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Generating set R110 - User manual - SDMO

1. MAX CONNECTION CABLE CROSS SECTION 185MM M12 BOLT M12 NUT 14 263 2 TT EDF OPTION HI05 TO CIRCUIT BREAKERS NF C15 100 EARTHIING EDF EARTHING SYSTEM I SYSTEM MAX CONNECTION CABLE CROSS SECTION 185MM M12 BOLT M12 NUT 15 263 M128 M129 50Hz FR DIFFERENTIAL SWITCH Q10 4x63A 30 mA X03 16A 400V SOCKET 16A CIRCUIT BREAKER 008 X08 16A 230V SOCKET 4x32A CIRCUIT BREAKER Q02 4x16A CIRCUIT BREAKER Q03 X02 32A 400V SOCKET 16A D
2. 02 8 7000 Hours of operation 02 8 7500 Hours of operation 02 9 8000 Hours of operation 02 9 8500 Hours of operation 02 10 9000 Hours of operation 02 10 9500 Hours of operation 02 11 10000 Hours of operation 02 11 Serial Numbers PowerTech label 03 1 Engine serial number plate 03 1 Record engine serial number 03 2 Engine option 03 3 Record fuel injection pump model number 03 4 Record Engine Control Unit ECU Serial 03 5 Record High Pressure Fuel Pump Model 03 5 HE 05 1 Fuels Lubricants and Coolant Diesel e 10 1 Handling and Storing Diesel Fuel 10 1 Diesel Engine Break In Oil 10 2 Diesel Engine Oil 10 2 Lubricant Storage 10 3 Mixing of Diesel Engine Coolant Operating in Warm Temperature Climates
3. al rma Check system parameters Eee wmm Action alert outputstaus _ PEE Acton alert output openishotioB oooo 5 Ml Acton att ouput open cicut Overspeedouputstaus _ 3 goeeewesm sens Mil overspeed output shortto ms zs Coolant temperature outputstaus Ae v0 mom 206 on pressure oupas _ 3 gyseeeeemscemsetoss O a oeeeee99m 1 5 jSmMomomussus 3 shutdown ouput openshor toe O 5 shutdown ouput open crcut warning ref m 09 Temperature sensor in the EGR valve E OW ENGINE RUN output status 1 jewsen O John Deere Volvo 5 Warning output open circuit Input voltage of the temperature sensor 16 E dz Temperature in the EGR moderately high Engine run output short to B p 4 Warning output short to ground NENNEN pe Temperature in the EGR extremely high DD Gear selection invalid Not possible with Genset application 253 263 Io oe Data link faulty 41587 608 redundancy 41939 bus 608 132 Redundancy of the accelerator 8 informatio
4. e 61 Tele ge fe bo ES 61 17 2 ENOO eR I D lr DLL E TEL TT P RS 61 1 3 PATO PINAL OM mL 61 oio T 62 8 1 Storage and WANS DOU 62 8 2 SUING quem NM rm 63 8 3 dic qu Pers 63 8 4 koad 72 1415 ea up uM LL LAC A 64 8 5 Faults sand TeiriedieS ot ea E A Lc DEI CU A 65 D ANG M ELM E LL LEE 67 9 1 Appendix Engine user and maintenance 67 9 2 Appendix B Alternator user and maintenance 191 9 3 Appendix o COMMONS ale Dalton aded isse itpe e te ed Pete a s eade ui vate ad tei aisi se os dum fuis ee a 247 9 4 Appendix D List of John Deere Volvo and Perkins fault 4 249 2 263 1 Preface 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to help you operate and maintain your electrical generating set correctly The information contai
5. 03 5 Wiring harness E fuel 03 5 With Denso High Pressure Common 55 3 Engine Control Unit ECU serial 03 5 With Stanadyne DE10 55 2 Index 2 190 263 9 2 Appendix B Alternator user and maintenance manual 191 263 192 263 User guide maintenance manual LEROY SOMER Alternator 43 2 amp 44 2 SHUNT AREP amp PMG 3434 j 33522059401 7 1 01 06 2011 193 263 194 263 LEROY SOMER 3434 en 2011 06 j LSA 43 2 44 2 4 POLES ALTERNATORS Installation and maintenance 195 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased We wish to draw your attention to the contents of this maintenance manual SAFETY MEASURES Before using your machine for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical supportservice will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommenda tions or symbols to alert the user to the potential risk of accidents It is vital that you understand and take
6. 50 1 Replace fan and alternator belts 4045 Torque charts and 6068 90 5 Melit RERO 65 9 Daily or every 10 25 1 UNEA OD 65 8 Observe service 20 1 Trouble codes 55 11 Use correct fuel lubricant and coolant 20 1 Troubleshooting Maintenance 02 1 zc 55 8 Metric bolt and screw torque values DOS 55 4 Mixing IUDICA RE ca vets teat E 10 3 General information scsssssssssssnn 55 1 U Operating the engine Unified inch bolt and screw torque values 65 8 Break in period xn LV I T d M E E 15 25 Units of measure changing peta te heats ee el oe 15 13 Changing Generator Frequency 15 29 Standby power units 15 29 Starting 15 25 Stopping 15 29 valve clearance Menge OF Naat 1528 Adjust 3029 4039 35 3 S Adjust 4045 and 6068 engines 40 1 Serial number Engine Control Unit ECU
7. 260 263 Description Comment John Deere Volvo LINE Lu actuator does not respond or is 2 in the expected position e Tm sensors output 1 Supply voltage of the sensor too high voltage Supply voltage of the sensor too high the sensor too high Exceeding 5 volts 5 volts Supply voltage of the sensor shorted to ground Common supply voltage of UD output 2 Supply voltage of the sensor too high voltage Supply voltage of the sensor too high the sensor too high Exceeding 5 volts 5 volts Supply voltage of the sensor shorted to ground Common supply voltage of UT output 3 Supply voltage of the sensor too high Exceeding 5 volts ground Common supply voltage of output 4 Supply voltage of the sensor too high Exceeding 5 volts ground Common supply voltage of Non output 5 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground mI gom m o SAE J1939 73 March 2004 FMI and Description FMIZO DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition Region e of the signal range
8. Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 70 19 22JAN07 1 1 8000 Hours of operation Engine oil drain Cooling system drain and flush if COOL GARD is not used Engine oil filter replace Valve clearance adjust POWERTech Fuel filter replace Air intake system check Check belt and tensioning system Vibration damper check Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 71 19 22JAN07 1 1 072209 02 9 PN 18 88 263 Maintenance Records 8500 Hours of operation Engine oil drain Engine oil filter replace n Fuel filter replace manual tensioner Valve clearance adjust 300 Series Belt check tension and wear 300 Series and POWERTech with Number of hours Job done by Observation Dealer or distributor stamp 9000 Hours of operation DPSG CD03523 72 19 22JAN07 1 1 Engine oil drain Engine oil filter replace n Fuel filter replace Check belt and tensioning system Crankcase vent tube clean Air intake system check Number of hours Job done by Observation Dealer or distributor stamp 02 10 89 263 DPSG CD03523 73 19 22JAN07 1 1 072209 PN 19 Maintenance Records 9500 Hours of operation Engine oi
9. 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 as per paragraph 5 2 1 Hitching and unhitching the trailer Immobilise the trailer by placing chocks under the wheels Fully engage the parking brake if fitted Using the front wheel position the generating set as close to horizontal as possible Lower the stands if fitted and lock them 4 6 Break transmission adjustment A The handbrake is used only as a parking brake Setting is carried out starting with the brakes moving to the brake control Important After fitting the wheels on the axle turn the wheels in the FORWARD direction on all RA 2 type brakes check that the adjustment screw 8 reaches the FORWARD stop on the brake backing plate Adjust the brake setting using screw 8 with the cables not connected to cross bar s The shoes should rub 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
10. Maintenance 2500 hours 3 years Drain and flush cooling system Maintenance As required Additional service information Do not modify fuel system Welding Near Electronic Control Units Keep Electronic Control Unit Connectors Clean Clean or replace air filter one piece Clean or replace air filter element Replacing fan and alternator belt 4045 and 6068 Bleeding the fuel system Troubleshooting General troubleshooting information Engine Wiring Layout Electronic Fuel system With Stanadyne DE10 Injection Pump eere Engine Wiring Layout Electronic Fuel oystem With Denso High Pressure COMMON Gl secet vans dabas eere imet oi Uia Engine troubleshooting Electrical troubleshooting Displaying Of Diagnostic Trouble DT Using blink code method for retrieving Diagnostic Trouble Codes DTC s Using diagnostic gauge for retrieving Diagnostic Trouble Codes DTC s Listing of Diagnostic Trouble Codes DTCs Intermittent Fault Diagnostics With Electronic St
11. ine 65 8 engine 10 2 Hardware torque values WG UNC I 65 9 INCH 65 8 Configuration data viewing 15 3 Diesel zx cnet 10 3 Instrument panel Drain and flush cooling system 45 1 Adjust bDacklighitlng siue ten date ent ata edo deua uo beet ue Ue 15 10 Pressure testing cooling system 35 5 sicot a 15 12 Warm temperature Climates 10 4 Changing units of measure 15 13 Crankcase vent tube Main menu 15 1 GC 35 1 Setup 1 up display 15 15 Setup 4 up display 15 21 D SIMULG OWN CODES NEP 15 9 Using diagnostic 15 1 Danmberssz s as es DEM LLL 40 4 Viewing active service 15 7 5 1 51467 6 55 10 Viewing configuration 15 3 Using diagnostic 15 1 Viewing stored service codes 15 5 Diagnostic trouble code
12. Continued on next page OURGP11 0000237 19 210CT03 2 6 15 10 117 263 Operating the Engine 3 Once the Adjust Backlight menu item has been highlighted press the Enter key to activate the cbe Adjust Backlight function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT e od Press Enter Key RG13182 UN 020CT03 OURGP11 0000237 19 210CT03 3 6 4 Use the Arrow keys to select the desired backlight intensity ADJUST BACKLIGHT Om 2 9420 Adjust Backlight Intensity A o o 1 2 lt O X OURGP11 0000237 19 210CT03 4 6 9 Press the Menu key to return to the main menu ADJUST CONTRAST RG13184 UN 26SEP03 Return To Main Menu Continued on next page OURGP11 0000237 19 210CT03 5 6 15 11 PN 48 118 263 Operating the Engine 6 Press the Menu key to exit the main menu and return to the engine parameter display 1000 RPM 1800 RPM TEMP 14 2 PSI RG13159 UN 26SEP03 Exit Main Menu OURGP11 0000237 19 210CT03 6 6 Adjusting Contrast mmi ENG EP 1 Turn the key switch to the ON position Starting at 1800 RPM the single or four engine parameter display press the Menu key RG13159 UN 26SEP03 Menu Key OURGP11 00000AF 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow GO 1 UP DISPLAY
13. Diode 1A 12V LEROY SOMER 13 207 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 4 6 Dismantling reassembly see sections 5 4 1 amp 5 4 2 WARNING During the warranty period this operation should only be carried out in an LEROY SOMER approved workshop or in our factory otherwise the warranty may be invalidated Whilst being handled the machine should remain horizontal rotor not locked in position Check how much the machine weighs see 4 8 7 before choosing the lifting method 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 8 10 12 mm 1 socket set 8 10 13 16 18 21 22 24 1 size 5 key eg Facom ET5 6 Allen key ET6 10 Allen key ET10 14 Allen key ET14 1 20 and T30 TORX bit 1 puller U35 032 350 4 6 2 Screw tightening torque See section 5 4 4 6 3 Access to diodes Remove the air intake grille 51 Remove the surge suppressor 347 Disconnect the 6 diodes using an ohm meter or a battery lamp see section 4 5 2 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 4 Access to connections and the regulation system The terminals are accessed directly by
14. High self discharge through Check the load Me electrolyte contamination etc Replace the battery Sulphation storage of discharged battery Incorrect battery part no Define the correct battery part no for Sheen lite 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 Check the charger voltage regulator Charging voltage too high Spark after battery charging Short circuit Replace the battery Ventilate well The battery explodes Connection or disconnection during charging Internal fault and low electrolyte level 65 263 66 263 EN 9 Appendix 9 1 Appendix A Engine user and maintenance manual 67 263 68 263 User guide maintenance manual JOHN DEERE OMCD16564 06 07 2009 Engine 3029TF120 3029DF120 6068TF220 4045TF220 4045HF 120 4045TF120 6068HF120 153 3029TFS70 TF270 3029HFS70 HF270 4045HFS72 HF275 4045HFS73 HF279 4045HFS80 HF280 4045HFS82 HF285 4045HFS83 HF285 4045TFS70 TF270 6068HFS72 HF275 6068HFS73 HF279 6068HFS76 HF475 6068 582 HF285 6068 583 HF285 6068HFS77 HF475 6068 89 485 69 263 33522039401 4 1 70 263 Engines amp Power Units for Generator Sets Saran Built OPERATOR S MANUAL Engines amp Power Unit
15. Max current A Emergency power Prime power Load factor Emergency Prime kW kVA kW 400 230 50 3 08 159 145 88 110 80 100 1 ESP Stand by output available for emergency use under variable charge up to 200hrs year as per ISO 8528 1 no overload available under these service conditions 2 PRP Main output available continuously under variable load for an unlimited time period per year as per ISO 8528 1 an overload of 1096 one hour every 12 hours is available as per ISO 3046 1 Engine data Manufacturer model JOHN DEERE 4045HF 120 Type 4 cycles Turbo air air Cylinder configuration 4 XL Cubic capacity 4 48L Rotation speed 1500 Rpm Max emergency prime power at nominal speed 100 91 kW Adjustment type Fuel consumption 100 main power 75 main power 19 263 Lubrication Oil capacity with filter Min Oil pressure Nominal oil pressure Oil consumption 100 96 load 0 024 L h Refrigerant type Gencool Emissions S 26 mg Nm3 310 mg Nm3 100 mg Nm3 Compliant with NEMA MG21 standards UTE NF 51 111 The alternator is protected against short circuits Vacuum impregnation epoxy winding IP23 protection rating Power factor cos Ph ooo OB Control unit s Standard specifications Frequency meter Voltmeter Ammeter Alarms and faults Oil pressure Coolant temperature Fail to start Overspeed Alternator min max Fuel level low Emergency shutdow
16. 136 225 ses 165 so ji i jw sew ug p 1 2790 sw wr Yom jw GP LR 57008 4 Conforme 1 34 1 1994 According to I E C 34 111994 x Made by Leroy Somer 32 1 Vel 2 3 34 1 YDE ALTERNATORE AUTOREGG_ATO SELF REBULATED ALTERNATOR ALTERNATEUR AUTOREGULE EN 6003 0590 354999 5000 NF 1711 Alt AR N D E bearing 309 28 Graissa Grease lEsse Valeurs excit Exeil values 3 phases 1 Phase Ess ECO28 1L 4 cos 0 8 S s ls ss D IDLIZZ Hz 50 50 60 50 50 60160 50 60 50 60 ea Eod EA E a s n Fc i pape peus a Figure 1 9 Examples of alternator identification plates Designation ARMOIRE DE 400K VA 40217010 Cde AVP31650 01C Reference SOREEL 371562 03 No OF 02280753 Figure 1 10 Example of control box identification plate 12 263 2 General description 2 1 Description Overview Electric sockets 2 Connection termination box 8 Starterbattery 3 Circuit breakers _ 19 Control unit 6 Battery charge alternator Figure 2 1 General description of the generating set 13 263 Fittings Socket control panels and terminals by enclosure type 2 HI05 TO CIRCUIT BREAKERS N1 R1 51 T1
17. Continued on next page OURGP11 00000B2 19 035 03 5 14 15 22 PN 59 129 263 Operating the Engine 6 Custom Setup To perform a custom setup of the 4 Up Display use the arrow buttons to scroll to and highlight Custom Setup on display RG13227 UN 26SEP03 Custom Setup OURGP11 00000B2 19 03SEP03 6 14 7 The quadrant with the highlighted parameter value is the current selected parameter Use the Arrow keys to highlight the value in the quadrant you wish to change to a new parameter 125 1000 COOL TEMP ENG RPM 57 PSI BAT VOLT OIL PRES OPO Select Parameters A Lu o 1 2 2 N N lt O X OURGP11 00000B2 19 03SEP03 7 14 8 Press the Enter key and a list of engine parameters will be displayed 125 F 4000 RPM COOL TEMP ENG RPM NEVER 57 PSI BAT VOLT OIL PRES Gc og List Of Engine Parameters RG13229 UN 26SEP03 Continued on next page OURGP11 00000B2 19 03SEP03 8 14 15 23 PN 60 130 263 Operating the Engine The parameter that is highlighted is the selected ENGINE SPEED The numger to the right cf the parameter for the screen Use the arrow keys to ENGINE HOURS indicates quadrant highlight the new parameter to be placed in the 4 Up ENGINE COOLANT TEMPERATURE 1 Displav BATTERY POTENTIAL 1 Joper Left OLadrent ISplay 2 Lower Guadrent Upper Right Quadrent 4
18. Drip proof machine self cooled Degree of protection IP 23 2 1 1 Mechanical options Air inlet filter Regreasable ball bearings only for LSA 44 2 and SHUNT or AREP version IP 44 protection STATOR 12 wire marking T1 to T 12 T1 T7 T2 T8 T3 T9 T4 T10 T11 6 T12 Power supply Detection STATOR 12 wire marking T1 to T 12 TT Tf T2 T8 19 T4 T10 T5 T11 T6 T12 Voltage reference STATOR 12 wire marking T1 to T12 T1 17 T2 T8 T9 T4 T10 5 111 TO T12 Voltage reference LEROY SOMER 5 199 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 3 INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electri cal hazards 3 1 Assembly mechanical handling operations must be undertaken using suitable equipment and the machine must be horizontal Check how much the machine weighs see 4 8 3 before choosing the lifting tool 3 1 1 Handling The generously sized lifting rings are for handling the alternator alone They must not be used to lift the genset The choice of liftinghooksorhandlesshouldbe determined by the shape of these rings Choose a lifting system which respects the integrity and the environment of the alternators During this operation do not allow anyone to stand under the lo
19. 66 Maintenance Observe service intervals Using hour meter as a guide perform all services at the hourly intervals indicated on following pages At each scheduled maintenance interval perform all previous maintenance operations in addition to the ones specified Keep a record of hourly intervals and services performed using charts provided in Maintenance Records Section Use correct fuels lubricants and coolant IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine Consult your John Deere engine distributor servicing dealer or your nearest John Deere Parts Network for recommended fuels lubricants and coolant Also available are necessary additives for use when operating engines in tropical arctic or any other adverse conditions Maintenance interval chart IMPORTANT Recommended service intervals are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine DPSG CD03523 24 19 22JAN07 1 1 p 2 jet TS100 UN 23AUG88 DPSG CD03523 25 19 22JAN07 1 1 Item 500 H 1000 H 1 year 2000 H 2 years 2500 H 3 years As required 10 daily Check engine oil and coolant level Check air filter restriction indicator Change engin
20. 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 and E on the AVR Voltage between and E SHUNT 20V AREP PMG 10V Check the speed or U F bend set too high Voltage between and E SHUNT 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 242 263 LEROY SOMER R438 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 017 4 2 Technical support service Our technical support service will be happy to provide any information you require When ordering spa
21. e l vehictespeea C Not possible with MEME Lo pa ME eem umet m jDmemosicoupustaus 1 1 ewtwtessus ai 9 Seed vaiue inva ormissing 970 Auxiliary engine shutdown switch status EMS Auxiliary engine shutdown switch signal invalid Auxiiary engine shutdown switch active External engine derate switch status at Ml engine de rate switch active Notused 1069 SCL 2 ov o nome O o w Tr pump ormo ua crea Aem pump or open circuit _ Pump coil short to ground s HH we Fuctinjection pump status Pump control valve closure toolong injection Pump contol vave closure too shor WecionDEO Pump detected defect injecionvpaa _ Pump solenoid current high mjectonDEt0 Pump solenoid circuit open _ Pump solenoid circuit severely shorted DE10 Pump control valve closure not detected Injection Pump solenoid circuit moderately shorted Injection DE10 Pump current decay time invalid DE10 Not used 258 263 Io oe _ Fuel injection pump controller status Pump supply voltage outofrange EM Pump self test er
22. 072209 15 8 PN 45 115 263 Operating the Engine Engine Shutdown Codes 1 During normal operation the single or four parameter screen will be displayed RG13172 UN 26SEP03 Normal Operation OURGP11 00000AE 19 03SEP03 1 6 2 When the diagnostic gauge receives a severe trouble code from an engine control unit the single or four tex SHUTDOWN parameter screen will be replaced with the Shutdown SPN 100 FMI 1 message The SPN and FMI number will be displayed along with description of the problem and the CORRECTIVE ACTION corrective action needed CHECK OIL LEVEL If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code RG13238 UN 29SEP03 Shutdown Message OURGP11 00000AE 19 03SEP03 2 6 acknowledge and hide the trouble code and return to the single or four parameter display press the 1 of x SHUTDOWN Enter key SPN 100 FMI 1 FAULT 5 ENGINE OIL PRESSURE LOW IMPORTANT Ignoring the shutdown message can CORRECTIVE ACTION result in severe engine damage CHECK OIL LEVEL lt NEXT gt RG13239 UN 29SEP03 Hide Trouble Code OURGP11 00000AE 19 03SEP03 3 6 4 The display will return to the single or four parameter display but the display will contain the Shutdown 1000 RPM icon Pressing the Enter key will redisplay the hidden trouble code IMPORTANT Ignoring th
23. 251 voltage sensing 0 gt T1 110 V gt T2 3 3 2 Exciter field connection Series connection shunt excitation Parallel connection AREP or PMG excitation AN Single phase dedicated SHUNT version R 251 AVR 2 wire output without terminal block 3 3 3 Option connection diagram R 791 T interference suppression kit standard for CE marking Voltage potentiometer OOO WM Voltage adjustment by remote potentiometer 130 C Blue wire 150 C Black wire 180 C Red white wire LSA 43 2 44 2 LEROY SOMER 9 203 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 3 3 4 Connection checks Electrical installations must comply with the current legislation in force in the country of use Check that The residual circuit breaker conforms to legislation on protection of personnel in force in the country of use and has been correctly installed on the alternator power output as close as possible to the alternator In this case disconnect the wire of the interference suppression module linking the neutral Any protection devices in place have not been tripped If there is an external AVR the connections between the alternator and the cabinet are made in accordance with the connection diagram There is no short circuit phase phase phase neutral between the alternator output terminals and the generator set control cabinet part of the circuit not protected by c
24. 98 1 1 Handle Fuel Safely Avoid Fires Handle fuel with care it is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean up spilled fuel O 2 2 o N o DX FIRE1 19 03MAR93 1 1 Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone TS291 UN 23AUG88 DX FIRE2 19 03MAR93 1 1 072209 05 3 PN 28 98 263 Safety Handle Starting Fluid Safely Starting fluid is highly flammable Keep all sparks and flame away when using it Keep starting fluid away from batteries and cables To prevent accidental discharge when storing the pressurized can keep the cap on the container and store in a cool protected location Do not incinerate or puncture a starting fluid container TS1356 UN 18MAR92 DX FIRE3 19 16APR92 1 1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomf
25. LEROY SOMER 235 263 LEROY SOMER R438 A V R 2 R438 A 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 slow 250V Voltage sensing 5 VA isolated via trans former e 0 110 V terminals 95 to 140 V 0 220 V terminals 170 to 260 V 0 380 V terminals 340 to 520 V Voltage regulation 190 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 secondary 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 1 ST1 3 5 Open for module pn installation tri detection ST2 Fast Response time 50 ou 60 Hz Frequency selection External ST4 potentio meter ST5 Without win LAM Others Potentiometer LAM voltage drop amplitude U f function bend position 13
