 11 3 154 202 Chapter 11 TROUBLESHOOTING Exhaust smoke is white or blue Table 11 4 Exhaust smoke is white or blue Cause Remedies Improper fuel property Check cetane index and use appropriate fuel Refer to P4 1 Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system ele Check ignition noise exhaust smoke temperature Uneven fuel injection a l Consult a dealer of Mitsubishi Heavy Industries Ltd Incorrect fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Check amount of engine oil and lubrication system oa Combustion of engine oil Refer to P3 2 Consult a dealer of Mitsubishi Heavy Industries Ltd Check radiator Refer to P8 13 Cooling Bucicacies eCheck control system system Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Consult a dealer of Mitsubishi Heavy Industries Ltd 155 202 Chapter 11 TROUBLESHOOTING Exhaust smoke is black or cha
212. y Starting test incorrect Battery sulphated Fit a new battery Baten terminale meid Incorrect electrical connection Tighten the ends of the battery y Battery cabling incorrect cables or replace them if necessary One or two cells release a lot of gas at Cell s faulty Fit a new battery high charge Charge status too low Short circuit in the current circuit High self discharge through Check the load electrolyte contamination etc Replace the battery Sulphation storage of discharged battery Incorrect battery part no Define the correct battery part no for Repeated deep discharging the recommended use Battery stored too long without It is recommended to charge the charge battery using a regulator Overload High water consumption Charging voltage too high Check the charger voltage regulator Spark after battery charging Short circuit The battery explodes Connection or disconnection during charging Internal fault and low electrolyte level The battery discharges very quickly Short service life Replace the battery Ventilate well 66 202 EN 9 Appendix 9 1 Appendix A Engine user and maintenance manual 67 202 68 202 User guide and maintenance manual MITSUBISHI Engine SERIE SS 99610 2912 ne 33522051001 3 1 01 07 2009 69 202 70 202 OPERATION amp MAINTENANCE MANUAL MITSUBISHI DIESEL ENGINES The operator and supervisor ar
213. you must ensure that the following points are observed The lifting machinery or equipment is suitable for the work required The sling is correctly positioned in the central lifting eye or the lifting arms are correctly positioned in the fork lift pockets intended for this purpose The ground is able to bear the load of the generating set and its lifting machinery without stress otherwise lay down stabilising beams of sufficient strength The generating set is put down as close as possible to its place of use or transport in a clear space with free access Example of equipment to be used v crane slings lifting beam safety hook shackles Y Forklift truck 19 202 EN 3 1 2 Instructions for unloading Hoisting Attach the sling on the lifting equipment to the ring on the generating set no 1 provided for this purpose Tension the slings Slightly Check that the sling is correctly attached and the equipment is steady Lift the generating set carefully Direct the generating set towards the chosen location and stabilise it Carefully set down the equipment while continuing to position it 00 Release the sling then detach it Forklift truck Position the arms of the forklift truck in the forklift pockets no 2 Lift the equipment handling it gently 000 Set down the generating set in its unloading position 20 202 EN 3 2 Choice of location This shall be determined according to the appli
214. ys prepare stable scaffold When working on the upper part of the engine and other hard to reach places use a stable work platform Standing on a decrepit stool or parts box may result in personal injury Do not place any unnecessary objects on a work plat form Chapter 1 BASIC SAFETY PRECAUTIONS Protect ears from noise A CAUTION Wear ear plugs Always wear ear plugs when entering the machine room engine room Combustion sound and mechanical noise generated by the engine can cause hearing problems Be careful of burns _ OA CAUTION Do not touch the engine during or immediately after operation To avoid burns do not touch the gt tion work wait until the engine has cooled sufficiently by checking the temperature gauge engine during or immediately after operation A hot engine can cause burns To conduct maintenance and inspec Do not open the radiator filler cap when the engine is hot Never open the radiator filler cap while the engine is running or immediately after the engine is stopped When opening the cap stop the engine and allow the coolant temperature to lower sufficiently When opening the radiator filler cap open slowly to discharge the pressure inside the tank Also to avoid a risk of getting scalded by steam wear thick rubber gloves or wrap a cloth around the cap When closing the cap be sure to tighten securely The coolant is hot while engine is running and immedi at

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