26. Piston Fuel injection pump CALIFORNIA PROPOSITION 65 WARNING Intake manifold Diesel engine exhaust and some of its constituents are known Turbocharger to the State of California to cause cancer Charge air cooling system birth defects and other reproductive harm DPSG CD03523 1 19 06JUL09 2 2 072209 PN 3 73 263 Introduction 072209 PN 4 74 263 Contents Page Identification Views Identification views 01 1 Maintenance Records Using maintenance records 02 1 100 Hours of operation 02 1 500 Hours of operation 02 2 1000 Hours of operation 02 2 1500 Hours of operation 02 3 2000 Hours of operation 02 3 2500 Hours of operation 02 4 3000 Hours of operation 02 4 3500 Hours of operation 02 5 4000 Hours of operation 02 5 4500 Hours of operation 02 6 5000 Hours of operation 02 6 5500 Hours of operation 02 7 6000 Hours of operation 02 7 6500 Hours of operation
27. Prime POWER 1500 rpm kW hp Standby POWER 1800 rpm kW hp 134 180 161 216 214 287 Prime POWER 1800 rpm kW hp 147 197 177 237 235 315 Standby Width overall mm 784 784 960 Length overall mm 1500 1500 1509 Height overall mm 1137 1137 1381 Weight dry kg 764 764 764 Engine oil quantity L 32 32 32 Engine coolant quantity L 32 32 35 With Fan Approximate CD03523 00001D4 19 08JUL09 1 1 65 7 de PN 115 185 263 Specifications Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAYO3 O BCO 8 amp Bolt or SAE Grade 1 SAE Grade 2 SAE Grade 5 5 1 or 5 2 SAE Grade 8 or 8 2 Screw Lubricated Lubricated Lubricated Lubricated Size 16 Nm Ib in Ib in Nm Ib in Ib in Nm Ib in Nm Ib in Ib in 1 4 3 7 33 4 7 42 6 53 7 5 66 9 5 84 12 106 13 5 120 17 150 Ib ft 5 16 7 7 68 9 8 86 12 106 15 5 137 19 5 172 25 221 28 20 5 35 26 Ib ft Ib ft 3 8 13 5 120 17 5 155 22 194 27 240 35 26 44 32 5 49 36 63 46 Ib ft Ib ft Nm Ib ft 7 16 22 194 28 20 5 35 26 44 32 5 56 41 70 52 80 59 100 74 Ib ft 1 2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115 9 16 48 35 5 60 45 76 56 95 70 125 92 155 115 175 130 220 165 5 8 67 49 85 63 105 77 135 100 170 12
28. following screen appears 3 uuu h 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 6 2 3 Switching off trigger the circuit breaker located at the base of the centre console O Let the motor run under no load for 1 to 2 minutes to allow it to cool O press the STOP button to stop the generating set switch off the MICS Nexys module by switching the key to OFF without forcing it 40 263 6 2 4 Alarms and faults The appearance of a fault or an alarm causes the following screen to be displayed one or more pictograms or a fault i M i code along with the SOS message are displayed E WI iu um The user can access the following screens by pressing the key 1 i Gal Gal Um The fault or alarm screen will disappear once the fault or alarm has been removed Only one fault is displayed on this screen the fault which caused the generating set to stop If one or more faults have appeared after the first fault they can only be displayed after the first fault has been reset press Reset as many times as the number of faults present Note an alarm can appear at the same time as a fault 6 2 5 F
29. Lower Right Quadien RG13230 UN 26SEP03 Select Desired Engine Parameter OURGP11 00000B2 19 03SEP03 9 14 10 Press the Enter key to change the selected parameter in the quadrant to the new parameter ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL 2 ENGINE TEMPERATURE ENGINE OIL PRESSURE RG13231 UN 26SEP03 Enter Selected Parameter OURGP11 00000B2 19 03SEP03 10 14 11 Use the Menu keys to return to the 4 Up Custom ENGINE SPEED Setup screen ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL 3 Note the number the right of the selected parameter nd cating that the parameter i now assigned 16 that display location RG13232 UN 26SEP03 Return To 4 Up Custom Setup OURGP11 00000B2 19 03SEP03 11 14 12 The selected quadrant has now changed to the new selected parameter 125 F 1000 RPM COOL TEMP ENG RPM 143 F 57 PSI OIL TEMP OIL PRES RG13153 UN 24SEP03 4 Up Display Continued on next page OURGP11 00000B2 19 03SEP03 12 14 19 24 PN 61 131 263 Operating the Engine 13 Repeat the parameter selection process until all spaces are as desired 125 1000 14 Press the Menu key to return to main menu COOL TEMP ENG RPM 14 of PSI OIL TEMP OIL PRES RG13154 UN 24SEP03 Return To Main Menu OURGP11 00000B2 19 03SEP03 13 14 15 Press the Menu key to exit the main menu and return E to the engine paramet
30. Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The information contained in this document may therefore be changed without notice LEROY 2 SOMER 220 263 LEROY SOMER R250 SUMMARY SU PREY e 4 TT SHUNT excitation users nep e nne etes ilo b tur a oen e seb ue 4 A E E 5 A Exec e MENTRE 5 2 2 U F fonction and 5 A V T ODIO coulis athe a eet ated aM RO Dr 5 24 LAM GhatracterislieS ee e CE ir OE a 6 2 5 Typical Obthed AM oue ce des 7 INSTALLATION COMMISIONINGQ 8 3 1 Electrical checks on the AV Ree be Enti os deste orto uim eee foe aa aD ines ats 8 nos 8 OO RNC 9 A SPARE PAR VS Seer Aer eee A Lr SM A or Da 10 99 METER 10 4 2 Technical support service 10 maintenance or breakdown operations A V R are to be done by personnel trained on commisioning servicing and maintenance for the electrical and mechanical elements The R250 is an IPOO product It must be installed inside a unit so that t
31. RG13225 UN 020CT03 Select Setup 4 Up Display Continued on next page OURGP11 00000B2 19 03SEP03 2 14 15 21 PN 58 128 263 Operating the Engine 3 Once the Setup 4 Up Display menu item has been ae t GO TO 1 UF DISPLAY highlighted press the Enter key to activate the STORED CODES Setup 4 Up Display menu ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT e m og Press Enter Key RG13226 UN 020CT03 OURGP11 00000B2 19 03SEP03 3 14 4 Two options are available for the 4 Up Display USE DEFAULTS a Use Defaults This option contains the following CUSTOM SETUP engine parameters for display Engine Speed Battery Voltage Coolant Temperature and Oil Pressure Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters Q Select Factory Defaults ke A 1 2 29 QI O x OURGP11 00000B2 19 035 03 4 14 To reset the display parameters to the factory defaults scroll to and highlight Use Defaults Press the Enter key to activate the Use Defaults function RESTORED A message indicating the display parameters are DEFAULTS reset to the factory defaults will be displayed then the display will return to the Setup 4 Up Display menu Restored To Defaults RG13149 UN 24SEP03
32. 103 263 TS281 UN 23AUG88 DX RCAP 19 04JUN90 1 1 TS220 UN 23AUG88 DX DUST 19 15MAR91 1 1 TS1133 UN 26NOV90 DX DRAIN 19 03MAR93 1 1 072209 PN 33 Fuels Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area Sulfur Content for Interim Tier 4 and EU Stage IIIB Engines In general diesel fuels are blended to satisfy the low temperature requirements of the geographical area in Diesel fuel quality and fuel sulfur content must comply which they are marketed with all existing emissions regulations for the area in which the engine operates Diesel fuels specified to EN 590 or ASTM D975 are Use ONLY ultra low sulfur diesel ULSD fuel with a recommended Renewable diesel fuel produced by maximum of 0 0015 15 ppm sulfur content hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel Renewable diesel that Sulfur Content for Other Engines meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in Use of diesel fuel with sulfur content less than 0 10 In all cases the fuel shall meet the following properties 1000 ppm is STRONGLY recommended T Use of diesel fuel with sulfur content 0 10 1000 ppm Cetane number of 45 minimum Cetane numb
33. 16 660 31798 0 195 50x10 450 1790 9 60 Wheel with 4 holes Wheel with 5 holes 3 8 34 263 5 Preparation before operating 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 5 1 Installation checks e Check that the general recommendations given in the installation section ventilation exhaust fluids etc are observed e Carry out the level checks oil water diesel fuel battery e Check the generating set earth connection is earthed e Check that the electrical connections are in order 5 2 Checks after starting the generating set out the mechanical checks oil pressure water temperature absence of noise etc e out the electrical checks voltage and frequency e out the safety checks emergency stop oil pressure water temperature etc 6 Using the generator set 6 1 Pre Start Inspection e Inspecting the engine compartment Inspect the engine carefully Wipe all the grease fittings and caps before carrying out any maintenance in order to reduce the risk of contaminating the circuits e Checking the engine oil level A Do not top up the oil if the oil level is not
34. 259 263 Io oe John Deere 1348 1 status _ NE controivave 2 erormismatch o Pump control valve 2 fuel flow not 10 detected ECU main relay of VOLVO 8 8 ESS PUP power relay fault 3 w Torquecuvesetecion Torve curve secioni _ Torque curve inputvotage Toraue curve selection missing if seo Fuetsuppystus Redeme jFansmedzemsorabet _ cM Fan speed more than 300 rpm above its setpoint for at least 180s 16 setpoint for at least 1805 2000 Vehicle ID missing Security violation Artemperaureatiheaircooeroule rmpeaueexremlyhgh Airtemperaturehigh Airtemperature moderate high _ Flowlevel ofthe EGR valve Calculated EGR Calculated EGR fowratherhigh Calculated EGRowratheriow _ Air temperature at turbo compressor outlet Temperature at compressor outlet 16 moderately high EENE Input voltage of the position sensor high Short to V Input voltage of the position sensor low Short to V Inability of the EGR valve to reach the expected position BEEN The EGR valve is out of calibration DI Error in position of the valve 999 13
35. Check Sensor and Wiring Check Sensor and Wiring Stop and Drain Water Separator Check Oil Level Check Sensor and Wiring Check Sensor and Wiring Check Oil Level Check Air Cleaner Aftercooler or Room Temperature Check Sensor and Wiring Check Sensor and Wiring Check Air Cleaner Aftercooler or Room Temperature Check for plugged air filter Check Cooling System Reduce Power Check Sensor and Wiring Check Sensor and Wiring Check Cooling System Reduce Power Check Cooling System Reduce Power Check Operator s Manual Adding Coolant Contact Servicing Dealer Contact Servicing Dealer Add Fuel or Switch Fuel Tanks Check Sensor and Wiring Check Sensor and Wiring Add Fuel or Switch Fuel Tanks Check Fault Codes or Contact Servicing Dealer Reduce Engine Speed Reduce Engine Speed Check Wiring Check Wiring Check Wiring Check Wiring OURGP12 00001E2 19 15MARO6 1 2 072209 PN 105 Troubleshooting SPN 000627 000629 000636 000637 000639 000651 000652 000653 000654 000655 000656 000898 000970 000971 001069 001079 001080 001109 001110 001347 001568 001569 002000 FMI 01 13 02 08 10 02 07 08 10 13 05 06 07 05 06 07 05 06 07 05 06 07 05 06 07 05 06 07 09 31 31 09 31 03 04 03 04 31 31 03 05 07 02 31 13 Description of Fault All Injector Currents Are Low ECU Programming Error Engine Position Sensor Signal Unreliable Engi
36. Check Wiring Check Wiring Check Wiring Check Wiring Shut Down Engine Check Fault Codes Shut Down Engine Check Fault Codes Contact Servicing Dealer Check Pump Wiring Check Fuel Filter and Lines Contact Servicing Dealer Check Fault Codes Contact Servicing Dealer OURGP12 00001E2 19 15MAR06 2 2 072209 PN 106 Troubleshooting Intermittent Fault Diagnostics With Electronic Controls Intermittent faults are problems that periodically go away A problem such as a terminal that intermittently doesn t make contact can cause an intermittent fault f the problem is intermittent try to reproduce the Other intermittent faults may be set only under certain operating conditions that were present when the operating conditions such as heavy load extended idle diagnostic trouble code DTC set etc When diagnosing intermittent faults take special f a faulty connection or wire is suspected to be the note of the condition of wiring and connectors since a cause of the intermittent problem clear DTCs then high percentage of intermittent problems originate here check the connection or wire by wiggling it while Check for loose dirty or disconnected connectors Inspect watching the diagnostic gauge to see if the fault resets the wiring routing looking for possible shorts caused by contact with external parts for example rubbing against Possible causes of intermittent faults sharp sheet metal edges Inspect the con
37. Fan Engine Coolant Heater Radiator Exhaust Manifold Ventilator System Starting Motor Alternator Instrument Panel Fuel Filter Front Plate Fuel Transfer Pump Thermostat Housing Oil Dipstick Belt Driven Front Auxiliary Drive Starting Aid Timing Gear Cover with Gears Balancer Shaft Cylinder Block With Liners and Camshaft Crankshaft and Bearings Connecting Rods and Pistons Valve Actuating Mechanisms Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No Description Exhaust Elbow Turbocharger Temperature Switch Electronic Tachometer Sensor Damper Engine Serial Number Plate ECU Electronic Software Option Air conditioner Compressor Mounting Air Restriction Indicator Oil Pressure Switch Primary Fuel Filter Electronic Software Electrical Wiring Harness Fan Pulley Automatic Belt Tensioner Oil Filter Special Equipment Factory Installed Vehicle Timing Identification label Special Equipment Field Installed Shipping DPSG CD03523 14 19 22JAN07 2 2 CD30749 UN 24SEP99 DPSG CD03523 15 19 22JAN07 1 1 072209 PN 24 Serial Numbers Record Engine Control Unit ECU Serial Number Record the part number and serial number information found on the serial number label A on the Engine Control Unit ECU mounted on or near the engine Part No Serial No RG14635 UN 13AP
38. LEROY SOMER 4067 en 2009 05 b 250 1 Slow fuse 250V8A Voltage Stabilit CN i ST4 External potentiometrer for voltage adjusting s R250 A V R Installation and maintenance 219 263 LEROY SOMER R250 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your A V R you can look forward to many years of trouble free operation SAFETY MEASURES Before using your machine for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommendations or symbols to alert the user to potential risks of accidents It is vital that you understand and take notice of the following warning symbols WARNING Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel
39. O OURGP11 00000B1 19 03SEP03 3 18 4 Three options are available for modification of the 1 Up Display USE DEFAULTS CUSTOM SETUP a Use Defaults This option contains the following AUTOMATIC SCAN OFF engine parameters for display Engine Hours Engine Speed Battery Voltage Load Coolant Temperature and Oil Pressure Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters This option can be used to add parameters available for scrolling in the 1 Up Display 1 Up Display Options RG13196 UN 26SEP03 Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected set of parameters one at a time momentarily pausing at each Continued on next page OURGP11 00000B1 19 03SEP03 4 18 15 16 PN 53 123 263 Operating the Engine 5 Use Defaults To select Use Defaults use the Arrow keys to scroll to and highlight Use Defaults in the USE DEFAULTS menu display CUSTOM SETUP AUTOMATIC SCAN OFF RG13195 UN 26SEP03 Select Defaults OURGP11 00000B1 19 03SEP03 5 18 6 Press the Enter key to activate the Use Defaults USE DEFAULTS function CUSTOM SETUP AUTOMATIC SCAN OFF A 1 2 2 Qo Defaults Selected OURGP11 00000B1 19 03SEP03 6 18 7 The display parameters are reset to t
40. Retention container Drain the retention high level container Figure 1 4 Information pictograms 5 263 Flammable product Reading the manual for the equipment is Do not smoke or create sparks or flames compulsory ALIMENTATION FUEL GENSET FUEL SUPPLY ALIMENT ATION DU GROUPE PAR LE JOD RRALIER CEMEET FUEL SUPPLY PROM DALY TANK ALBAEHWTATION DL GROPE CUVE ExT RIEURE GENSET FUEL SUPPLY FROM EXTERNAL Fuel supply Securing straps routing point Selection valve Figure 1 5 Specific pictograms Rinse any splashes of acid on the skin or in the eyes using clean water Consult a doctor immediately Wearing suitable protective clothing and goggles is compulsory Wash contaminated clothing with water Figure 1 6 Pictograms relating to battery operations 6 263 1 3 Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows You should also refer to any local and national regulations that apply in accordance with your own jurisdiction KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries 1 3 1 General advice Use The operating and
41. Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand If ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other two fuel filters primary and final Whenever the knowledgeable medical source fuel system has been opened up for service lines disconnected or filters removed it will be necessary NOTE Engines with mechanical fuel system have a to bleed air from the system On dual fuel filter single fuel filter while electronically controlled system bleed air only from final filter engines DE10 and HPCR fuel systems have X9811 UN 23AUG88 Continued on next page DPSG CD03523 46 19 09 07 1 3 072209 50 5 PN 92 162 263 Maintenance As required A Mechanical and DE10 fuel systems 1 Loosen the air bleed screw A two full turns On DE10 fuel system loosen only air bleed screw on final fuel filter 2 Operate supply pump primer lever B until fuel flow is free from air bubbles 3 2 3 Tighten bleed screw securely continue operating hand Y primer until pumping action is not felt 4 Start engine and check for le
42. Your equipment can operate at top efficiency only when clean lubricants are used Make certain that all containers are properly marked to identify their contents handle all lubricants Properly dispose of all old containers and any residual Whenever possible store lubricants and containers lubricant they may contain in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation DX LUBST 19 18MAR96 1 1 Mixing of Lubricants In general avoid mixing different brands or types of oil Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements Consult your John Deere dealer to obtain specific information and recommendations Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance DX LUBMIX 19 18MAR96 1 1 Diesel Engine Coolant The engine cooling system is filled to provide year round protection against corrosion and cylinder liner pitting and winter freeze protection to 37 C 34 F John Deere COOL GARD is preferred for service If John Deere COOL GARD is not available use a low silicate ethylene glycol or propylene glycol base coolant concentrate in a 50 mixture of concentrate with quality Water quality is important to the performance of the water cooling system Distilled deionized or demineralized water is recommended f
43. a R et mee ee en a a a 40 LM Lu PM LL EE 41 02 Fats and alarms 41 6 3 Generator set with TELYS control panel vice Fede E oes E leo Re ee 43 98811159 1 43 6 3 1 1 NWOT meton panel D cr 43 6 3 1 2 PSSCHIPOM OPANG SCLC a E 45 6 3 1 3 Description of the pictograms zone 1 46 6 3 1 4 Description of the pictlograms In ZONE 2 etie Md 47 6 3 1 5 Description of he pictograms Im Zone ba Fea eret ee eee do dece ee Ure ERE 48 6 3 1 6 Display or MESSAGES IN ZOMG 4 e 51 D NEP RD ERE 55 incus MM NI Retna chs iene ccc 56 6 5 4 Alarms and 56 6 3 4 1 VIEWING alarms n Derbi 56 6 3 4 2 Abalon alsmmor tones inb ob aan 57 6 3 4 3 Activation of an alarm and Qiu DRE TRO EET 58 6 3 4 4 Engine fault Codes display dete eie Vea aL cep eee bu 59 6 3 4 5 BAO ROSS GN ORI DTE Ic na 60 1 263 7
44. cens ddan fen 21 23 SDBEIICSIDIIS aN ete hae 21 231 enel 21 2 3 1 2 Specificationssof Coolalits ec eor etna de uses eds d LAE LE Le E 22 DATS VAN titel E P E 23 3 b Merc 23 3 1 1 Safety during 23 2 unloading ek eS 24 S st x UE 24 3122 FOKI A Kea E E E A 24 3 2 ele Wrote rites T TTE 25 39 glo 9 m 26 3 4 27 3 5 So c Md M We IU LEM Mb IR a 29 MCI er a 29 4 gna a 29 4 2 Check DEIOFe a a m ML me S erp enema te Ae 29 4 3 A RON NTC PCM ON UCM OEC 30 4 4 MING Me WANG TO D ET LT o TIS SET 30 4 5 Implementation
45. cycle comprising 3 attempts to start up the engine Oil pressure il Temperature EI 55 263 6 3 3 Switching off Open the circuit breaker manually OR byselecting menu 12 CONTROL LOAD The following display will disappear supply stopped Press the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24 08 2005 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 D Alarms All alarms will cause the yellow LED to flash General alarm In conjunction with this LED aflashing pictogram appears on the LCD screen message on graphic display example representing the circuit affected by the alarm and the associated indicator if present FAULT example ALARM Low Fuel Level 25 12 05 15 30 OK HELP 56 263 2 Faults All faults will cause the generating set to stop immediate or gradual stop coolant temperature and overload or short circuit the red LED to flash General fault In conjunction with this LED aflashing pictogram appears on the LCD screen message on graphic display example representing the circuit affected by the fault and the associated indicator if present FAULT example FAULT Oil Pressure gt 25
46. 0 128 1 41 0 23 45 0 105 1 57 0 23 165 0 083 1 76 0 23 L8 0 063 1 96 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field 4 8 2 3 phase LSA 43 2 4 P AREP excitation Resistances at 20 C 02 Armat 0 23 0 23 0 23 0 23 0 23 0 23 0 23 Field excitation currenti exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 43 2 51 515 525 535 M45 L65 L8 4 8 3 Dedicated single phase LSA 43 2 4 pole SHUNT excitation 60 Hz only Resistances at 20 C 02 LSA 43 2 Stator L N 51 0 058 525 0 058 535 0 046 45 0 037 165 0 027 L8 0 019 Field excitation currenti exc A 240 V 60 Hz i exc excitation current of the exciter field LSA 43 2 no load atioad LSA 43 2 no load at load S1 51 0 59 1 44 15 525 0 59 1 68 S25 535 0 66 1 65 S35 M45 0 61 1 48 M45 L65 0 62 1 48 L65 L8 LEROY 16 SOMER 210 263 15 43 2 44 2 4 POLES ALTERNATORS 4 8 4 3 phase LSA 44 2 4 pole SHUNT excitation Resistances at 20 C Q LSA 44 2 Stator L N Armature 0 5 0 5 0 5 0 5 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 at load VS3 0 5 1 8 VS45 0 5 2 1 57 0 5 1 9 575 0 5 2 1 95
47. 0 6 2 112 0 5 1 9 4 8 5 3 phase LSA 44 2 4 AREP excitation Resistances at 20 C Q LSA Stator Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 44 2 no load at load VS3 3 6 VS45 4 2 1 S7 1 3 8 1 575 M95 22 4 8 6 Dedicated single phase 5 44 2 4 pole SHUNT excitation 60 Hz only Resistances at 20 C LSA 44 2 Stator L N Armature VS3 0 0194 0 5 VS45 0 0194 0 5 57 0 0140 0 5 M95 0 0088 0 5 Field excitation currenti exc A 240 V 60 Hz i exc excitation current of the exciter field LSA 44 2 VS3 545 57 M95 4 8 7 Table of weights values given for information only LSA 43 2 Total weight kg Rotor kg 220 220 220 S35 M45 L65 L8 LSA 44 2 Total weight kg VS3 405 140 VS45 405 140 S7 460 165 S75 460 165 M95 515 185 L12 570 210 Rotor kg After operational testing itis essential to replace all access panels or covers LEROY SOMER 17 211 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 5 SPARE PARTS 5 1 First maintenance parts Emergency repair kits are available as an option They contain the following items Emergency kit SHUNT ALT 432 KS 001 AVR R 2
48. 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 57 263 6 3 4 3 Activation of an alarm and fault The appearance of an alarm and a fault causes gt yellow and red LEDs to flash therelated screen to be displayed example below FAULTS 1 2 Emergency Stop If several faults are present the number of faults is 25 12 05 15 30 displayed at the top of the screen Esc RESET OK LIST The faults list can be accessed by pressing OK of the scrolling and selection wheel 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 scrolli
49. 13 Rated current A 8528 1 standard 14 Weight kg PRP main power 15 CE marking ESP emergency power 16 Non CE standard marking 7 Rated power factor e g GOSSTANDART 8 Maximum altitude of the site above sea level m 17 Sound pressure for the rated power 18 Sound power Figure 1 7 Example of generating set identification plate JOHN DEERE FRIEDRICHSHAFEN Dieselmotor Type 12V 4000 G60 MotorNr 526 100 950 UN 13NOV97 Baujahr 2002 DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE RG7935 Masse VOLVO PENTA gt ENGINE MODEL SPEC NO 399999 FRIEDRICHSHAFEN Dieselmotor SERIAL NO parses Sone t with fan kW hp POWER rpm MTU Motoren und Turbinen Union Friedrichshafen GmbH gt PRELIFT mm INJ TIMING MADE IN SWEDEN 3826077 Figure 1 8 Examples of engine identification plates 11 263 Roma n 20 36051 Tal 130 0444398111 R Nus C CREAZZO VICENZA ITALIA Fax 39 0444396766 SYATEN TYPE ECO28 1L 4 Xm 7 1 171 1 1 5 ALTERNATORS WASSE WEIGHT 0 1491 mee 4287684 Date 8 PUISSANCE RATING Roulements Bearings 6207 2RS 23 1172 Volle um UN 240 206 n 2006 m __ 2000 IN ITALY Jem FART AE 1 Cont eer WA Bae 120 108 120 1104 624 40 C wo wa
50. 96 Supply range voltage detection 85 to 139 V 50 60HZ Rapid response time 500 ms for a transient voltage variation amplitude of 20 96 Voltage setting P1 Stability setting P2 Power supply protected by 8 A fuse replacement product Ferraz Shawmut T084013T fast blow fuse 8 A FA 250 V breaking capacity 30 kA 2 2 U F Fonction and LAM The threshold position 50 Hz 60 Hz to action the U F fonction as well as the LAM setting type is selected using the potentionmeter WARNING The jumper settings must correspond to the rated operating The threshhold position and LAM fonction settings are done with the jumper Operating at 50 Hz U F gradient 0 threshold at 48 Hz without LAM for impacts between 30 and 409 of the rated load 1 threshold at 48 Hz with LAM 13 for impacts between 40 and 70 of the rated load 2 threshold at 48 Hz with LAM 259 for impacts gt 70 of the rated load Operating at 60 Hz U F gradient 3 threshold at58 Hz without LAM for impacts between and 40 of the rated load 4 threshold at 58Hz with LAM 1396 for impacts 40 and 7096 of the rated load 5 threshold at 58Hz with LAM 25 for impacts gt 70 of the rated load Specific operating 6 threshold at 57Hz without LAM for speed variations at a steady state gt 2 Hz 7 threshold at65Hz without LAM for variable speed and tractelec gearlec U F gradient 8 special the factory setting
51. Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Defective turbocharger Low engine temperature 55 7 171 263 Solution Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace if necessary Use correct grade of fuel Use proper type of fuel Service air cleaner Reduce load oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor Check thermostat DPSG CD03523 49 19 22JAN07 4 4 072209 PN 101 Troubleshooting Electrical troubleshooting Symptom Undercharged system Battery uses too much water Batteries will not charge Starter will not crank Starter cranks slowly Entire electrical system Problem Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connec
52. G 3 A 6068HFU74 Engine shown A Engine Coolant Temperature E Optional Instrument Panel Fuel Rail Pressure Sensor M Fuel Temperature Sensor ECT Sensor Generator Instrument Panel J Crankshaft Position Sensor B Electronic Injector Connector F Engine Wiring Harness K Pump Position Sensor C Manifold Air Temperature G Engine Oil Pressure Sensor L Pump Control Valve Solenoid MAT Sensor Connector D ECU Connector H Power and Ground Battery Connections CD03523 000018F 19 02FEBO07 1 1 072209 55 3 PN 97 167 263 Troubleshooting Engine troubleshooting Symptom Engine cranks but will not start Engine hard to start or will not start Engine knocks Problem Incorrect starting procedure No fuel Exhaust restricted Fuel filter plugged or full of water Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Engine starting under load Improper starting procedure No fuel Air in fuel line Cold weather Slow starter speed Crankcase oil too heavy Improper type of fuel Water dirt or air in fuel system Clogged fuel filter Dirty or faulty injection nozzles Injection pump shut off not reset Low engine oil level Injection pump out of time Low coolant temperature Engine overheating Continued on next page 55 4 168 263 Solution Verify correct starting procedure Check fuel in tank and manual shut o
53. In specific cases where there is to be a connection to existing electrical networks this must only be installed by a qualified electrician who should take the operating differences of the equipment into account according to whether the mains supply network or generating set is being used Protection against electric shocks is ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications v lf 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 SAA KAS 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 breathin
54. MERCEDES BENZ MAN KHD Approved by BMW VOLKSWAGEN MERCEDES PORSCHE GENERAL MOTORS Conforms with VOLVO IVECO VANHOOL and Conforms with VOLVO OPEL SEAT and SKODA STAYR TRUCK specifications 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 Improves the efficiency and longevity of the cooling system e GenCOOL PC 26 is especially recommended for engines fitted with aluminium or light alloy radiators HIGH TEMPERATURE SUITABILITY 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 22 263 PACKAGING STORAGE e GenCOOL PC 26 is supplied in 210 metallic barrels with smooth interior linings e It can be stored for 2 years in its
55. O D lt N 1 2 2 N O IMPORTANT The air intake system must not leak Any leak no matter how small may result in engine failure due to abrasive dirt and dust entering the intake system Check clamps on piping A which connect the air filter engine and if present turbocharger and air to air radiator Tighten clamps as necessary Test air restriction indicator B for proper operation 1 Inspect all intake hoses piping for cracks Replace Replace indicator as necessary as necessary Continued on next page DPSG CD03523 33 19 22JAN07 1 2 072209 35 1 PN 77 147 263 Maintenance 1000 hours 1 year If engine has a rubber dust unloader valve C inspect the valve on bottom of air filter for cracks or plugging Replace as necessary 5 Service air filter as necessary Checking automatic belt tensioner 4045 and 6068 Engines Belt drive systems equipped with automatic spring belt tensioners cannot be adjusted or repaired The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt If tensioner spring tension is not within specification replace tensioner assembly Checking belt wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used If the tensioner stop on swing arm A is hitting the fixed stop B check mounting
56. Replace tensioner assembly as required Specification Spring Force 18 22 N m 13 16 lb ft Align marks A Mark on swing arm B Mark on tensioner mounting base Check and adjust engine valve clearance 3029 and 4039 Engines NOTE Valve clearance must be adjusted after the first 500 hours of operation then every 1000 hours thereafter Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 JDG820 Flywheel Turning Tool A rotate engine flywheel in running direction clockwise viewed from water pump until No 1 piston front has reached top dead center TDC on compression stroke Insert timing pin JDE81 4 or JDG1571 into flywheel bore Continued on next page 35 3 149 263 RG7977 UN 14NOV97 RG12054 UN 08JAN02 DPSG CD03523 34 19 30JAN07 2 2 CD30544 UN 19MAY98 DPSG CD03523 35 19 31JAN07 1 2 072209 PN 79 Maintenance 1000 hours 1 year 3 Check and adjust valve clearance to specifications according to following procedures Specification Valve clearance engine COG enact aicencod 0 35 mm 0 014 in EXN AUS EET 0 45 mm 0 018 in gt gt NOTE If rocker arm is equipped with adjusting screw i and jam nut A tighten jam nut to 27 N m 20 1 lb ft after adjusting valve clear
57. Speed too low when on load or AVR LAM set too high If no effect try normal or fast stability modes ST2 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 DC SHUNT lt 20V AREP PMG 10V Check the speed or AVR LAM set too high Faulty rotating diodes Short circuit in the revolving field coil Check the resistance Faulty exciter armature Check the resistance Voltage between E and E SHUNT gt 30V AREP gt 15V Voltage disappears during operation 12 Check the AVR the surge suppressor the rotating diodes and replace any defective components Exciter winding open circuit Faulty exciter armature Faulty AVR Revolving field coil open circuit or short circuited The voltage does not return to the rated value LEROY SOMER 206 263 15 43 2 44 2 4 POLES ALTERNATORS 4 5 1 Checking the winding You can check the winding insulation by performing a high voltage test In this case you must disconnect all AVR wires WARNING Damage caused to the AVR in such conditions is not covered by our warranty 4 5 2 Checking the diode bridge A diode in good working order should allow the current to flow only in the anode to cathode direction A Anode Cathode Oy M repe OFe
58. 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 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 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 Particular attention must be paid to tightness of the wheels on vehicles Red rear lights Front reflective devices white 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 30 263
59. a See from the fuel filter s Ex ridi RN the filter b Replacethefuelfilerelement s lo o e J y treautomatctonsimery o the automatic tensioner oe Pos o adjust if necessary d Clean the breather 4 JL e 4J 0 J j hoses and unions Check the cooling circuit pressure Check the damper 6 cyl e gts su Check the engine speed and regulator droop Drain and flush the cooling circuit f Clean the air filter element a Check the thermostat and the injectors g a Clean the air filter when the clogging indicator is red Replace the filter element after it has been cleaned 6 times or once a year Drain the oil and change the filter after the first 100 hours of operation c Check the tension of the belt every 500 hours on 3029 and 4039 engines and on 4045 and 6068 engines fitted with a manual tensioner Check the automatic tensioner every 1000 hours once a year on 4045 and 6068 engines d This operation should be carried out by one of our agents After the first 500 hours of operation then every 1000 hours for 3029 and 4039 engines Every 2000 hours for 3029 and 4039 engines Operation to be carried out by one of our agents The Damper must be changed every 4500 hours every 5 years f Using John Deere COOL GARD coolant dr
60. alternator does not work normally the source of the malfunction must be identified see sections 4 4 and 4 5 LEROY SOMER 11 205 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 4 4 Mechanical defects Bearing Excessive temperature rise in one or both bearings bearing temperature more than 80 C with or without abnormal bearing noise If the bearing has turned blue or if the grease has turned black change the bearing Bearing not fully locked abnormal play in the bearing cage Check the end shield alignment flange not properly fitted Abnormal temperature Excessive temperature rise in the alternator housing more than 40 C above the ambient temperature Air flow intake outlet partially clogged or hot air is being recycled from the alternator or engine Alternator operating at too high a voltage gt 105 of Un on load Alternator overloaded Excessive vibration Misalignment coupling Defective mounting or play in coupling Rotor balancing fault Engine Alternator Excessive vibration and humming noise coming from the machine Phase imbalance Stator short circuit Alternator damaged by a significant impact followed by humming and vibration 4 5 Electrical faults Faut Acion j Effect O No voltage at no load on start up Connect a new battery of 4 to 12 volts to terminals E and E respe
61. 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 00 Tighten all the lock nuts Checking the setting trailer on axle stands pui tne 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 pul tne 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 Checkthe transmission setting after 180 miles 300 km running in period and if necessary adjust the gap J1 using the tensioner Parking Thelever must be fully pulled up so that the compensating spring is fully compressed gt Every 900 miles 1500 km check the braking settings and distribution on all the wheels Important The brake controls are designed to draw trailers behind flexible suspension touring vehicles If used behind an HGV be sure to provide the fitted ball joint with a shock absorber to prevent premature wear gt During any manoeuvres with the trailer coupled do not turn more than 90 or force reverse gt specifications of our brake controls
62. 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 31 263 EN NUT 5 COMPENSATING TENSIONER6 CROSS BAR7 BRAKE CABLE SPRING 5 tEn SS ee SLIDE 2 E LINKAGES LINKAGE CASING STOP SETTING SCREW B AUTOMATIC BACKWARD JAW if SIMPLE JAW RETRACTOR LEFT RA2 BRAKE Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 32 263 4 7 Faults and repairs Fault observed Solutions Braking too weak the towing vehicle are in the same horizontal plane Incorrect brake setting Adjust the settings Drum temperature abnormally high Incorrect linkage setting Adjust the settings Interfering parts on the slide Remove clean and grease Corroded slide Remove the corrosion and grease Jerky braking 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 Different brake setting on the two sides Adjust the brake settings Trailer tending to swerve upon braking Cables damaged or incorrectly fitted parts P
63. as soon as the alternator stops It is installed at the rear of the machine Its standard power is 250W with 220V or 250W with 110V on request Warning the power supply is present when the machine has stopped 5 3 2 Temperature sensors with thermistors PTC These are thermistor triplets with a positive temperature coefficient installed in the stator winding 1 per phase There can bea maximum of 2 triplets in the winding at 2 levels warning and trip and 1 or 2 thermistors in the shields These sensors must be linked to adapted sensing relays Supplied optionally Cold resistance of cold thermistor sensors 100 to 250 per sensor 5 3 3 Connection accessories 12 wire machines coupling F 3 flexible SHUNTS After operational testing itis essential to replace all access panels or covers LEROY 18 SOMER 212 263 15 43 2 44 2 4 POLES ALTERNATORS 5 4 Exploded view parts list and tightening torque 5 4 1 LSA 43 2 44 2 single bearing 44 2 coupling LEROY 19 SOMER 213 263 20 LSA 43 2 44 2 4 POLES ALTERNATORS 5 4 2 LSA 43 2 44 2 double bearing E fit AAA AT AT AT LSA 44 2 LEROY SOMER 214 263 15 43 2 44 2 4 POLES ALTERNATORS Description Description Stator assembly NDE bearing Preloading wavy washe
64. case that the mechanical subsystem is determined to be out of calibration This failure mode does not relate to the signal range definition as do many of the 262 263 14 5 INSTRUCTIONS Special Instructions is the FMI to be used when the on board system can isolate failure to small number of choices but not to a single point of failure When the FMI is used there is clear necessity for the service technician to take some action to complete the specific diagnosis and the manufacturer has provided instructions for the completion of that diagnosis There are two cases where this will be used 1 for emission related diagnostics where the particular failure cannot be separated between a sensor out of range and the case where the actual value is at the edge of a diagnostic region and 2 for the older SPN 611 to 615 where the problem is in determining which of two or more circuits which may interact is the one that needs repair SPNs 611 through 615 are defined as System Diagnostic Codes and are used to identify failures that cannot be tied to a specific field replaceable component Specific subsystem fault isolation is the goal of any diagnostic system but for various reasons this cannot always be accomplished These SPNs allow the manufacturer some flexibility to communicate non specific component diagnostic information Since SPNs 611 615 use the standard SPN FMI format it allows the use of standard diagnosti
65. definition Broadcast of data values is continued as normal Broadcast of data values is continued as normal FMI 1 DATA VALID BUT BELOW NORMAL OPERATIONAL RANGE MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region e of the signal range definition Broadcast of data values is continued as normal FMIZ2 DATA ERRATIC INTERMITTENT OR INCORRECT Erratic or intermittent data includes all measurements that change at a rate that is not considered possible in the real world condition and must be caused by improper operation of the measuring device or its connection to the module Broadcast of data value is substituted with the error indicator value Incorrect data includes any data not received and any data that is exclusive of the situations covered by FMIs 3 4 5 and 6 Data may also be considered incorrect if it is inconsistent with other information collected or known about the system 261 263 FMIZ3 VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE a A voltage signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic co
66. for at least 2 minutes at fast idle and no load Changing Generator Frequency Generator sets powered by 6068HFU74 engine are dual frequency 50 Hz 1500 rpm or 60 Hz 1800 rpm 15 29 136 263 Unusual noise or vibration Excessive black exhaust Excessive fuel consumption e Excessive oil consumption e Fluid leaks Recommendation for turbocharger engines Should the engine stall when operating under load IMMEDIATELY restart it to prevent overheating of turbocharger components Idling engine Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system If an engine will be idling for more than 5 minutes stop and restart later NOTE Generator set applications have the governor locked at a specified speed and do not have a slow idle function These engines idle at no load governed speed fast idle DPSG CD03523 21 19 22JAN07 weeks DO NOT allow engine to run extended period of time with no load 1 1 DPSG CD03523 22 19 22JAN07 1 1 2 Stop the engine DPSG CD03523 23 19 22JAN07 1 1 Refer to the generator set documentation for more information CD03523 000018C 19 26JAN07 1 1 PN 072209
67. from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 UN 23AUG88 DX AIR 19 17FEB99 1 1 072209 05 6 PN 31 101 263 Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere amp Company Medical Department in Moline Illinois U S A Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can accidentally burst when heat goes beyond the immediate flame area Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a to
68. is initialised Data displayed Fuel level indicator Alarm Fault Alarm Fault low fuel level high fuel level Coolant level temperature indicator Alarm Alarm High 4 Hiah preheating Low level level fault 9 fault temperature 4 fault alarm fault Min battery Battery charge voltage indicator ON 1 UN voltage flashing flashing flashing bars Oil pressure temperature indicator High or low oil Fault Alarm Fault Emergency stop Oil pressure level on ih Alarm Fault gt Alarm lt Emergency stop fault Overload or short circuit Tripping of circuit breaker following an overload or short circuit Engine speed Underspeed fault Non starting fault 47 263 6 3 1 5 Description of the pictograms in zone 3 Zone 3 pictograms All the pictograms for these zones are activated when the TELYS is initialised The pictograms below are shown for information only Generating set stopped Fuel Level Indication High temperature HT coolant temperature indication units as per settings menu By Battery Voltage indication Oil Temperature Indication units as per settings menu t start up or genset started or genset stoppage in progress Screen Pictograms Data displayed O F 1 1 RPM Engine Speed Indication High temperature HT coolant temperature el 1 indication units as p
69. notice of the different warning symbols used WARNING Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel WARNING SYMBOLS We wish to draw your attention to the following 2 safety measures which must be complied with a During operation do not allow anyone to stand in front of the air outlet guards in case anything is ejected from them b Do notallow children younger than 14 to go near the air outlet guards Aset of self adhesive stickers depicting the various warning symbols is included with this maintenance manual They should be positioned as shown in the drawing below once the machine has been fully installed WARNING The alternators must not be put into service until the machines in which they are to be incorporated have been declared compliant with Directives EC and plus any other directives that may be applicable Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The informa contained in this document may therefore be changed without notice Copyright 2004 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may notbe reproduced in any form without prior authorization All brands and models have been regis
70. obtained no more than 8 A LEROY 10 SOMER 240 263 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 2 10 seconds and then drop to 1A Toreset switch off the power supply by ope ning switch A Note After setting the excitation ceiling as described adjust the voltage again see section 2 1 1 In some countries itis alegal 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 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 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 104 Diode Exciter field Forced excitation Time Guaranteed voltage build up Parallel operation de energized Parallel operation at standstill Frequency starting Sustained
71. operation to prevent water condensation and freezing during cold weather Keep all storage tanks as full as practicable to minimize When fuel is stored for an extended period or if there is a condensation slow turnover of fuel add a fuel conditioner to stabilize the fuel and prevent water condensation Contact your fuel Ensure that all fuel tank caps and covers are installed supplier for recommendations properly to prevent moisture from entering Monitor water content of the fuel regularly DX FUEL4 19 19DECO03 1 1 072209 10 1 PN 34 104 263 Fuels Lubricants and Coolant Diesel Engine Break In Oil New engines are filled at the factory with John Deere ENGINE BREAK IN OIL During the break in period add John Deere ENGINE BREAK IN OIL as needed to maintain the specified oil level Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine After engine overhaul fill the engine with John Deere ENGINE BREAK IN OIL If John Deere ENGINE BREAK IN OIL is not available use a diesel engine oil meeting one of the following during the first 100 hours of operation e API Service Classification CE e API Service Classification CD e API Service Classification CC ACEA Oil Sequence E2 ACEA Oil Sequence E1 PLUS 50 is a trademark of Deere amp Company Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes D
72. 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 0 380 V Voltage minimum fully anti clockwise Stability NONSE centre position Voltage quadrature droop Not set operation with C T fully anti 0 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 and A C voltmeter cal 300 500 or 1000V on the alternator output terminals c Make sure that the ST3 jumper is positio ned on the desired frequency 50 or 60 Hz d Voltage potentiometer P2 at minimum fully anti clockwise e Stability potentiometer P3 to around 1 3 of the anti clockwise limit f Start the engine and set its speed to a fre quency of 48 Hz for 50 Hz or 58 for 60 Hz g Set the output voltage to the desired va lue using P2 Rated voltage UN for solo operation eg 400 V Or UN 2 to 4 for parallel operation with C T eg 410 V If the voltage oscillates use P3 to make ad justments try both direc
73. original container and packaging e Avoid zinc coated containers RECOMMENDATIONS FOR USE Compatible with the original fluid e It is recommended that the cooling system is completely drained when replacing the fluid SPECIFICATIONS UNITS SPECIFIED VALUES TRIAL METHODS R 15 602 pa 78085 NF T 78 103 NE T 78 101 150024 C 26 2 NF T 78 102 Freezing point Glassware corrosion test with antifreeze mg test piece R 15 602 7 Copper Weld Brass Steel Cast iron Cast aluminium Corrosion on warm plate test with antifreeze mg cm week 0 17 R 15 602 8 3 Installation 3 1 Unloading 3 1 1 Safety during unloading To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions you need to ensure that the following points are observed Lifting machinery or equipment appropriate to the work required Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members Ground able to take the load of the set and the lifting machinery without stress otherwise lay down beams of sufficient strength and stability Set put down as close as possible to its point of use or transportation in a clear area with free access Example of equipment to be used crane slings cross bar safety catch shackles v Fork lift truck 23 263 3 1 2 Instructions for unloading 3
74. 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 PERKINS CID Component parameter This term used by PERKINS has an equivalent in the J1939 standard SPN This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by JOHN DEERE SPN Suspect Parameter 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 FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault FMI Failure Mode identifier 59 263 Terminology used MTU The ADEC and MDEC general system faults are indicated on the equipment in Displaying faults the following way fault code numbers generated by the ECU Engine control unit In the event of a fault the screen will display the following message Engine fault code Pressing OK will display fault finding informatio
75. place off the engine or machine RIGHT HAND AND LEFT HAND sides are determined by standing at the drive or flywheel end rear of the engine and facing toward the front of the engine SETTING FUEL DELIVERY beyond published factory specifications or otherwise overpowering will result in loss of warranty protection for this engine Information relative to emissions regulations Depending on final destination this engine can meet the emissions regulations according to the US Environmental Protection Agency EPA California Air Resources Board CARB and for Europe the Directive 97 68 EC relating the measures against the emissions of gaseous and particulates pollutants from internal combustion engines In this case an emission label is stuck on the engine Emission regulations prohibit tampering with the emission related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications It is also illegal to install a part or component where the principal effect of that component is to bypass defeat or render inoperative any engine component or device which would affect the engine conformance to the emissions regulations To summarize it is illegal to do anything except return the engine to its original published specifications Continued on next page DPSG CD03523 1 19 06JUL09 1 2 072209 PN 2 72 263 Introduction List of emission related components
76. safety instructions must be made known to operating personnel They will be regularly updated Read and understand the manuals provided with the generating set pump unit or lighting column properly The manufacturer s instructions must remain at the disposal of technicians if possible in situ 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 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 Warn personnel present to keep their distance during operation Do not run the generating set pump unit or lighting column without refitting the protective covers and closing all the access doors v Never let a child touch the generating set pump unit or lighting column even when shut down Avoid operating the generating set pump unit or lighting tower in the presence of animals disturbance scares etc Y Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site When chocking the trailer on a slope ensure that there is nobody in the path of the trailer v Never start the engine without an air filter or exhaust Engine with turbocharger never start the engine without fitting the air filter The compre
77. 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 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 8 263 1 3 3 Risks related to toxic products VV Glycol is a toxic product and dangerous if absorbed Avoid The corrosion inhibitor contains alkali all contact with the skin or eyes Read the instructions on the Do not swallow packaging This substance should not come into contact with the eyes In the event of contact with eyes rinse immediately with plenty of water for at least 15 minutes 4 Avoid any prolonged or repeated contact with skin In the event of skin contact wash thoroughly with water and soap CALL A DOCTOR IMMEDIATELY KEEP THE PRODUCT OUT OF TH
78. the machine RT has a short circuit current capacity and This excitation system consists of a PMG permanent magnet generator This is fitted Te to distortions generated by ide Ps The AVR monitors and corrects the alterna The PMG supplies bc AIR constant d voltage by adjusting the excitation deal a 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 9 ix2 71 122 0 110 1220 380 e 4 x holes 5 8 x 175 115 mm Slow fuse 250V ST5 With LAM without LAM 2 _ gt ST3 T I 1 T m Frequency U 50Hz 60 2 5 9 14 110 LAM 13 25 J 0 P Excitation ceiling p ST4 Option open External potentiometer ST 1 1 knee point 65 Hz for adjusting the voltage Response normal ST2 time fast P3 Stability 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 LI Option R731 3 ph detection AN i in 3 ph detection ST1 open Single phase detection
79. three times long pause flash five times short its 2 digit number If there is more than one active pause flash three times DTC the ECU will flash each code in numerical order CD03523 0000191 19 02 7 1 1 072209 55 9 PN 103 173 263 Troubleshooting Using diagnostic gauge for retrieving Diagnostic Trouble Codes DTC s NOTE The method below applies on applications having the optional diagnostic gauge shown refer to the generator documentation for more information 1 Make sure all engine mechanical and other systems not related to the electronic control system are operating properly See ENGINE TROUBLESHOOTING in this section NOTE Diagnostic gauge A uses the menu key B to access various engine functions two arrow keys C to scroll through the engine parameter list and view the menu list and an enter key D for selecting highlighted items 2 Read and record DTC s displayed on LCD of diagnostic gauge A For procedure to access diagnostic trouble codes refer to Using Diagnostic Gauge to Access Engine Information earlier in this manual 3 Go to the LISTING OF DIAGNOSTIC TROUBLE CODES DTOs later in this section to interpret the DTC s present gt 2 2 2 N Z O X Trouble Code Display On Instrument Panel A Diagnostic Gauge B Menu Key C Arrow Keys D Enter Key 4 Contact your nearest engine distributor or servicing dea
80. voltage on overload LEROY SOMER 11 241 263 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 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 modes ST2 Check the speed possibility of cyclic irregularity
81. 0 4045TF270 4045TFS70 4045TFU70 25 L 26 5 qt 4045HF 158 4045HFU72 6068TF158 6068TF258 28 L 29 5 qt 4045HFS73 4045HFS82 4045HFS83 4045HFU79 6068HF 120 6068HF 158 6068HF220 6068HF258 6068HF275 6068 572 6068HFS73 6068 582 6068HFS83 6068HFU72 6068HFU79 32 L 34 qt 6068HF475 6068 576 6068 77 6068 589 6068HFU74 35 37 qt DPSG CD03523 41 19 15JUL09 4 5 lt gt 1 2 2 O DPSG CD03523 41 19 15JUL09 5 5 072209 PN 87 Maintenance As required Additional service information This manual does not allow a complete repair of your engine If you want want more detailed service information the following publications are available from your regular parts channel e PC2451 Parts Catalog for Non Emission Certified engines PC3235 Parts Catalog for Stage 11 Emission Certified engines CTM3274 Component Technical Manual for 3029 and 4039 engines English e CTM104 Component Technical Manual for 4045 and 6068 base engines English CTM207 Component Technical Manual for e CTM502 C t Technical Manual for HPCR Mechanical Fuel Systems on 4045 and 6068 engines Fuel System A with VR Head English Engi English e CTM320 Component Technical Manual for Technical Manual for OEM Fuel System on 4045 and 6068 with 4 Valve Head Engine accessor
82. 1 UN 30SEP03 50g Press Enter Key to Select OURGP11 00000B0 19 03SEP03 5 7 6 Press the Menu key to return to the main menu ENGLISH A o 2 2 D O x Return To Main Menu OURGP11 00000B0 19 03SEP03 6 7 7 Press the Menu key to return to the engine parameter display 1000 RPM 14 2 27 PSI BAT WOLT TIL PRES RG13159 UN 26SEP03 Press Menu Key OURGP11 00000B0 19 03SEP03 7 7 Setup 1 Up Display 1000 RPM ENG QPM 1 Turn the key switch to the ON position Starting at the 1800 RPM single engine parameter display press the Menu key 14 2 57 PSI FXG temp wat o PRES RG13159 UN 26SEP03 Menu Key Continued on next page OURGP11 00000B1 19 03SEP03 1 18 15 15 PN 52 122 263 Operating the Engine 2 Use the Arrow keys to scroll through the menu until GO TO 1 UP DISPLAY Setup 1 Up Display is highlighted STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT OGPO Setup 1 Up Display RG13193 UN 020CT03 OURGP11 00000B1 19 03SEP03 2 18 3 Once Setup 1 Up Display menu item has been highlighted press the Enter key to access the Setup GO TO 1 UP DISPLAY STORED CODES 1 Up Display function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLKSHT eg Press Enter Key H A 1 2 2 o NT
83. 1 2 1 Slings Attach the lifting vehicle slings to the rings on the generating set designed for this procedure Hang the slings carefully Check that the slings are correctly attached and the equipment is solid Lift the generating set carefully Direct and stabilise the set towards the chosen position Carefully set down the equipment while continuing to position it Q Release the slings then detach and remove the lifting rings 3 1 2 2 Fork lift truck Position the forklift arms under the base frame except with generating sets fitted with forklift pockets in which case position the forklift arms in these pockets making sure that only its cross members are resting on the arms Lift the equipment handling it gently set down the generating set in its unloading position Figure 3 1 Transporting a generating set using a forklift truck 24 263 3 2 Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container if the generating set is fitted with this option The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Three different fittings are available Figure 3 2 Fluid retention container integrated into the tank chassis Figure 3 3 Offset fluid retention container underneath the generating set ch
84. 11 103 138 rpm Standby POWER 1800 kW hp rpm Prime POWER 1800 kW hp rpm Standby Width overall mm 751 765 751 765 Length overall mm 1362 1365 1362 1365 Height overall mm 1137 1162 1137 1162 Weight kg 505 505 505 505 Engine oil quantity L 16 16 16 16 Engine coolant 28 32 28 32 quantity With Fan Approximate Continued on next page 65 4 182 263 CD03523 0000194 19 08JUL09 1 3 072209 PN 112 Specifications ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight Engine oil quantity Engine coolant quantity With Fan Approximate ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight Engine oil quantity Engine coolant quantity With Fan Approximate ITEM Number of Cylinders Fuel Bore Stroke UNIT OF MEASURE kW hp kW hp kW hp kW hp UNIT OF MEASURE kW hp kW hp kW hp kW hp UNIT OF MEASURE 4045TFS70 4045TFU70 4 4 Diesel Diesel 106 5 106 5 110 127 4 5 4 5 17 0 1 17 0 1 55 74 55
85. 170 125 265 195 330 245 375 275 475 350 440 325 560 410 20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580 22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800 M24 330 245 425 315 650 480 820 600 920 680 1150 8501 1080 800 1350 1000 M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475 M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 Torque values listed are for general use only based on the strength of Shear bolts are designed to fail under predetermined loads Always the bolt or screw DO NOT use these values if a different torque value or replace shear bolts with identical property class Replace fasteners with tightening procedure is given for a specific application For stainless steel the same or higher property class If higher property class fasteners are fasteners or for nuts on U bolts see the tightening instructions for the used tighten these to the strength of the original Make sure fastener specific application Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement When by turning the nut to the dry torque shown in the chart unless different possible lubricate plain or zinc plated fasteners other than l
86. 251 263 9 John Deere 1181 jBateyvolagesenso I jBECUPwedownemr _ jWmelspedseor o 2 Wheel speedinput noise 0 ______ 164 164 m LH Elie T Electrical system voltage low system voltage low Fam Tm EPI CIE voltage high input voltage high EIN voltage low input voltage low circuit alarm warning 16 aaa e temperature sensor input voltage low Fultmpeauengh Tena s L jOMememtresmsor oitemperature exremeiyhigh 8 sensor input voltage high oitemperature sensorinputvotagetow EE on Jrransmission oil temperature sensor _ T Not possible with LICHE E pt E cttemporaure inate S ddl Rated enginespeed ME Enginespecdderated Engine speed de rated Engine speed sensor extreme NENNEN C Z NENNEN Engine speed sensor data intermitent Engine speed sensor abnormal update Engine speed sensor sigrast Engine speed sensor sigrast Ovmpedmodae 252 263 28 21 calibration RR rain timing abnormal
87. 4 jumper or the remote adjustment potentiometer have been connected 3 2 Settings The different settings made during the trialareto bedoneby qualified personnel Respecting the load speed specified on the nameplate is vital in order to start a settings procedure After operational testing replace all access panels or covers The only possible settings on the machine are to be done with the A V R 3 2 1 R250 settings SHUNT system Initial potentiometer positions voltage setting potentiometer P1 for the A V H full left remote voltage setting potentiometer in the middle Operate the alternator at its rated speed if the voltage does not rise it is necessary to re magnatise the magnetic circuit slowly adjust the voltage potentiometer of theA V R P1 untilthe output voltage reaches its rated value Stability setting with P2 3 2 2 Special type of use WARNING Excitation circuit E E must not be left open when the machine is running A V R damage will occur 3 2 2 1 R250 field weakening SHUNT The exciter is switched off by disconnecting the A V R power supply 1 wire or 110V Contact rating 16A 250V AC Do notreclose the power supply until the voltage has reached a value 15 of the rated voltage approximately 5 seconds after opening 3 2 2 2 R250 field forcing 400V Diode Excitation Inducer The battery must be isolated
88. 48Hz 2U F gradient a special programme is possible on request This programme must be specified before ordering during the project study 9 threshold at 47 5 Hz without LAM for speed variations at a steady state gt 2 Hz For hydraulic applications it is advisable to select frequency see the nameplate on the position O for 50 Hz alternator position 3 for 60 Hz Risk of destruction for the alternator LEROY SOMER 5 223 263 LEROY SOMER R250 A V R 2 3 R250 A V R option Potentiometer for voltage setting 1000 W 0 5 W min setting range 5 Remove the ST4 jumper For wiring upthe external potentiometer the earth wires must be isolated as well as the potentiometer terminals wires at the same voltage as the power 2 4 LAM characteristics Load Acceptance Module 2 4 1 Voltage drop The LAM system is integrated in the A V R It is active as standard It can be adjusted to 1396 or 25 Hole of the LAM Load Adjustment Module On application of a load the rotation speed of the generator set decreases When it passes below the preset frequency threshold the LAM causes the voltage to drop by approximately 1396 or 25 and consequently the amount of active load applied is reduced by approximately 2596 to 5096 until the speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its duration for a given applied
89. 5 R438 A V R if INSTALLATION COMMISSIONING nennen nnne nennen nnn nnn nnns 8 3 1 Electrical checks on the ara MV NU de 8 lcs NEN 8 ek een Vater E 11 4 5 12 4 1 Designation RTT 12 4 2 Technical support DRE RO RE Pw p hb E P aD ke RP 12 All such operations performed on the A V R should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components The R438 is an IPOO product It must be installed inside a unit so that this unit s cover can provide IP20 minimum total protection it must only be installed on LS alternators in the ap propriate location so that when viewed externally it has a higher degree of protection than IP20 Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 3 233 263 LEROY SOMER R438 A V R 1 SUPPLY 1 1 AREP excitation system For both AREP amp PMG excitation systems the alternator voltage regulator is the R438 With AREP excitation the R438 ele
90. 5 215 160 240 175 305 225 3 4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400 7 8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640 1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960 1 1 8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 1 1 4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 Torque values listed are for general use only based on the strength of the bolt Replace fasteners with the same or higher grade If higher or screw DO NOT use these values if a different torque value or tightening grade fasteners are used tighten these to the strength of the procedure is given for a specific application For plastic insert or crimped steel original Make sure fastener threads are clean and that you type lock nuts for stainless steel fasteners or for nuts on U bolts see the properly start thread engagement When possible lubricate tightening instructions for the specific application Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts wheel bolts under predetermined loads Always replace shear bolts with identical grade or wheel nuts unless different instructions are given for the specific application Grade 2 applies for hex cap screws not h
91. 50 Diode bridge assembly Surge suppressor AVR 450 Diode bridge assembly Surge suppressor ALT 432 KS 002 Single bearing kit ALT 432 KB 002 Non drive end bearing O ring Preloading Double bearing kit ALT 432 KB 001 Non drive end bearing Drive end bearing ring mq qu Preloading washer Single bearing kit ALT 442 KB 002 Non drive end bearing ring Preloading Double bearing kit Non drive end bearing Drive end bearing ring Preloading ALT 442 KB 001 5 2 Technical support service Ourtechnical 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 nameplate Address your enquiry to your usual contact Part numbers should be identified from the exploded views and their description from the parts list Our extensive network of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage 5 3 Accessories 5 3 1 Space heater for use when stopped The space heater must run
92. 6068 Engines with manual tensioner Inspect belts for cracks fraying or stretched out areas Replace if necessary NOTE Belt adjustment is measured using a gauge stamped on the top edge of the alternator bracket Loosen cap screws B and C Slide alternator in slot by hand to remove all excess 24 Y A T 8 S slack in belt Scribe a reference mark D on line with SC Lh 7 notch E on upper alternator bracket RG9132 UN 040CT99 7 Manual belt tensioner 4045 and 6068 engines IMPORTANT Do not pry against alternator rear frame 3 Using the gauge A on the alternator bracket stretch belt by prying outward on alternator front frame Stretch the belt 1 gauge unit for a used belt and 1 5 gauge units for a new belt 4 Tighten cap screws B and C Belt gauge D Reference mark B Cap screw E Alternator upper bracket C Cap screw notch CD30843 UN 10JAN03 CD30843 Reference marks DPSG CD03523 57 19 30JAN07 1 1 3 0 6 072209 PN 76 146 263 Maintenance 1000 hours 1 year Cleaning crankcase vent tube If you operate the engine in dusty conditions clean the tube at shorter intervals 1 Remove and clean crankcase vent tube A 2 Install the vent tube Be sure the O ring fits correctly in the rocker arm cover for elbow adapter Tighten hose clamp securely CD30773 UN 27AUG99 DPSG CD03523 32 19 22JAN07 1 1 Checking air intake system O
93. 74 61 81 61 81 637 600 867 1230 979 1010 451 505 12 12 25 25 6068HFS72 6068HFS73 6 6 Diesel Diesel 106 5 106 5 127 127 6 8 6 8 17 0 1 19 0 1 112 150 139 186 123 165 153 205 784 784 1500 1500 1137 1137 764 764 32 32 32 32 6068HFU72 6068HFU74 6 6 Diesel Diesel 106 5 106 5 127 127 Continued on next page 65 5 183 263 6068HFS76 6 Diesel 106 5 127 6 8 17 0 1 167 224 184 247 960 1509 1381 764 32 35 6068HFU79 6 Diesel 106 5 127 6068HFS77 6 Diesel 106 5 127 6 8 17 0 1 189 253 207 277 960 1509 1381 764 32 35 CD03523 0000194 19 08JUL09 2 3 072209 113 Specifications ITEM UNIT OF MEASURE 6068HFU72 Displacement 6 8 Compression Ratio 17 0 1 POWER 1500 rpm 111 149 Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall 123 165 Height overall Weight dry Engine oil quantity Engine coolant quantity With Fan Approximate General engine pack specifications EPA Tier 2 Emission Certified Engines ITEM UNIT OF MEASURE 3029TF270 Number of Cylinders 3 Fuel Diesel Bore 106 5 Stroke 110 Displacement 2 9 Compression Ratio 17 2 1 POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight dry Engine oil quantity Engine
94. 8 51 42 56 43 58 48 64 519 716 819 316 8 14 5 40450 158 Diesel 106 5 127 4 5 17 6 1 41 56 42 57 48 65 51 69 606 1038 959 493 8 20 Continued on next page 65 1 179 263 3029TF158 Diesel 106 5 110 2 9 17 2 1 36 49 40 54 40 54 45 61 582 888 979 350 8 14 5 4045 120 Diesel 106 5 127 4 5 17 0 1 91 122 102 137 598 861 980 396 12 28 4045HF 158 Diesel 106 5 127 4 5 17 0 1 88 120 96 131 108 147 120 163 198 1209 1197 599 12 28 DPSG CD03523 55 19 08JUL09 1 3 072209 PN 109 Specifications Approximate ITEM UNIT OF MEASURE 4045TF120 4045TF158 4045TF220 4045TF258 Number of Cylinders 4 4 4 4 Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 127 127 127 127 4 5 4 5 4 5 4 5 17 0 1 17 0 1 17 0 1 17 0 1 63 84 61 83 75 101 72 98 Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWERe 1800 rpm Prime POWER 1800 rpm Standby Width overall mm 598 606 598 652 Length overall mm 861 1191 861 1225 Height overall mm 980 1027 980 1027 Weight kg 396 505 396 520 Engine oil quantity L 12 12 12 12 Engine coolant L 25 25 25 25 quantity kW hp kW hp 70 94 68 92 83 111 80 109 kW hp 72 98 90 121 80 109 kW hp 79 107 100 134 88 120 With Fan Approximat
95. 86 Standby Width overall 652 652 Length overall 1364 1364 Height overall 1070 1070 Weight 651 651 Engine oil quantity L 20 20 Engine coolant quantity L 28 28 With Fan Approximate DPSG CD03523 55 19 08JUL09 3 3 072209 65 3 PN 111 181 263 Specifications General engine pack specifications Stage ll Emission Certified Engines ITEM UNIT OF 3029HFS70 3029HFU70 3029TFS70 3029TFU70 MEASURE Number of Cylinders 3 3 3 3 Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 110 110 110 Displacement 2 9 2 9 2 9 2 9 Compression Ratio 2 17 2 1 17 2 1 17 2 1 POWER 1500 kW hp 37 50 37 50 28 37 28 37 rom Prime POWER 1500 kW hp 41 56 41 56 31 41 31 41 rpm Standby POWER 1800 kW hp rpm Prime POWER 21800 kW hp rpm Standby Width overall mm 582 582 582 582 Length overall mm 888 888 888 888 Height overall mm 974 974 974 974 Weight dry kg 350 350 350 350 Engine oil quantity L 8 8 8 8 Engine coolant 14 5 14 5 14 5 14 5 quantity With Fan Approximate ITEM UNIT OF 4045HFS72 4045HFS73 4045HFU72 4045HFU79 MEASURE Number of Cylinders 4 4 4 4 Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 110 127 127 Displacement L 4 5 4 5 4 5 4 5 Compression Ratio 17 0 1 19 0 1 17 0 1 19 0 1 POWER 1500 kW hp 75 100 94 126 75 100 94 126 rpm Prime POWER 1500 kW hp 83 111 103 138 83 1
96. 88 DX ALERT 19 29SEP98 1 1 DANGER A WARNING TS187 19 30SEP88 A CAUTION DX SIGNAL 19 03MAR93 1 1 TS1343 UN 18MAR92 DX WW HPCR1 19 07JANO3 1 1 072209 PN 26 Engine lifting procedure The only recommended method for lifting the engine is with JDG23 Engine Lifting Sling A and safety approved lifting straps B that come with engine Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended Lift engine with longitudinal loading on lifting sling and lifting straps only Angular loading greatly reduces lifting capacity of sling and straps RG7784 UN 11NOV97 NOTE If engine does not have lifting straps universal straps can be procured through service parts under larger components such as power take off part numbers JD 244 1 and JD 244 2 transmission generator air compressor etc are attached to engine the lifting straps If not equipped install lifting straps and torque to 200 provided with engine or through parts channel N m 145 lb ft are not intended for this purpose Technician is responsible for providing adequate lifting Attach JDG23 Engine Lifting Sling A to engine lifting devices under these situations See machine straps B and overhead hoist manuals for additional information on IMPORTANT Lifting straps are designed to lift the emoving engine tremmsenine edge and accessories such as r
97. 9 15 7 PN 44 114 263 Operating the Engine IMPORTANT Ignoring active trouble codes can result in severe engine damage 1 of x WARNING SPN 94 FMI 18 FAULT 4 To acknowledge and hide the code and return to the FUEL DELIVERY PRESSURE single or four parameter display press the Enter Key CORRECTIVE ACTION CHECK FUEL FILTER LIMES lt NEXT gt CoG Hide Trouble Codes RG13242 UN 30SEP03 OURGP11 00000AD 19 03SEP03 4 7 The display will return to the single or four parameter display but the display will contain the warning icon a TOOU Pressing the Enter key will redisplay the hidden 1800 RPM trouble code STG 1 14 2 RG13176 UN 26SEP03 Active Trouble Code Icon OURGP11 00000AD 19 03SEP03 5 7 IMPORTANT Ignoring active trouble codes can result in severe engine damage 1 of x WARNING SPN 94 FMI 18 FAULT 6 Pressing the Enter key once again will hide the FUEL DELIVERY PRESSURE trouble code and return the screen to the single or four CORRECTIVE ACTION parameter display CHECK FUEL FILTER AND LINES RG13242 UN 30SEP03 Enter Key OURGP11 00000AD 19 03SEP03 6 7 7 The single or four parameter screen will display the warning icon until the trouble code condition is 1000 RPM ENG corrected 1800 RPM SE TEMP RG13243 UN 010CT03 Active Trouble Code Condition OURGP11 00000AD 19 03SEP03 7 7
98. CD03523 8 19 22JAN07 1 1 1000 Hours of operation Engine oil drain Air intake system check Engine oil filter replace n Fuel filter replace Check belt and tensioning system Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 9 19 22JAN07 1 1 0 2 2 072209 PN 11 81 263 Maintenance Records 1500 Hours of operation Engine oil drain Engine oil filter replace n Fuel filter replace manual tensioner Valve clearance adjust 300 Series Belt check tension and wear 300 Series and POWERTech with Number of hours Job done by Observation Dealer or distributor stamp 2000 Hours of operation DPSG CD03523 10 19 22JAN07 1 1 Engine oil drain Engine oil filter replace n Fuel filter replace Check belt and tensioning system Crankcase vent tube clean Cooling system drain and flush if COOL GARD is not used Valve clearance adjust POWERTech Air intake system check Vibration damper check Number of hours Job done by Observation Dealer or distributor stamp DPSG CD03523 59 19 22JAN07 1 1 02 3 82 263 072209 PN 12 Maintenance Records 2500 Hours of operation Engine oil drain Cooling system drain and flush if COOL GARD is used Engine oil filter replace n
99. E DPSG CD03523 51 19 22JAN07 1 1 with appropriate coolant See DIESEL ENGINE COOLANT Fill the fuel tank Remove fan alternator belt if desired Remove and clean batteries Store them in a cool dry place and keep them fully charged Clean the exterior of the engine with salt free water and touchup any scratched or chipped painted surfaces with a good quality paint Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint Seal all openings on engine with plastic bags and tape Store the engine in a dry protected place If engine must be stored outside cover it with a waterproof canvas or other suitable protective material and use a strong waterproof tape DPSG CD03523 53 19 22JAN07 1 1 IMPORTANT DO NOT operate starter more than 30 seconds at a time Wait at least 2 minutes for starter to cool before trying again 6 Crank engine for 20 seconds with starter do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated Start engine and run at no load for several minutes Warm up carefully and check all gauges before placing engine under load On the first day of operation after storage check overall engine for leaks and check all gauges for correct operation DPSG CD03523 54 19 22JAN07 1 1 072209 PN 108 Specifications General engine pack
100. E REACH OF CHILDREN Warning The anti rust product is toxic and dangerous if absorbed Avoid all contact with the skin or eyes Read the instructions on the packaging v v v Never expose the equipment to splashes rainfall and not place it on wet ground Always use the recommended fuels Using low quality fuels risks damaging the engine and altering performance The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 1 3 4 Risk of fire burns and explosion The engine should not be operated in environments containing explosive products As not all of the electrical and mechanical components are shielded there is a risk of sparks forming lt lt Make sure not to create sparks or flames and not to smoke near the batteries as the electrolyte gases are highly flammable especially if the battery is charging Their acid also poses a risk to the skin and in particular to the eyes Never cover the generating set pump unit or lighting tower with any material during operation or just after shutdown wait for the engine to cool Do not touch hot parts such as the exhaust pipe or put combustible materials on it Keep all flammable or explosive materials e g petrol oil cloth etc out of the way w
101. ETUP AUTOMATIC SCAN ON A o 2 2 N N O X Automatic Scan On OURGP11 00000B1 19 03SEP03 15 18 17 Press the Enter key again to toggle the Automatic Scan function off USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF Automatic Scan Off RG13223 UN 26SEP03 Continued on next page OURGP11 00000B1 19 03SEP03 16 18 15 20 PN 57 127 263 Operating the Engine 18 Once the Use Defaults Custom Setup and Automatic Scan functions have been set press the USE DEFAULTS Menu key to return to the main menu CUSTOM SETUP AUTOMATIC SCAN ON RG13224 UN 26SEP03 Menu Key OURGP11 00000B1 19 O3SEP03 17 18 19 Press the Menu key to exit the main menu and return to the engine parameter display S84 1000 RPM 1800 RPM 14 2 27 PSI BAT WOLT TAL PRES 13159 UN 26SEP03 Exit Main Menu OURGP11 00000B1 19 03SEP03 18 18 Setup 4 Up Display ENG 1 Turn the key switch to the ON position From single or four engine parameter display press the 1800 RPM 14 2 57 PSI Menu key BAT VOLT CIL PRES RG13159 UN 26SEP03 Menu Key OURGP11 00000B2 19 03SEP03 1 14 The main menu will be displayed Use the Arrow keys to scroll through the menu until Setup 4 Up Display is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT
102. Fuel filter replace Belt check tension and wear 300 Series and POWERTech with manual tensioner Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 60 19 22JAN07 1 1 3000 Hours of operation Engine oil drain Air intake system check Engine oil filter replace Fuel filter replace Check belt and tensioning system Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 61 19 22JAN07 1 1 072209 02 4 PN 13 83 263 Maintenance Records 3500 Hours of operation Engine oil drain Engine oil filter replace n Fuel filter replace manual tensioner Valve clearance adjust 300 Series Belt check tension and wear 300 Series and POWERTech with Number of hours Job done by Observation Dealer or distributor stamp 4000 Hours of operation DPSG CD03523 62 19 22JAN07 1 1 Engine oil drain Engine oil filter replace n Fuel filter replace Check belt and tensioning system Crankcase vent tube clean Cooling system drain and flush if COOL GARD is not used Valve clearance adjust POWERTech Air intake system check Vibration damper check Number of hours Job done by Observation Dealer or distribu
103. IESEL ENGINE OIL Section for determining correct engine oil To determine the correct oil fill quantity for your engine see the Specifications Section NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase to full mark or within crosshatch on dipstick whichever is present DO NOT overfill 7 Start engine and run to check for possible leaks FD000047 FD000047 UN 13MAR96 8 Stop engine and check oil level after 10 minutes If Oil dipstick necessary top up DPSG CD03523 29 19 01JUL09 3 3 3 0 3 072209 PN 73 143 263 Maintenance 500 hours Replacing fuel filter element s A Retaining ring B Final fuel filter element C Drain plug D Bleed plug Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand If any fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result Doctors unfamiliar with this type of injury may call the Deere amp Company Medical Department in Moline Illinois or other knowledgeable medical source NOTE Engines with mechanical fuel system have a single fuel filter whi
104. IGHT RG13168 UN O020OCT03 Select Stored Codes Continued on next page OURGP11 00000AC 19 03SEP03 2 6 072209 15 5 PN 42 112 263 Operating the Engine 3 Once the Stored Codes menu item has been highlighted press the Enter key to view the stored codes GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT IF Enter Key RG13169 UN 020CT03 OURGP11 00000AC 19 03SEP03 3 6 4 Ifthe word Next appears above the Arrow keys there are more stored codes that may be viewed Use the Arrow key to scroll to the next stored code SPN 94 FMI 18 FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER LINES NEXT gt HIDE RG13245 UN 020CT03 Use Arrow Keys To Scroll OURGP11 00000AC 19 03SEP03 4 6 5 Press the Menu key to return to the main menu 1ofx SPN 110 FMI 16 FAULT ENGINE COOLANT HIGH CORRECTIVE ACTION CHECK COOLING SYSTEM REDUCE POWER NEXT gt HIDE Return To Main Menu RG13246 UN 020CT03 Continued on next page OURGP11 00000AC 19 03SEP03 5 6 072209 15 6 PN 43 113 263 Operating the Engine 6 Press the Menu key to exit the main menu and return to the engine parameter display 1000 RPM 14 2 97 PSI WOLT TAL PRES RG13159 UN 26SEP03 Exit Main Menu OURGP11 00000AC 19 03SEP03 6 6 Accessing A
105. IRUPTOR CIRCUIT BREAKER Q05 X05 16A 230V SOCKET 16 263 M128 M129 50Hz EU 5 6 7 8 9 DIFFERENTIAL SWITCH Q10 4x40A 30 mA X03 16A 400V SOCKET 16A CIRCUIT BREAKER Q09 X09 16A 230V SOCKET 4x63A CIRCUIT BREAKER 001 4x16A CIRCUIT BREAKER 003 X01 63A 400V SOCKET 16A DIRUPTOR CIRCUIT BREAKER 005 X05 16A 230V SOCKET 17 263 M128 M129 50Hz UK DIFFERENTIAL SWITCH Q03 4x40A 30 mA X01 125A 400 3P N T SOCKET 1X32A DIRUPTOR CIRCUIT BREAKER Q04 Q05 Q06 4x63A CIRCUIT BREAKER Q02 X02 63A 400V SOCKET X04 X05 X06 32A 220V SOCKET 18 263 2 2 Technical specifications Range Generating set type RENTAL POWER R110 Weights and Dimensions Dimensions with standard tank Dimensions x w x h 2554mm x 1150mm x 1680mm Weight 1765kg dry weight 1955kg in operating configuration Sound pressure level LpA at 1 m 77 dB A Measurement uncertainty 0 21 Dimensions x w x h 2602mm x 1150mm x 1900mm Weight 2049kg dry weight 2554kg in operating configuration Sound pressure level LpA at 1 m 77 dB A Measurement uncertainty 0 21
106. NET 12 4 6 Dismantling reassembly RR m 14 4 7 Installation and maintenance of 16 4 8 0 17 SPARE PARTS bum bd EUM HM 4n md aeiia 18 5 1 First maintenance qur o IS EIL deas 18 5 2 Technical support service inn asd 18 5 9 ETT T E 18 5 4 Exploded views parts list and tightening 1 19 EC declaration of incorporation 22 LEROY SOMER 3 197 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 1 RECEIPT 1 1 Standards and safety measures Our alternators comply with most international standards See the EC Declaration of Incorporation on the last page 1 2 Inspection On receipt of your alternator check that it has not suffered any damage in transit If there are obvious signs of knocks contact the transporter you may be able to claim on their insurance and after a visual check turn the machine by hand to detect any malfunction 1 3 Identification The alternator is identified by means of a nameplate fixed on the machine see drawing Make sure that the nameplate on the machine conforms to your order The machine name is defined according to various criteria for exa
107. NG Tension Voltage o J e MU Connex 2 2 zi Continue kVA N Continuous kW 40C Secours kVA 59 kW 27C Tension maxi maximum voltage 6 166631 C Conforme 1 60034 1 According to I E C 60034 1 US LEROY SOMER 198 263 15 43 2 44 2 4 POLES ALTERNATORS 2 TECHNICAL CHARACTERISTICS 1 1 Electrical characteristics The LSA 43 2 44 2 alternator is a machine without sliprings or revolving armature brushes wound as 2 3 pitch 12 wire with class insulation and a field excitation system available in either SHUNT AREP or PMG version see diagrams and AVR manuals 2 1 1 Electrical options Stator temperature detection sensors Space heater Interference suppression conforms to standard EN 55011 group 1 class B Europe SHUNT SYSTEM com EXCITER Varistor Amature AREP SYSTEM s EXCITER Varistor Armature Aux windings MAIN FIELD PMG SYSTEM EXCITER Armature 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
108. OOLANT TEMPERATURE Deselect Parameters RG13219 UN 26SEP03 OURGP11 00000B1 19 03SEP03 11 18 12 Use the Arrow keys to scroll and highlight the desired fencing SPEED parameter that has not been selected for display PERCENT LOAD AT CURRENT RPM 2 parameter without a number to right of it ENGINE OIL PRESSURE 4 Note tite numbers ENGINE COOLANT TEMP now indicate the new order of display for rrr the parameters Select Desired Parameters A Lu o 1 2 2 as LO O x OURGP11 00000B1 19 03SEP03 12 18 13 Press the Enter key to select the parameter for inclusion in the Single Engine Parameter Display ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 fo me 1 06 a p ENGINE COOLANT TEMP Menu key at any time to return to the Custom Setup menu Select Parameters For Display RG13220 UN 26SEP03 Continued on next page OURGP11 00000B1 19 O3SEP03 13 18 15 19 PN 56 126 263 Operating the Engine 15 Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected USE DEFAULTS set of parameters one at a time Use the Arrow keys CUSTOM SETUP to scroll to the Automatic Scan function AUTOMATIC SCAN OFF RG13221 UN 26SEP03 Automatic Scan Off OURGP11 00000B1 19 03SEP03 14 18 16 Press the Enter key to toggle the Automatic Scan function on USE DEFAULTS CUSTOM S
109. OeeeO FY C C 4 5 3 Checking 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 Exciter field 5 Rh 509 300W 12V battery Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation power of the machine see the nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 L2 L3 checking the excitation voltage and current at no load see the machine nameplate or ask for the factory test report When the output voltage is at its rated value and balanced within 196 for the rated excitation level the machine is in good working order The fault therefore comes from the AVR or its associated wiring ie sensing auxiliary windings ASSEMBLY B 6 Exciterfield 5 4
110. Operating the Engine Using Diagnostic Gauge to Access Engine Information Optional equipment Main Menu Engine Configuration Data Accessing Stored Trouble Codes Accessing Active Trouble Codes Engine Shutdown Codes Adjusting Backlighting Adjusting Selecting Units Of Measurement Setup T UD DISplay Setup 4 Up Display Break in period Starting the engine Cold weather operation Using a booster battery or charger Engine operation Standby power units Stopping the Changing Generator Frequency Maintenance Observe service intervals Use correct fuels lubricants and coolant Maintenance interval chart Maintenance Daily or every 10 hours Daily prestarting checks Maintenance 500 hours Changin
111. PERATION NOTE Do not operate the starter motor more than 20 seconds at a time DPSG CD03523 18 19 22JAN07 1 1 15 25 PN 62 132 263 Operating the Engine Cold weather operation Depending on equipment various cold weather starting aids are available to assist in starting the engine at temperature below 0 C 32 F Air intake heater A DO NOT use starting fluid on engines equipped with grid type air intake heater or glow plug s Ether starting fluid is highly flammable and may explode causing serious injury uhd riim TS1356 UN 18MAR92 NOTE On engines with electronically controlled fuel system DE10 HPCR the air intake heater operates automatically controlled by the ECU An engine preheater indicator light comes on when the key switch is turned ON In warm weather the light comes on briefly for a light check In cold weather the light remains ON during the automatic operation of the air intake heater or glow plug s Operating time depends on temperature Do not crank engine until light goes OFF Handle starting fluid with care 3029 and 4039 engines are optionally equipped with the single glow plug B screwed in cylinder head intake manifold Activate the glow plug preheater position for 30 seconds maximum then start the engine 4045 and 6068 engines except HPCR 4 valve head are optionally equipped with the grid type air heater A installed between cylinder h
112. R06 A Serial Number Label ecord Record High Pressure Fuel Pump Model Number Record the high pressure fuel pump model and serial number information found on the serial number plate A Model No Manufacturer s No Serial No RG13718 UN 11NOV04 A Serial Number Plate Record High Pressure Fuel Pump Serial Number CD03523 000018A 19 06 7 1 1 0 3 m 5 072209 PN 25 95 263 Safety Recognize Safety Information This is a safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices Understand Signal Words A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual Do Not Open High Pressure Fuel System High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform repairs See your John Deere dealer 05 1 96 263 T81389 UN 07DEC
113. RROR Any failure that is detected when the data received via the network is found substituted with the error indicator value i e FE16 see J1939 71 This type of failure is associated with received network data The component used to measure the real world signal is wired directly to the module sourcing the data to the network and not to the module receiving the data via the network The FMI is applicable to Region f and g of the signal range definition This type of fault may or may be directly associated with the value of general broadcast information FMIz20 30 RESERVED FOR SAE ASSIGNMENT FMIZ31 CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in cases when the reported SPN name spells out the component and a non standard failure mode This type of fault may or may be directly associated with the value of general broadcast information This FMI will mean not available when the associated SPN is also not available as when the remainder of the packet is filled with binary ones after all data has been transmitted 263 263
114. 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 0000000 Hook the handbrake safety wire onto the hook on the tow vehicle CORRECT CORRECT Tow vehicle Tow vehicle Trailer Trailer INCORRECT INCORRECT Tow vehicle Tow vehicle Trailer Trailer Figure 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 gt gt 29 263 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 road trailer
115. T VOLT AL PRES RG13159 UN 26SEP03 Menu Key Continued on next page OURGP11 00000B0 19 035 1 7 15 13 PN 50 120 263 Operating the Engine 2 The main menu will be displayed Use the Arrow GO TO 1 UP DISPLAY keys to scroll through the menu until Select Units is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 9420 Select Units RG13188 UN 020CT03 OURGP11 00000B0 19 03SEP03 2 7 3 Once the Select Units menu item has been GO TO 1 UP DISPLAY highlighted press the Enter key to access the Select STORED CODES Units function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT o Press Enter Key RG13189 UN 020CT03 OURGP11 00000B0 19 03SEP03 3 7 4 There are three choices for units of measurement English Metric kPa or Metric Bar ENGLISH English is for Imperial units with pressures displayed in PSI and temperatures in F Metric kPa and Metric bar are for IS units with pressures displayed in kPa and bar respectively and temperatures in C Use the Arrow keys to highlight the desired units of measurement RG13190 UN 26SEP03 Select Desired Units Continued on next page OURGP11 00000B0 19 03SEP03 4 7 15 14 PN 51 121 263 Operating the Engine 5 Press the Enter key to select the highlighted units ENGLISH METRIC METRIC BAR RG1319
116. Tor TristallatlOFi sees dao re olore lusso nium iu edad iei duoc Seded ta 31 4 6 Break transmission adjustment sien co amas Decora Ur eate hec DON e aa v Dv eter ua ieee 31 T Tm 33 4 8 34 4 9 Complete wheels technical infOrmation c ccccccseccceecccseeeeceeeecee cess eeeseeeeseeeeseacessaeeeseeeeseaeessaeeeecsaeessaeesseeeseeeseusesseeesseeess 34 5 Preparation before operating ele edu aa al a LM LIUM x LEM MAL MT 35 5 1 coe eee ae m eee E 35 512 Checks after starting the Generating Set bcc tdeo poe es ene aloe Ac united abu festus MAU ents 35 Mehl O MSC ou fee ativan obere oot uti terat dr 35 6 1 35 6 2 Generator set with NEXYS control panel etre io ote ntn ge ra 38 62 1 Control panel Dr esentallOPDiso 92 0 er mes ie d Prades tea ddd vos dd Dacus ples goad aimed simae dvds destin eee 38 6 2 1 1 to PICIOON aN Ssss E EE E bd dba cu ER 39 02 Mangal Star UN eer ea S 40 THe
117. User and maintenance manual for generating sets Translation of the original instructions R110 33501720001NE 3 1 IN r eee 3 T General recommenhdallorisss es asci 3 1 2 mesniflds uus eds uo an dis 4 1 3 Instructions and safety regulations 7 3 General AOV ICC MEET NT 7 1 3 2 Risks related to exhaust gases and fuels 8 Risksrelated to TOXIC Of OCICS met rc c M 9 13 4 RisKottie burns and koe trc a CO IER visas Race a dE Oc 9 1 3 5 Risks related to electrical DebWOEKS rhe oon E E eR Deae Eua Oed eene toa o cue eie ete eid 10 1 3 6 Dangers presented by electric currents first nnne nnne nnns nnne 10 zi emregiae dieit cp 10 1 4 11 2 MSSM CT COSCO IO Magis elas deal de 13 21 PVCS GIO UOM T T UU Tu 13 22 TSS INS MUN ON cR 19 2 5 Fuel ANG constlitidbles
118. ad 3 1 2 Coupling 3 1 2 1 Single bearing alternator Before coupling the machines check that they are compatible by undertaking a torsional analysis of the transmission checking the dimensions of the flywheel and its housing the flange coupling discs and offset WARNING When coupling the alternator to the prime mover do not use the fan to turn the alternator or rotor The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Make sure the alternator is securely bedded in position during coupling Check that there is lateral play on the crankshaft 3 1 2 2 Double bearing alternator Semi flexible coupling Careful alignment of the machines is recommended checking that the lack of concentricity and parallelism of both parts of the coupling do not exceed 0 1 mm This alternator has been balanced with a 1 2 key 3 1 3 Location The room where the alternator is placed must be ventilated to ensure that the ambient temperature cannot exceed the data on the nameplate 3 2 Checks 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 LEROY 6 SOMER 200 263 15 43 2 44 2 4 POLES ALTERNATORS There are 2 possible methods for restoring the above minimum values a Dry out the machi
119. adiator 3 Carefully move engine to desired location air filter and other small components If DPSG CD03523 95 19 22JAN07 1 1 Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your John Deere dealer There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator s manual TS201 UN 23AUG88 Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need assistance contact your John Deere dealer DX READ 19 16JUNO09 1 1 072209 05 2 PN 27 97 263 Safety Prevent Machine Runaway Avoid possible injury or death from machinery runaway Do not start engine by shorting across starter terminals Machine will start in gear if normal circuitry is bypassed NEVER start engine while standing on ground Start engine only from operator s seat with transmission in neutral or park TS177 UN 11JAN89 DX BYPAS1 19 295
120. ain and flush the cooling circuit every 2500 hours every 3 years In all other cases carry out this operation every 2000 hours every 2 years g Operation to be carried out by one of our agents Replace the injectors every 5000 hours and the thermostat every 10000 hours If in doubt about the operation of one of these components contact one of our agents 7 3 Alternator After 20 hours in operation check the tightness of all the mounting bolts the general condition of the machine and the various electrical connections of the installation The bearings fitted on the machine are greased for life to around the service life of the grease depending on use 20 000 hours or 3 years Regularly clean the inlet and outlet grid 61 263 8 Fit the battery so that it is properly ventilated Maintenance should only be carried out by qualified personnel If replacing the batteries use the same type of batteries Do not throw the old battery in the fire Only use insulated tools the operator should not be wearing a watch chain or any metal object Never use sulphuric acid or acid water to top up the electrolyte level Use an approved battery fluid Batteries release oxygen and hydrogen gas which are flammable Never bring flames or sparks near the battery risk of explosion Discharge any static electricity before handling the batteries by first touching an earthed metal surface Do not use the battery when the fluid l
121. ake sure rotating shields turn freely Wear close fitting clothing Stop the engine and be sure the PTO driveline is stopped before making adjustments EI performing any type service on the engine or PTO driven equipment TS1644 UN 22AUG95 CD PTO 19 22JANO07 1 1 072209 05 5 PN 30 100 263 Safety Practice Safe Maintenance Understand service procedure before doing work Keep area clean and dry Never lubricate service or adjust machine while it is moving Keep hands feet and clothing from power driven parts Disengage all power and operate controls to relieve pressure Lower equipment to the ground Stop the engine Remove the key Allow machine to cool Securely support any machine elements that must be raised for service work Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine O D lt 2 2 N o H DX SERV 19 17 99 1 1 Work In Ventilated Area Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes
122. aks 3 If engine does not start it will be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next 2 lt 1 2 1 5 5 2 2 2 2 8 cp30928 4 2 a Mechanical injection pump return line DE10 Fuel return line At Fuel Injection Pump c Securely tighten return line connector a Slightly loosen fuel return line connector C at fuel injection pump b Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return line connection Continued on next page DPSG CD03523 46 19 09FEBO07 2 3 072209 50 6 PN 93 163 263 Maintenance As required At Fuel Injection Nozzles a Using two open end wrenches loosen fuel line connection at injection nozzle b Crank engine over with starting motor but do not start engine until fuel free from bubbles flows out of loosened connection Retighten connection to 27 N m 20 Ib ft c Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing dealer or engine distributor RG7725 UN 08JAN97 TS1343 UN 18MAR92 RG12220 UN 24MAY02 B HPCR fuel system 2 or 4 valve head A High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect fuel lines between the high pressure fuel pump and nozzles Only bleed the fuel system at the
123. al Active Power Indication au i Alternator Frequency Indication N Order of appearance of screens based on the type of network with the genset started P3 if genset started P3 if genset P3 if genset started P3 if genset started P11 if genset started P11 if genset P11 if genset coupled P11 if genset coupled coupled The screen is changed using the scrolling and validation wheel When the wheel is turned clockwise the screens scroll upwards and backwards The screens scroll in a loop Example in a 3P N network after screen 7 then screen 1 and in reverse 50 263 6 3 1 6 Display of messages in zone 4 The graphic zone zone 4 is used to display messages relating to the generating set s operation These messages are as follows Initialisation of the TELYS Screen No Screen Data displayed Initialisation of the TELYS when switching on and or when loading a configuration SERIAL No 08030010000 Generating set serial number SOFTWARE 6 1 0 TELYS software version NOMINAL VOLTAGE 400V Alternator nominal voltage FREQUENCY 50Hz Alternator nominal frequency NOMINAL KW 320kW Nominal active power EARTH SYSTEM TNS Neutral speed Bar graph indicating the screen display time Generating set stopped MANUAL OPERATION Press START Operation mode genset in MAN mode ready to start to start Date and time depending on settings 24 08 2005 AUTOMATIC OPERATION IMPORTANT Operation mode genset in AUTO mod
124. ance 4 Reinstall rocker arm cover and crankcase vent tube j 3 Cylinder Engine NOTE Firing order is 1 2 3 a Lock No 1 piston at TDC compression stroke D b Adjust valve clearance on No 1 and 2 exhaust valves and No 1 and 3 intake valves c Rotate flywheel 360 Lock No 1 piston at S exhaust stroke E 1 d Adjust valve clearance on No 3 exhaust valve and 1 No 2 intake valve E 4 Cylinder Engine NOTE Firing order is 1 3 4 2 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves c Rotate flywheel 360 Lock No 4 piston at compression stroke C d Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves A Front of engine D No 1 Piston at TDC B Exhaust valve compression stroke C lIntake valve E No 1 Piston at TDC exhaust A stroke 5 1 A Front of engine E Exhaust valve 1 B No 1 Piston at TDC I Intake valve d compression stroke C No 4 Piston at compression stroke s if 1 DPSG CD03523 35 19 31JAN07 2 2 072209 35 4 PN 80 150 263 Maintenance 1000 hours 1 year Pressure testing cooling system Test radiador cap CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engines Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop
125. and completely safe working conditions The ground must be able to withstand the load of the generating set pump unit or lighting column and its lifting machinery without stress otherwise put down beams of sufficient strength in a stable configuration Position the generating set pump unit or lighting column as close as possible to its place of use or transport in a clear space with free access v Never perform work on a generating set pump unit or lighting tower just hanging from a lifting device 10 263 1 4 Identifying sets Generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documentation contained in the appendices of this manual 12 10 2 7 3 14 16 GROWPE ELHCTROGENE GENERATING SET PRESSION ACOUSTIQUE SOUND PRESSURE PLAQUE CONSTRUCTEUR MANUFACTURER PLATE im 7m 415m T T Type m 7 749 6S 61 Execution a m 67 Version Masse Kg mu io wA 914 18 PUISSANCE ACOUSTIQUE SOUND POWER EC 2000 14 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
126. armed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration Change engine oil and replace filter Used oil will not give adequate protection See CHANGING ENGINE OIL AND FILTER Service air cleaner See CLEAN OR REPLACE AIR FILTER Draining and flushing of cooling system is not necessary if engine is to be stored only for several months However for extended storage periods of a year or longer it is recommended that the cooling system be drained flushed and refilled Refill Removing engine from long term storage Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with 1 Remove all protective coverings from engine Unseal all openings in engine and remove covering from electrical systems Remove the batteries from storage Install batteries fully charged and connect the terminals Install fan alternator belt if removed Check for filled fuel tank Perform all appropriate prestarting checks See DAILY PRESTARTING CHECKS 60 1 178 263 John Deere engines expected to be stored more than six 6 months long term storage preparation MUST BE taken See PREPARING ENGINE FOR LONG TERM STORAG
127. assis 25 263 Figure 3 4 Offset fluid retention container integrated into the chassis and tank Generating sets fitted with the offset tank option DW above also have a high level indicator in the retention container In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers either via the drain port or by using the drain pump for containers fitted with this pump Note Never allow these fluids to drain onto the ground ensure they are collected in a designated container 3 3 Choice of location It should be determined on the basis of use There are no specific rules governing the choice of location other than proximity to the electric distribution panel and disturbances caused by the noise However fuel supply burnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered Incorrect exhaust and ventilation Ground too uneven or soft Reduced access Set incorrectly positioned Fuel filling impossible Opening cover doors impossible Figure 3 5 Examples of problems that may be encountered 26 263 N 3 4 Electricity a Connections general information As with low voltage electrical installations use and maintenance is go
128. at fast idle and therefore they do not have slow idle Specification Fast idle 50 Hz Generator set 1550 1580 rpm 60 Hz Generator set 1865 1890 rpm NOTE Fast idle is settled by the factory then the idle adjusting screw A is sealed to prevent from tampering Fast idle adjustment can only be done by an authorized fuel system agent CD30763 UN 24SEP99 A Fast idle adjusting screw DPSG CD03523 38 19 31JAN07 1 1 Adjust speed droop governor Mechanical fuel system 1 Warm engine to normal operating temperature Run engine at fast idle 2 3 Apply full load 4 If specified power cannot be obtained turn screw B to adjust droop until the requested power is reached NOTE If surging exits upon removing the load turn screw B clockwise to eliminate CD30764 UN 24SEP99 B Speed droop governor adjusting screw DPSG CD03523 39 19 31JAN07 1 1 072209 40 3 PN 84 154 263 Maintenance 2000 hours 2 years Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY 1 Remove belts shown removed 2 Grasp vibration damper with both hands and attempt to turn it in both directions If rotation is felt damper is defective and should be replaced IMPORTANT The vibration damper assembly is not repairable and should be replaced every 4500 hours or 5 years whichever occurs first RG8018 UN 15JAN99 Check vibration damper radial runout by positioning a dial indicator so probe c
129. ata is changing at a rate that is outside the predefined limits that bound the rate of change for a properly functioning system outside Region c of the signal range definition Broadcast of data values is continued as normal FMl 11 ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known Broadcast of data value is substituted with the error indicator value 12 INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU used here to mean the packaged unit that includes some microprocessor and its associated components and circuits can be assumed that the communications subsystem is not the part that has failed and the manufacturer has determined that there is no serviceable component smaller than the ECU involved in the failure Broadcast of data value is substituted with the error indicator value if appropriate as there may or may not be any broadcast involved This error is to include all internal controller trouble codes that can not be caused by connections or systems external to the controller FMIZ13 OUT OF CALIBRATION A failure that can be identified to be the result of not being properly calibrated This may be the case for a subsystem which can identify that the calibration attempting to be used by the controller is out of date Or it may be the
130. aults and alarms Details List of faults which will cause the generating set to stop and generate a pictogram Associated pictogram Oil pressure fault Indicates that the oil pressure is incorrect Associated pictogram Engine temperature fault Indicates that engine temperature is too high Associated pictogram Non starting fault Indicates that there have been three consecutive unsuccessful starting attempts Associated pictogram Overspeed fault Indicates an excessive generating set running speed Associated pictogram 6 Low fuel level fault Indicates need to top up fuel 41 263 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 Differential fault 1 insulation fault 2 1 Differential fault optional with a differential fault causing the activation of the differential relay the generating set stops immediately also causing the main circuit breaker to be tripped 2 Insulation fault optional with an insulation fault ca
131. ay contain asbestos fibers are brake pads brake band and lining assemblies clutch plates and some gaskets The asbestos used in these components is usually found in a resin or sealed in some way Normal handling is not hazardous as long as airborne dust containing asbestos is not generated Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding material containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean asbestos If not available apply a mist of oil or water on the material containing asbestos Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with John Deere equipment include such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer Keep bystanders away from the area 05 8
132. below the low level marker Do not exceed the hatched area Important The oil level is correct if it is within the hatched area Check the oil level using the dipstick A oe Top up the oil as required Use an oil whose viscosity is suited to the seasonal conditions Pour the oil through the rocker cover filling port B 35 263 Checking the coolant level A Fluid may abruptly exit the cooling circuit and cause serious burns Only remove the filler cap once the engine and cap have cooled sufficiently to enable them to be handled with bare hands Firstly loosen the cap slightly by one notch to eliminate any pressure then remove it Remove the cap from the radiator E and check the coolant level The level should reach the lower section of the filler neck Fill the radiator with the appropriate coolant if the level is too low Check for leaks in the cooling circuit e Checking the air filter The maximum authorised vacuum in the air filter is 6 25 kPa 0 06 bar 1 0 psi 25 in water A clogged filter element limits the engine s air intake Important If the air filter is fitted with a dust control valve C press the tip of the valve to evacuate any accumulated dust particles Check the air filter clogging indicator D If the indicator is red clean the air filter 36 263 e Checking the fuel filters A The fuel is highly flammable and its vapours are combustible The f
133. ble filter wrench Oil new packing C and install new filter element Hand tighten element according to values printed on filter element If values are not provided tighten element approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element 4045 and 6068 engines a b C Remove and discard oil filter element A using a suitable filter wrench Apply clean engine oil to inner B and outer C seals and to filter threads Wipe both sealing surfaces of the header D E with a clean rag Ensure notches in dust seal F are properly installed in the slots in the housing Replace dust seal if damaged Install and tighten oil filter by hand until firmly against dust seal F DO NOT overtighten CD30760 UN 26AUG99 filter seals CD30759A UN 29JANO7 Filter and mounting header A Oil filter element D Sealing surface B lInner seal E Sealing surface C Outer seal F Dust seal 5 Close oil pan drain valve CD30926 UN 30JANO7 RG11617 UN 240CT01 RG11618 UN 240CT01 Continued on next page DPSG CD03523 29 19 01JUL09 2 3 30 2 142 263 072209 PN 72 Maintenance 500 hours CD30927 UN 01FEB07 7 A E x Oil filler on rocker arm cover 6 Fill engine crankcase with correct John Deere engine oil through opening on rocker arm cover C or on the side of the engine D See D
134. ble formation Never use petrol or other inflammable substances to clean the parts Use only approved cleaning solvents Do not use a high pressure cleaner for cleaning the engine and equipment The radiator hoses electrical components etc may be damaged Avoid accidental contact with parts at high temperatures exhaust manifold exhaust Before any maintenance operation on a lighting column light cut the electrical power supply and wait for the bulbs to cool down SCA lt Consumables Y Observe regulations in force concerning use of fuel before using your generating set pump unit or lighting tower Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit 7 263 ALAS lt lt Environment The operator must take the necessary measures to comply with the aesthetics of the site of use The whole site must be maintained in a good state of cleanliness The premises must be kept clean and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust which could ignite or cause an explosion The cleaning equipment must be suited to the risks posed by the products and dust The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements Facilities must be operated under the constant supervision of a qualified person who must regularly ch
135. brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed see REPLACING FAN AND ALTERNATOR BELTS A Swing arm stop B Fixed cast stop Continued on next page 35 2 148 263 RG4687 UN 20DEC88 DPSG CD03523 33 19 22JAN07 2 2 RG8098 UN 18NOV97 CENE E Earlier design tensioner RG13744 UN 11NOV04 Later design tensioner DPSG CD03523 34 19 30JAN07 1 2 072209 PN 78 Maintenance 1000 hours 1 year e Checking tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below Release tension on belt using a breaker bar and socket on tension arm Remove belt from pulleys Release tension on tension arm and remove breaker bar Put a mark A on swing arm of tensioner as shown Measure 21 mm 0 83 in from A and put a mark B on tensioner mounting base NOTE Earlier engines have a LEFT HAND thread roller cap screw while later engines have a 12 7 mm 1 2 in square hole in tensioner Install torque wrench on roller cap screw or in square hole so that it is aligned with center of roller and tensioner as shown Rotate the swing arm using a torque wrench until marks A and B are aligned Record torque wrench measurement and compare with specification below
136. c tools electronic dashboards satellite systems and other advanced devices that scan Parameter Groups containing the SPN FMI formats Because manufacturer defined codes are not desirable in terms of standardization the use of these codes should only occur when diagnostic information cannot be communicated as a specific component and failure mode Possible reasons for using a System Diagnostic Code include 1 Cost of specific component fault isolation is not justified or 2 New concepts in Total Vehicle Diagnostics are being developed or 3 New diagnostic strategies that are not component specific are being developed Due to the fact that SPNs 611 615 are manufacturer defined and are not component specific 0 13 and 15 31 have little meaning Therefore FMI 14 Special Instructions is usually used The goal is to refer the service personnel to the manufacturer s troubleshooting manual for more information on the particular diagnostic code This failure mode does not relate to the signal range definition as do many of the FMls This type of fault may or may be directly associated with the value of general broadcast information FMI 15 DATA VALID BUT ABOVE NORMAL OPERATING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined least severe level limits for that particular measure of th
137. 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 LEROY SOMER 15 209 263 LEROY SOMER LSA 43 2 44 2 4 POLES ALTERNATORS 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 WARNING Mounting is impossible with the regreasable bearings option with the LSA 44 2 4 8 Table of characteristics Table of average values Alternator 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 1096 weaker 4 8 1 3 phase LSA 43 2 4 P SHUNT excitation Resistances at 20 C LSA 43 2 Stator L N Rotor Armature 51 0 155 1 35 0 23 515 0 155 1 35 0 23 25 0 155 1 35 0 23 35
138. charger A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables Ah om Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems RG4678 UN 14DEC88 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the POSITIVE post of the booster battery 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery o ALWAYS complete the hookup by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the bat
139. coolant quantity With Fan Approximate 65 6 184 263 6068HFU74 6 8 17 0 1 166 223 188 252 184 247 207 277 191 256 201 269 960 1509 1381 764 32 35 4045 270 4 Diesel 106 5 127 4 5 17 0 1 6068HFU79 6 8 19 0 1 139 186 153 205 CD03523 0000194 19 08JUL09 3 3 6068HF475 6 Diesel 106 5 127 6 8 17 0 1 213 286 234 314 627 1161 1044 587 32 35 CD03523 00001D3 19 08JUL09 1 1 072209 PN 114 Specifications General engine pack specifications EPA Tier 3 Emission Certified Engines ITEM UNIT OF MEASURE 4045HFS80 4045HFS82 4045HFS83 Number of Cylinders 4 4 4 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 110 Displacement L 4 5 4 5 4 5 Compression Ratio 19 0 1 19 0 1 19 0 1 POWER 1500 rpm kW hp Prime POWER 1500 rpm kW hp Standby POWER 1800 rpm kW hp 67 90 85 114 107 143 Prime POWER 1800 rpm kW hp 74 99 94 126 118 158 Standby Width overall mm 600 765 765 Length overall mm 1230 1365 1365 Height overall mm 1010 1162 1162 Weight dry kg 505 505 505 Engine oil quantity L 12 16 16 Engine coolant quantity L 25 32 32 With Fan Approximate ITEM UNIT OF MEASURE 6068HFS82 6068HFS83 6068HFS89 Number of Cylinders 6 6 6 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 127 Displacement L 6 8 6 8 6 8 Compression Ratio 19 0 1 19 0 1 17 0 1 POWER 1500 rpm kW hp
140. cting the polarity for 2 to 3 seconds System short circuit Mis paralleling Possible consequences Broken or damaged coupling Broken or bent shaft extension Shifting and short circuit of revolving field winding Fan fractured or coming loose on shaft Irreparable damage to rotating diodes AVR surge suppressor 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 Check the connection of the voltage reference to the AVR does not reach the rated value when Faulty diodes the battery is removed Armature short circuit The alternator builds up but its Faulty AVR voltage disappears when the battery Field windings open circuit check winding is removed Revolving field coil open circuit check the resistance Check the drive speed Check the AVR connections AVR may be faulty Field windings short circuited Rotating diodes burnt out Revolving field coil short circuited Check the resistance Correct speed Increase the drive speed do not touch the AVR voltage pot P2 Speed too low before running at the correct speed Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Voltage oscillations Adjust the AVR stability potentiometer Check the speed possibility of cyclic irregularity Loose connections Faulty AVR
141. ctive Trouble Codes NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine Start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine is running RG13172 UN 26SEP03 For description of trouble codes see chart in Troubleshooting Section Normal Operation During normal operation the single or four parameter screen will be displayed OURGP11 00000AD 19 03SEP03 1 7 When the diagnostic gauge receives a trouble code from an engine control unit the single or four WARNING parameter screen will be replaced with the Warning SPN 94 FMI 18 message The SPN and FMI number will be displayed along with a description of the problem and the CORRECTIVE ACTION corrective action needed CHECK FUEL FILTER AND LINES NEXT gt HIDE IMPORTANT Ignoring active trouble codes can result in severe engine damage RG13240 UN 30SEP03 Active Trouble Codes Displayed OURGP11 00000AD 19 03SEP03 2 7 3 Ifthe word Next appears above the arrow keys there are more trouble codes that can be viewed by using Pens WARNING the arrow keys to scroll to the next trouble code SPN 94 FMI 18 FUEL DELIVERY PRESSURE CORRECTIVE ACTION CHECK FUEL FILTER LINES NEXT gt HIDE RG13241 UN 30SEP03 Use Arrow Keys To Scroll Continued on next page OURGP11 00000AD 19 03SEP03 3 7 07220
142. ctronic 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 aie with LAM without LAM ST3 onn 1 50 2 60Hz LAM 13 25 Excitation P5 3 ceiling open knee point 65 Hz Response normal ST2 time fast 4 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 175 x 115 mm 200 mm pis oe Ph 1 1 514 External potentiometer for adjusting the voltage P2 R731 3 ph A in 3 ph detection ST1 open LEROY SOMER 234 263 LEROY SOMER R438 A V R 1 2 excitation system alternator winding As a result
143. d droop governor Engine serial number plate 03 1 Mechanical fuel system 40 3 Fuel pump model number 03 5 Adjust valve clearance 4045 and 6068 POWER Tech 03 1 40 1 Record engine serial 03 2 Check engine speed Mechanical fuel Record fuel injection pump model number 03 4 doses eta 40 3 Specifications 40 4 Engine Pack 2500 hours 3 years EPA Tier 2 Emission Certified Engines 65 6 Drain and flush cooling system 45 1 EPA Tier 3 Emission Certified Engines 65 7 500 hours Non Emission Certified Engines 65 1 Changing engine oil and filter 30 1 Stage 1 Emission Certified Engines 65 4 CHECKING DONG a Cove ciere eas 30 5 Storage Replace fuel filter 30 4 jap 60 1 As required Lor DIMUS MUS 10 1 Additional service information 50 1 Storing JUbFICanis nota or soo 10 3 Clean or replace air filter one piece 50 3 Clean or replace air filter element 50 4 T Do not modify fuel system
144. d in parallel and 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 28 263 3 5 Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 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
145. de operation in AUTO mode Genset cooling in progress Countdown of the Engine Stop delay cooling OR Gradual Stop delay Water temperature OR Overload Gradual Stop delay OR No Load Test delay Date and time depending on settings Operation mode operation in AUTO mode Synchronisation of the genset with the grid or another genset Date and time depending on settings Operation mode operation in AUTO mode Transfer of power from the generating set to the grid Date and time depending on settings Operation mode operation in AUTO mode Transfer of power from the grid to the generating set Date and time depending on settings Generating set stoppage G 11 STOPPAGE Genset stoppage IN PROGRESS Date and time depending on settings 24 08 2005 Change of operation mode switch from MAN mode to AUTO mode when an automatic start demand is issued AUTOMATIC start demand Do you want to switch G 12 to AUTO mode Operation mode operation in MAN mode IMPORTANT AUTOMATIC start demand Immediate start OK Esc Generating set stop demand if a fault occurs or if STOP is pressed in AUTO mode MAN mode activated l Operation mode operation in AUTO mode genset Do you want to switch running ot to AUTOMATIC mode Warning message for switch to MAN mode if STOP is pressed or if a fault occurs OK Esc The 51 Hz offset must be applied to Operating phase genset operating stable voltage all of the
146. de the specifications Recalibration of the injectors required Recalibration of the injectors Injector outside the specifications required Short circuit high side to iC Short circuit high side to low side or low side to B CID Volvo Short circuit high or low side to ground Cylinder 5 circuit open Cylinder 5 circuit shorted Cylinder 5 balancing error mechanical failure Cylinder 5 unknown error mechanical failure Injector outside the specifications dips te el required Short circuit high side to side to Cylinder 6 balancing error mechanical failure failure Glow plug relay voltage high 5 Glowplugrelayvoltagelow _____ 06771 1391 3 J Startrelaystatus Ny BB Startretaycontrtshortcicutiow _ 5 SSS restau evotpowersupply 4 8 Volt DC supply open short to ground Cylinder 6 injector status Injector outside the specifications required Imm NEM 257 263 Io oe Regulation sensor of the injection control Secondaryspeedsensor Speed sensor John Deere intermittent Lundi signal Loss of signal sensor failure AZ 729 70 Inlet air heater signal Preheat miet eir heaters
147. dition ADVANTAGES Less frequent oil services this product has been put to the test during thousands of hours of use on worksites under varying conditions demonstrating its high quality v 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 0 883 Cinematic viscosity at 40 105 mm s cSt Cinematic viscosity at 100 mm s cSt Viscosity index Values given as examples only 5 SAE 15W 40 SAE 100 40 t GAE 0 40 1 1 1 4 2 p i 70 21 263 2 3 1 2 Specifications of coolants John Deere GENCOOL PC 26 C Mitsubishi GenPARTS GENCOOL PC 26 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 156 made from antifreeze and 48 inhibitors e It protects up to 26 C e Itis free from nitrates amines and phosphates e Itis a clear fluorescent orange liquid REFERENCES APPROVALS for the antifreeze HEAVY GOODS VEHICLE LIGHTER VEHICLES Approved by MTU
148. e ITEM UNIT OF MEASURE 6068HF120 115 6068HF120 183 6068HF 158 6068HF258 Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight Engine oil quantity Engine coolant quantity With Fan Approximate kW hp kW hp kW hp kW hp 6 Diesel 106 5 127 6 8 17 0 1 140 188 155 208 623 1141 1009 569 20 32 6 Diesel 106 5 127 6 8 17 0 1 166 223 183 245 623 1141 1009 569 20 32 6 Diesel 106 5 127 6 8 17 0 1 134 182 148 201 164 223 187 254 798 1500 1136 705 20 32 6 Diesel 106 5 127 6 8 17 0 1 160 218 177 241 179 243 200 272 798 1500 1204 764 32 32 ITEM UNIT OF MEASURE 6068TF158 6068TF220 6068TF258 Number of Cylinders 6 6 6 Continued on next page DPSG CD03523 55 19 08JUL09 2 3 072209 65 2 PN 110 180 263 Specifications ITEM UNIT OF MEASURE 6068TF158 6068TF220 6068TF258 Fuel Diesel Diesel Diesel Bore 106 5 106 5 106 5 Stroke 127 127 127 Displacement 6 8 6 8 6 8 Compression Ratio 17 0 1 17 0 1 17 0 1 POWER 1500 rpm 92 125 109 146 105 143 Prime POWER 1500 rpm 101 137 121 162 116 158 Standby POWER 1800 rpm 108 147 124 169 Prime POWER 21800 rpm 119 162 137 1
149. e SS 12 36 V From 50 recharge 12 18 V Risk of sulphation Unusble _____ 63 263 EN 8 4 Load preconization Y 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 Example of charge 12V 60 Ah battery 7 charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30 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 current 6A approximately 6 hours charging required Recharging is complete when the battery voltage and 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 chargi
150. e 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 b Max excitation 50Hz 60Hz Field 5 ohms R 438 rs STA 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 or adaptthe Iscto the actual operating power derated machine which is safer for the alternator and the installation Disconnect power supply wires X1 X2 and 21 22 the voltage reference 0 110V 220V 380V on the alternator Connect the mains power supply using a transformer 200 240V indicated X1 X2 48V Install a 10A D C ammeter in series with the exciter field Turn P5 fully anti clockwise and activate the power supply If there is no output current from the AVR turn potentiometer P2 voltage clockwise until the ammeter indicates a stable current Switch the power supply off then on again turn P5 clockwise until the required max current is
151. e oil and filter Replace fuel filter element s Check belt tension and automatic tensioner Check and adjust valve clearance Clean crankcase vent tube Check air intake hoses connections and system Pressure test cooling system Check vibration damper 6 cyl Check engine speed and speed drop governor Drain and flush cooling system Drain water and sediment from fuel filter Clean filter element see note a Test thermostat and injection nozzles see your dealer Test glow plugs HPCR 4 valve head Clean air filter element when restriction indicator is red Replace filter element after 6 cleanings or once a year Change oil and filter after the first 100 hours of operation then every 500 hours maximum thereafter see DIESEL ENGINE OIL information Change oil and filter at least once a year Check belt tension every 500 hours on 3029 and 4039 engines and on 4045 and 6068 engines with manual tensioner Check automatic belt tensioner every 1000 hours 1 year on 4045 and 6068 engines when equipped Have your authorized servicing dealer or engine distributor adjust valve clearance as follows After the first 500 hours of operation then every 1000 hours thereafter on 3029 and 4039 engines Every 2000 hours on 4045 and 6068 engines Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours 5 years Drain and flush cooling sy
152. e ready to IMMEDIATE START UP LM POSSIBLE Date and time depending on settings 24 08 2005 13 12 51 263 IMPORTANT Operation mode genset in AUTO mode with AUTOMATIC starting programmed start 19min30 Countdown of micro disconnection delay OR EJP for France only Date and time depending on settings 24 08 2005 Generating set start up G6 STARTING Operating phase genset starting IN PROGRESS Date and time depending on settings 24 08 2005 AIR PREHEATING Operating phase air preheating prior to genset starting Countdown of the air preheating delay 10sec Date and time depending on settings G7 24 08 2005 Generating set started AVAILABLE POWER G8 Operating phase genset operating stable voltage 75 and frequency TC Available power screen Date and time depending on settings 24 08 2005 52 263 AUTOMATIC STOP IN PROGRESS LOAD SUPPRESSION 1min30 24 08 2005 13 12 AUTOMATIC STOP IN PROGRESS COOLING 1min30 24 08 2005 COUPLING IN PROGRESS 24 08 2005 POWER TRANSFER Grid l r 24 08 2005 Generating set POWER TRANSFER Grid eta M 24 08 2005 Generating set 53 263 Operation mode operation in AUTO mode Power supply device opens motorised circuit breaker or changeover switch controlled by the TELYS Countdown of the Mains Return delay OR Test on load delay Date and time depending on settings Operation mo
153. e real world condition Region i of the signal range definition Broadcast of data values is continued as normal FMIZ16 DATA VALID BUT ABOVE NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region k of the signal range definition Broadcast of data values is continued as normal FMl 17 DATA VALID BUT BELOW NORMAL OPERATING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region h of the signal range definition Broadcast of data values is continued as normal FMIZ18 DATA VALID BUT BELOW NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region j of the signal range definition Broadcast of data values is continued as normal FMI 19 RECEIVED NETWORK DATA IN E
154. e shutdown message can result severe engine damage RG13179 UN 26SEP03 Flashing Shutdown Icon Continued on next page 11 00000 19 03SEP03 4 6 072209 15 9 PN 46 116 263 Operating the Engine 9 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four 10 SHUTDOWN parameter display SPN 100 FMI 1 ENGINE PRESSURE LOW CORRECTIVE ACTION CHECK CIL LEVEL lt NEXT gt RG13239 UN 29SEP03 Redisplay Trouble Code OURGP11 00000AE 19 03SEP03 5 6 6 The single or four parameter screen will display the shutdown icon until the trouble code condition is corrected IMPORTANT Ignoring the shutdown message can i result in severe engine damage RG13180 UN 26SEP03 Shutdown Icon OURGP11 00000AE 19 035 03 6 6 Adjusting Backlighting 989 ENG 1 Turn the key switch to the ON position Starting at 1800 RPM the single or four engine parameter display press the Menu key Temp RG13159 UN 26SEP03 Menu Key OURGP11 0000237 19 210CT03 1 6 2 The main menu will be displayed Use the Arrow AH T GO TO 1 0 DISPLAY keys to scroll through the menu until Adjust Backlight STORED CODES Is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13181 UN 020CT03 Select Adjust Backlight
155. e with or without a Voltage LAM U F only Underspeed and LAM ST5 disconnected n een cs 2 4 1 Voltage U f without LAM 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 without is restored Ra 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 V Drop N lt 46 Hz Time Load on the shaft kW Drop N 46 Hz LEROY SOMER T 237 263 LEROY SOMER R438 A V R 2 5 R438 A V R options Current transformer for parallel operation of 1A 5 1 Remote voltage adjustment potentiometer 470 0 5 W min adjustment range 5 range limited by internal voltage potentio meter P2 Remove 5 4 to connect the po ten tiometer A 1 potentiometer can also be used to extend the adjustment range For wiring upthe external potentiometer the earth wires must be isolated as well as the potentiometer terminals wires at the same voltage as the power 731 external module sensing of 3 phase voltage 200 to 500 V compatible with parallel operation Disconnect ST1 to connect the module s
156. ead and air intake pipe For mechanical fuel system activate the heating element preheater position for 30 seconds maximum then start the engine For electronically controlled engines DE10 HPCR 2 valve head turn key switch ON but DO NOT crank engine until engine preheater indicator light turns OFF HPCR 4 valve head engines are equipped with glow plugs one per cylinder C Turn key switch ON but DO NOT crank engine until preheater indicator light turns OFF CD30750 UN O3SEP99 A Grid Type heater 4045 and C Multiple Glow Plugs HPCR S 6068 non HPCR 4 valve 4 valve head engines head engines 030925 B Single Glow Plug 3029 and 4039 engines lt Glow Plugs HPCR 4 valve head engine CD30925 UN 23JAN07 Continued on next page DPSG CD03523 19 19 06FEBO7 1 3 15 26 PN 63 133 263 Operating the Engine Coolant heater Connect plug of coolant heater A to a proper power source 110 or 220 V At an ambient temperature of 15 C 5 F the heating process takes approximatively 2 hours Extend heating period if ambient temperature is lower LX1017768 UN 240CT97 LX1017768 Fuel preheater Fuel preheater A switches ON and OFF automatically in relation with the ambient temperature OWN DEERE AD ML ru TER j LX1017708 0 090 97 DPSG CD03523 19 19 06FEB07 3 3 15 27 PN 64 134 263 Operating the Engine Using a booster battery or
157. eck that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply Apart from the combustion devices it is prohibited to use fire in any form This restriction must be clearly displayed Spreading of waste water sludge and waste is prohibited The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the combustion device manufacturer The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber Burning of waste in the open air is prohibited Always protect your hands when checking for leaks Pressurised liquids may penetrate body tissue and cause serious damage Risk of blood contamination Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil Except by special agreement once closed the gas supply main unit must only be re opened by the gas distributor However the user may access it under certain conditions Check these for each site 1 3 2 Risks related to exhaust gases and fuels The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high Always use generating sets pump units or lighting towers in a well ventilated place where gases cannot accumulate In case of indoor use Be sure to evacuate exhaust gases outdoors Provide appropriate ventilation so
158. ed on the diagnostic gauge indicate the engine is running RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu Key Menu key Continued on next page OURGP11 00000A9 19 035 03 1 5 072209 15 1 PN 38 108 263 Operating the Engine 2 The first seven items of the Main Menu will be displayed GO TO 1 UP DISPLAY RG13160 UN 020OCT03 Menu Display OURGP11 00000A9 19 03SEP03 2 5 3 Pressing the Arrow keys will scroll through the menu selections GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT H Q O A 1 2 co O Main Menu ltems OURGP11 00000A9 19 03SEP03 3 5 4 Pressing the right arrow key will scroll down to reveal the last items of Main Menu screen highlighting the next item down ADJUST CONTRAST UTILITIES RG13162 UN 26SEP03 Last Items On Main Menu Continued on next page OURGP11 00000 9 19 03SEP03 4 5 072209 15 2 PN 39 109 263 Operating the Engine 5 Use the arrow keys to scroll to the desired menu item GO TO 1 UP DISPLAY 98 or press the Menu Button to exit the main menu and STORED CODES 20 1000 RPM return to the engine parameter display SELECT UNITS 14 2 57 PSI ADJUST BACKLIGHT BAT VOLT On PRES RG13163 UN 020CT03 Use Arrow Bu
159. eeded engine CD03523 0000190 19 02FEBO07 1 1 Using blink code method for retrieving Diagnostic Trouble Codes DTC s NOTE The method below applies to applications having If there are no active DTCs the Fault Lamp will flash a fault lamp on instrument panel refer to the a code 88 tor d tation fi int tion Bene lath alan tolum Following the active codes the Fault Lamp will flash de 33 This indicates start of blinking stored The Electronic Control Unit ECU has the ability to display ae DTC mna blink f the fault codes If there any stored DTCs the Fault Lamp E M Md will flash its 2 digit number If there is more than one NOTE The ECU blinks the codes in 2 digit codes stored DTC the ECU will flash each code in numerical only See LISTING OF DIAGNOSTIC TROUBLE order If there are no stored DTCs the Fault Lamp CODES DTCS later in this Group will flash a code 88 1 Press down Override Shutdown Switch while turning 2 Once complete this sequence will repeat the ignition Switch 6 When complete turn ignition OFF times long pause This example is code 32 flash three times short pause flash two times long The ECU begins the flashing sequence by flashing pause flash one time short pause flash eight a code 32 this indicates the start of blinking active times long pause flash three times short pause flash codes If there are any active DTCs the ECU will flash
160. ehind the fuel filter for 4045 and 6068 engines and near the fuel supply pump CD indicates the engine was built in Saran France on 3029 and 4039 engines DPSG CD03523 12 19 22JAN07 1 1 0 3 1 072209 PN 21 91 263 Serial Numbers Record engine serial number Record all of the numbers and letters found on your engine serial number plate in the spaces provided below JOHN DEERE This information is very important for repair parts or ENGINE SERIAL NUMBER d warranty information 9 0403901 23456 Engine Serial Number 2 40 39D FO 08 Abs 2 D P S G SARAN MADE IN FRANCE CD30705B UN 24AUG99 Coefficient of Absorption Value D 3029 and 4039 engine plate JOHN DEERE Engine Serial Number CD60686G123456 Lesen DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE CD30747A UN 22JAN07 4045 and 6068 engine plate DPSG CD03523 13 19 22JAN07 1 1 0 3 2 072209 PN 22 92 263 Serial Numbers Engine option codes JOHN DEERE Order 2B0000000 NUMBER CD6068H123456 6068HF158 6 8 L 171ECD 1100 1200 1300 1400 1500 1600 1700 1800 1900 2100 2300 2400 2500 2700 2800 2900 3000 3100 3500 4000 4300 5200 5500 5600 5700 6000 6200 6400 6500 6600 7500 7600 8600 8700 8800 000000 OPTION CODES CD30748A UN 26AUG99 Engine option code label In addition to the serial number plate OEM engines have an engine option code label affixed to the roc
161. engine documentation 3 263 1 2 Pictograms and their meanings The aim of the pictograms is as follows To draw the attention of the operator or maintenance technician to the potential dangers To explain how to act in interest of personal safety and to avoid damaging the equipment The safety pictograms present on the equipment are explained below Important A Je Y Important Electrical risk 74 risk of explosion Warning danger Important rotating or moving parts Important pressurised fluids Important toxic materials Important 4 Important high temperature corrosive product Figure 1 1 Warning pictograms Entry prohibited to Jet washing prohibited unauthorised persons Figure 1 2 Pictograms indicating prohibited activities 4 263 Reading the Wearing _ suitable j Wearing suitable manual for the i E protective goggles protective clothing equipment 15 and ear defenders is compulsory compulsory is compulsory Lifting Forklift required for Battery charge required lifting must be checked Periodic maintenance compulsory Figure 1 3 Pictograms indicating compulsory operations IN OUT Battery isolating fuel switch connections Diesel fuel Drain the fuel Inspection flap Mains supply connection prohibited before filling with water Fill the coolant Drain the coolant Fill the oil Drain the oil
162. epending on Emission Regulation requirements the oil recommendations are different Refer to the chart to identify the proper oil to be used Non Emission Certified Engines and Stage ll or EPA Tier 2 Emission Certified Engines EPA Tier 3 Emission Certified Engines John Deere PLUS 50 Preferred John Deere PLUS 50 Preferred ACEA E7 ACEA E6 5 ACEA E4 7 ACEA E6 Multi viscosity diesel engine oils are preferred If diesel fuel with sulfur content greater than 0 5 is used or if oil does not meet the classification above reduce the service interval by 5096 DO NOT use diesel fuel with sulfur content greater than 1 PLUS 50 is a trademark of Deere amp Company 10 2 After the break in period use John Deere PLUS 50 or other diesel engine oil as recommended in this manual IMPORTANT Do not use PLUS 50 oil or engine oils meeting any of the following during the first 100 hours of operation of a new or rebuilt engine API CJ 4 ACEA E7 API CI 4 PLUS ACEA E6 API CI 4 ACEA E5 API CH 4 ACEA E4 API CG 4 ACEA E3 API CF 4 API CF 2 API CF These oils will not allow the engine to break in properly DX ENOIL4 19 135 06 1 1 SAE 15W 40 SAE 10W 40 SAE OW 40 SAE 5W 30 Oil Viscosities for Air Temperature Ranges TS1675 UN 09OCTO06 CD ENOIL 19 01JUL09 1 1 072209 PN 35 105 263 Fuels Lubricants and Coolant Lubricant Storage
163. er differential pressure sensor Air filter restriction high Air filter differential pressure sensor input voltage low Air filter differential pressure sensor open circuit Air filter restriction high Pa ff High barometric pressure sensor short to high 4 High barometric pressure sensor short to low 17 High barometric pressure SENSOR NO connected o0 Coolant temperature extremely high 5 Coolant temperature sensor input voltage high oe low 21 coolant temperature sensor open Grout 5 Coolant temperature high least severe moderately high 7 s m m Lj Cvotantievetsensor D engine coolantievelow _ Coolant evel sensor put vonagenon _ _ _ Coolantievel sensorinputvottagelow _ m _ _ Crankcase pressure sensor awaone 3 Crankcase pressure sensor input voltage high Crankcase pressure sensor open circuit NEN co W ee votage ofthe pressure sensor high ofthe pressure sensorlow ShorioV pressure detected Fuel pressure moderate righ Fuetramp pressure notreached Otpressure moderateyiow See Air filter differential pressure sensor input voltage high 31 m o N
164. er display 125 1000 RPM SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT PRES RG13155 UN 070OCT03 Select Remaining Parameters OURGP11 00000B2 19 03SEP03 14 14 Break in period Within first 100 hours of operation After the first 100 hours drain the crankcase and change During the first 100 hours of operation avoid overloading the oil filter see CHANGING ENGINE OIL AND FILTER excessive idling and no load operation Fill crankcase with seasonal viscosity grade oil see DIESEL ENGINE OIL If oil has to be added during this time see ENGINE BREAK IN OIL Check tension of alternator belt NOTE During the break in period a higher than usual oil Check connections of air intake hoses consumption should be considered as normal E Check for proper tightening of cap screws all around After first 100 hours of operation engine DPSG CD03523 17 19 22JANO07 1 1 Starting the engine CAUTION Before starting engine in a confined Perform all prestarting checks outlined in building install proper outlet exhaust ventilation Maintenance Daily Section equipment Always use safety approved fuel storage and piping Open the fuel supply shut off valve if equipped M Activate the starter motor switch to crank the engine NOTE If temperature is below 0 C 32 it may and release it as soon as engine starts be necessary to use cold weather starting aids See COLD WEATHER O
165. er greater to 0 50 5000 ppm may result in REDUCED oil and than 50 is preferred especially for temperatures below filter intervals Refer to table in Diesel Engine 20 4 or elevations above 1500 m 5000 ft Oil and era Service j Cold Filter Plugging Point should be atleast5 C BEFORE using diesel fuel with sulfur content greater 9 F below the expected lowest temperature or Cloud than 0 50 5000 ppm contact your John Deere Point below the expected lowest ambient temperature dealer Fuel lubricity should pass a maximum scar diameter of IMPORTANT Do not mix used diesel engine oil or any 0 45 mm as measured by ASTM D6079 or ISO 12156 1 other type of lubricating oil with diesel fuel Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines DX FUEL1 19 28APRO09 1 1 Handling and Storing Diesel Fuel CAUTION Handle fuel carefully Do not fill the When using bio diesel fuel the fuel filter may require more fuel tank when engine is running frequent replacement due to premature plugging DO NOT smoke while you fill the fuel tank Check engine oil level daily prior to starting engine A or service the fuel system rising oil level may indicate fuel dilution of the engine oil IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an original vented cap Fill the fuel tank at the end of each day s
166. er settings menu 4 Oil Pressure Indication units as per settings menu 3 Oil Temperature Indication units as per settings fua menu Genset started Fuel Level Indication Alternator Compound Voltage Indication Operation default screen Total Active Power Indication Alternator Frequency Indication Alternator U12 compound Voltage Indication Alternator U23 compound Voltage Indication Alternator U31 compound Voltage Indication Alternator Frequency Indication 48 263 Alternator V1 single Voltage Indication Alternator V2 single Voltage Indication Alternator V3 single Voltage Indication Alternator Frequency Indication Alternator U12 compound Voltage Indication Alternator V2 single Voltage Indication Alternator V1 single Voltage Indication Alternator Frequency Indication Alternator V1 single Voltage Indication Alternator phase 1 Current Indication Alternator Frequency Indication Alternator phase 1 Current Indication Alternator phase 2 Current Indication Alternator phase 3 Current Indication Alternator Neutral Current Indication Total Active Power Indication Total Reactive Power Indication Total Apparent Power Indication Total Output Factor Indication inductive capacitive 49 263 Fuel Level Indication P10 Battery Voltage indication Battery Ammeter Indication Total Reactive Power Indication du E 1 n Alternator 012 compound Voltage Indication P11 qm L 3 ij k Tot
167. error indicator value FMIZ7 MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of a mechanical system that with a reasonable confidence level is not caused by an electronic or electrical system failure This type of fault may or may be directly associated with the value of general broadcast information FMIZ8 ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD To be considered in cases of FMI 4 and 5 Any frequency or PWM signal that is outside the predefined limits which bound the signal range for frequency or duty cycle outside Region b or the signal definition Also if the signal is an ECM output any signal whose frequency or duty cycle is not consistent with the signal which is emitted Broadcast of data value is substituted with the error indicator value FMIZ9 ABNORMAL UPDATE RATE Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not at the update rate expected or required by the ECM outside Region c of the signal range definition Also any error that causes the ECM not to send information at the rate required by the system This type of fault may or may be directly associated with the value of general broadcast information FMIZ10 ABNORMAL RATE OF CHANGE Any data exclusive of the abnormalities covered by FMI 2 that is considered valid but whose d
168. es of using the generating set 9 263 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 The earth connection must be installed in accordance with the standards in force in each country in question and with the neutral system sold Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Never accidentally touch stripped cables or loose connections Never handle a generating set with wet hands or feet Maintain electrical wires and connections in good condition Using equipment in poor condition can lead to electrocution and damage to equipment Always disconnect the power to the equipment or facility generating set voltage battery voltage and network voltage before any operation The electrical connections must be made in accordance with current standards and regulations in the country of use Do not use faulty poorly insulated or provisionally connected wires Never reverse the positive and negative terminals on batteries when connecting them This could cause severe damage to the electrical equipment Follow the wiring diagram supplied by the manufacturer The generating set should not be connected to any other power sources such as the mains supply network
169. et the voltage via the module po tentiometer R734 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 internal impedance 1 5 e 0 5V enable a voltage setting of 10 LEROY 8 SOMER 238 263 LEROY SOMER R438 A V R INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached 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 ST2 jumper open if rapid response time used ST5 jumper open to suppress the LAM function 3 2 Settings The machine is tested and set at the fac tory When first used with no load make sure that the drive speed is correct and stable see the nameplate After opera tional testing replace all access panels or covers The only possible adjustments to the machine should be made on the AVR 3 2 1 R438 settings AREP
170. evel 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 seek medical attention as soon as possible If electrolyte is accidentally swallowed gargle with plenty of water and drink large quantities of water Consult a doctor immediately Large quantities of electrolyte sh
171. ex bolts up to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 long and for all other types of bolts and screws of any length 24 ubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or 7 8 in and larger fasteners with JDM F13C zinc flake coating Dry means plain or zinc plated without any lubrication or 1 4 to 3 4 in fasteners with JDM F13B zinc flake coating 65 8 186 263 DX TORQ1 19 24 9 1 1 072209 PN 116 Specifications Metric Bolt and Screw Torque Values TS1670 UN 01MAY03 Class 4 8 Class 8 8 or 9 8 Class 10 9 Class 12 9 Screw Lubricated Dry Lubricated Dry Lubricated Lubricated Dry Size Nm Ib in Ib in 16 Ib in Ib in Ib in Ib in M6 4 7 42 6 53 8 9 79 11 3 100 13 115 16 5 146 15 5 137 19 5 172 lb ft Ib ft Ib ft Nm Ib ft M8 11 5 102 14 5 128 22 194 27 5 243 32 23 5 40 29 5 37 27 5 47 35 Nm lb ft Ib ft Nm 16 6 M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70 Nm 16 6 12 40 29 5 50 37 75 55 95 70 110 80 140 105 130 95 165 120 14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190 16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300 18 135 100
172. f Range High High Pressure Fuel Pump Solenoid Number 1 Circuit Has High Resistance High Pressure Fuel Pump Not Able to Meet Required Rail Pressure Requested Torque Curve Signal Unreliable Engine in Derate Condition Security Violation 55 12 176 263 Corrective Action Check Battery Voltage and Wiring Contact Service Dealer Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Check Injector Wiring or Injector Solenoid Check Injector Wiring or Injector Solenoid Injector Failed or Flow Limiter Closed Contact Servicing Dealer Not Engine Fault Check Other Shutdown Devices Not Engine Fault Check Other Shutdown Devices Contact Servicing Dealer Contact Servicing Dealer
173. fective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Engine overloaded Low coolant level Faulty radiator cap otretched poly V belt or defective belt tensioner Continued on next page 55 6 170 263 Solution Drain fill crankcase with oil of proper viscosity and quality Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube oee your authorized servicing dealer or engine distributor Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner Reduce load oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor Reduce load Fill radiator to proper level check radiator and hoses for loose connections or leaks Have serviceman check Check automatic belt tensioner and check belts for stretching Replace as required DPSG CD03523 49 19 22JAN07 3 4 072209 PN 100 Troubleshooting Symptom High fuel consumption Problem Low engine oil level
174. ff valve Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement Remove load Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids oee Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors Turn key switch to OFF then to ON Add oil to engine crankcase oee your authorized servicing dealer or engine distributor Remove and check thermostat See Engine Overheats DPSG CD03523 49 19 22JAN07 1 4 072209 PN 98 Troubleshooting Symptom Engine runs irregularly or stalls frequently Below normal engine temperature Lack of power Low oil pressure Problem Low coolant temperature Clogged fuel filter Water dirt or air in fuel system Dirty or faulty injection nozzles Defective thermostat Defective temperature gauge or sender Engine overloaded Intake air restriction Clogged fuel filter Improper type of fuel Overheated engine Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Turbocharger not f
175. from the mass Exciter field may be at line potential LEROY 8 SOMER 226 263 LEROY SOMER Installation and maintenance R250 A V R 3 3 Electrical faults Effect Check cause No voltage at no load on start up Connect a new battery of 4 to 12 volts to terminals E and E respecting the polarity for 2 to seconds The alternator starts up and its voltage is still correct when the battery is removed Lack of residual magnetism The alternator starts up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to the A V H Faulty diodes Induced short circuit The alternator starts up but its voltage disappears when the battery is removed Faulty A V R Exciter field short circuited Short circuit in the main field Check the resistance Voltage too low Check the drive speed Correct speed Check the A V R connections A V R may be faulty Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the A V R pot P1 before returning to the correct speed Voltage too high Adjust A V R potentiometer Adjustment ineffective Faulty A V R 1 faulty diode Voltage oscillations Adjust A V R stability potentiometer Check the speed possibili
176. fuel filter bleed screw A 1 Loosen the air bleed screw A two full turns on final filter base only 2 Operate fuel supply pump primer lever B until fuel flow is free from air bubbles 3 Tighten bleed screw securely Continue operating primer until pumping action is not felt RG12221 UN 24MAY02 4 Start engine and check for leaks Fuel supply pump primer lever If engine will not start repeat steps 1 4 DPSG CD03523 46 19 09FEBO7 3 3 072209 50 7 PN 94 164 263 Troubleshooting General troubleshooting information Troubleshooting electronically controlled engine problems can be difficult The first thing to do is to identify the type of problem which can be mechanical or electrical Know the engine and all related systems e Study the problem thoroughly e Relate the symptoms to your knowledge of engine and An engine wiring layout is provided in this section to systems identify electrical components engine controller sensors Diagnose the problem starting with the easiest things connectors first e Double check before beginning the disassembly Later in this section is a list of possible engine problems Determine cause and make a thorough repair and diagnostic trouble codes that may be encountered e After making repairs operate the engine under normal accompanied by possible causes and corrections This conditions to verify that the problem and cause was troubleshooting i
177. g engine oil and filter Replacing fuel filter element s Checking belt 3029 and 4039 Engines Checking belt 4045 and 6068 Engines with manual Maintenance 1000 hours 1 year Cleaning crankcase vent tube Checking air intake system Checking automatic belt tensioner 4045 and 6068 oR oa Continued on next page Original Instructions All information illustrations and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice COPYRIGHT 2009 DEERE amp COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2007 2008 75 263 072209 PN 1 Contents Check and adjust engine valve clearance 3029 and 4039 Engines Pressure testing cooling system Maintenance 2000 hours 2 years Check and adjust engine valve clearance 4045 and 6068 Engines Checking engine speed Mechanical fuel System ccr e ti ao Adjust speed droop governor Mechanical fuel system Checking crankshaft vibration damper 6 CYLINDER ENGINE ONLY
178. g has stopped begin artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 1 3 7 Risks related to moving the set To unload the generating sets pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions you must ensure that the following points are observed 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 v 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
179. hanical Fuel System CD6068HFS72 DE10 Fuel System CD6068HFS73 HPCR System 2 Valve Head CD6068HFS76 HPCR System 4 Head CD6068HFS77 HPCR System 4 Valve Head CD6068HFU72 DE10 Fuel System CD6068HFU74 HPCR System 4 Valve Head CD6068HFU79 HPCR System 2 Valve Head Emission Certified Engines EPA Tier 2 CD3029TF270 Mechanical Fuel System CD4045TF270 Mechanical Fuel System CD6068HF275 VP44 Fuel System CD6068HF475 HPCR System 4 Valve Head Introduction Emission Certified Engines EPA Tier 3 CD4045HFS80 Mechanical Fuel System CD4045HFS82 HPCR System 2 Valve Head CD4045HFS83 HPCR System 2 Valve Head CD6068HFS82 HPCR System 2 Valve Head CD6068HFS83 HPCR System 2 Valve Head CD6068HFS89 HPCR System 4 Valve Head READ THIS MANUAL carefully to learn how to operate and service your engine correctly Failure to do so could result in personal injury or equipment damage THIS MANUAL SHOULD BE CONSIDERED a permanent part of your engine and should remain with the engine when you sell it MEASUREMENTS IN THIS MANUAL are given in metric Use only correct replacement parts and fasteners Metric and inch fasteners may require a specific metric or inch wrench WRITE ENGINE SERIAL NUMBERS and option codes in the spaces indicated in the Serial Number Section Accurately record all the numbers Your dealer also needs these numbers when you order parts File the identification numbers in a secure
180. he factory defaults then the display will return to the Setup 1 Up Display menu RESTORED TO DEFAULTS Restored To Defaults RG13149 UN 24SEP03 Continued on next page OURGP11 00000B1 19 03SEP03 7 18 15 17 PN 54 124 263 Operating the Engine 8 Custom Setup To perform a custom setup of the USE DEFAULTS 1 Up Display use the arrow buttons to scroll to and CUSTOM SETUP highlight Custom Setup on the display AUTOMATIC SCAN OFF RG13198 UN 26SEP03 OPO Select Custom Setup OURGP11 00000B1 19 03SEP03 8 18 9 Press the Enter key to display a list of engine CUSTOM SETUP AUTOMATIC SCAN OFF A o 2 2 o o O x Engine Parameters OURGP11 00000B1 19 03SEP03 9 18 10 Use the Arrow keys to scroll to and highlight a TEC selected parameter parameter with a number to right PERCENT LOAD AT CURRENT RPM a ENGINE OIL PRESSURE This number indicates ENGINE COOLANT TEMPERATURE the order of display lor parameters and 3 that the parameter is selected for display Select Parameters RG13150 UN 24SEP03 Continued on next page OURGP11 00000B1 19 O3SEP03 10 18 15 18 PN 55 125 263 Operating the Engine 11 Press the Enter key to deselect the selected parameter removing it from the list of parameters ENGINE SPEED being displayed on the 1 Up Display PERCENT LOAD AT CURRENT RPM 3 ENGINE PRESSURE 2 ENGINE C
181. hen the set is running Proper ventilation is required for your generating set pump unit or lighting column to work properly Without this ventilation the engine would very quickly rise to an excessively high temperature causing accidents or damage to the equipment and to surrounding property Do not remove the radiator cap if the engine is hot and the coolant is pressurised due to risks of burns Depressurise the air oil and cooling circuits before removing or disconnecting all the fittings pipes or connected components Watch out for the possible presence of pressure when disconnecting a device from a pressurised system Do not try to find pressure leaks by hand Oil at high pressure can cause bodily damage Some preservative oils are flammable Also some are dangerous to inhale Ensure proper ventilation Use a protective mask Hot oil causes burns Avoid contact with hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine with the oil filler cap off oil may splash out Never coat the generating set pump unit or lighting column with a thin layer of oil to protect it from rust Never top up the oil or coolant if the generating set pump unit or lighting column is running or if the engine is hot A generating set can only operate when stationary and cannot be installed on a vehicle or other mobile equipment without a prior study taking into account the various specific featur
182. his unit s cover can provide IP20 minimum total protection it must only be installed on LS alternators in the appropriate location so that when viewed externally it has a higher degree of protection than IP20 Copyright 2005 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for LEROY SOMER 3 221 263 LEROY SOMER R250 A V R 1 SUPPLY The regulator controls the excitation current _ Math according to the alternator s output voltage Tosca With very simple conception the SHUNT The SHUNT excitation alternator is auto excitation alternator does not have a short excited with a R 250 voltage regulator circuit capacity MAIN FIELD STATOR 12 wires marking T1 to T12 T1 T7 2 T3 9 T4 T1O0 5 11 T6 112 AR R250 4 x holes 5 8 x 50 x 115 mm 140 mm Slow fuse F1 250V8A P1 Voltage Frequency selector 50 Hz 60 Hz for U F fonction and LAM adjustement BANOO Osu Pd Stability D ST4 Option External potentiometrer for voltage adjusting 4 LEROY SOMER 222 263 LEROY SOMER R250 A V R 2 R250 A V R 2 1 Characteristics Storage 55 C 85 Operation 40 C 70 C Voltage regulation around 0 5
183. ies English only Engines English 77 Component Technical Manual for Alternators e CTM331 Component Technical Manual for DE10 and Starter Motors English only Fuel Systems on 4045 and 6068 engines English RG4624 UN 15DEC88 DPSG CD03523 42 19 31JAN07 1 1 Do not modify fuel system IMPORTANT Modification or alteration of the injection pump the injection pump timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser Do not attempt to service injection pump or fuel injectors yourself Special training and special tools are required See your authorized servicing dealer or engine distributor CD30768 UN 24SEP99 DPSG CD03523 43 19 22JAN07 1 1 072209 50 1 PN 88 158 263 Maintenance As required Welding Near Electronic Control Units IMPORTANT Do not jump start engines with arc welding equipment Currents and voltages are too high and may cause permanent damage lt A Disconnect the negative battery cable Disconnect the positive battery cable 2 a P Short the positive and negative terminals together Do 2 not attach to vehicle frame TS953 UN 15MAY90 Clear or move any wiring harness sections away from welding area Connect welder ground close to welding point and away from control units 6 After welding reverse Steps 1 5 DX WW ECUO2 19 11JUN09 1 1 Keep Electronic C
184. ircuitbreakers or relays in the cabinet The machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram aot anion 3 4 Commissioning The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The machine is tested and set up at the factory When first used with no load make sure that the drive speed is correct and Stable see the nameplate With the regreasable bearing option we recommend greasing the bearings at the time of commissioning see 4 2 2 On application of the load the machine should achieve its rated speed and voltage however in the event of abnormal operation the machine setting can be altered follow the adjustment procedure in section 3 5 If the machine still operates incorrectly the cause of the malfunction must be located see section 4 4 3 5 Setting up The various adjustments during tests must be made by a qualified engineer Ensure that the drive speed specified on the nameplate is reached before commencing adjustment After operational testing replace all access panels or covers The AVR 15 used to make any adjustments to the machine LEROY 10 SOMER 204 263 15 43 2 44 2 4 POLES ALTERNATORS 4 SERVICING MAINTENANCE 4 1 Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instr
185. istributor or servicing dealer correct this problem immediately CD03523 00000EC 19 22JAN07 1 1 072209 81 151 263 Maintenance 2000 hours 2 years Check and adjust engine valve clearance 4045 and 6068 Engines Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 Remove rocker arm cover and crankcase vent tube 2 Using JDE83 or JDG820 Flywheel Turning Tool A rotate engine flywheel in running direction clockwise viewed from water pump until No 1 piston front has reached top dead center TDC on compression stroke Insert timing pin JDE81 4 B into flywheel bore lt 2 2 O Continued on next page DPSG CD03523 36 19 31JAN07 1 2 072209 40 1 PN 82 152 263 Maintenance 2000 hours 2 years 3 Check and adjust valve clearance to specifications according to following procedures Specification Valve clearance engine COG enact aicencod 0 35 mm 0 014 in EXN AUS EET 0 45 mm 0 018 in 4 f valves need adjusting loosen locknut on rocker 5 arm adjusting screw Turn adjusting screw until feeler gauge slips with a slight drag Hold the adjusting screw from turning with screwdriver and tighten locknut to 27 N m 20 Ib ft Recheck clearance after tightening locknut Readjust clearance as necessary Reins
186. it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt 7 Bleed the fuel system DPSG CD03523 30 19 07 7 1 1 072209 PN 74 144 263 Maintenance 500 hours Checking belt 3029 and 4039 Engines 1 Inspect belt for cracks fraying or stretched out areas Replace as necessary 2 Check belt tension using one of following methods a Use of JDG529 Tension Gauge A Specification tension New belt 578 622 130 140 Ib force Used 378 423 85 94 Ib force NOTE Belt is considered used after 10 minutes 5 of operation b Use of tension tester B and straightedge A 89 N 20 Ib force applied halfway between pulleys should deflect belt by 19 mm 0 75 in If adjustment is necessary loosen alternator nuts D and E Pull alternator frame outward until belt is correctly tensioned z IMPORTANT Do not pry against the alternator rear frame Do not tighten or loosen 5 belts while they are hot 4 Tighten alternator bracket nuts firmly 5 engine for 10 minutes then recheck tension A JDG529 Tension Gauge D Upper nut B Tension tester E Lower nut C Straightedge 1 3 DPSG CD03523 31 19 30JAN07 1 1 3 0 5 072209 PN 75 145 263 Maintenance 500 hours Checking belt 4045 and
187. ker arm cover These codes indicate which of the engine options were installed on your engine at the factory When in need of parts or service furnish your authorized servicing dealer or engine distributor with these numbers An additional sticker may be also delivered in a plastic bag attached to the engine or inserted in the machine documentation It is recommended to stick this option code list sticker either On this page of your Operator s manual below this section or On the Engine Owner s Warranty booklet under the title OPTION CODES Engine manufacturing configuration NOTE The Machine Manufacturer may have already stuck it at a specific accessible place inside the enclosure or close to a maintenance area The engine option code label includes an engine base code A This base code must also be recorded along with the option codes At times it will be necessary to furnish this base code to differentiate two identical option codes for the same engine model The first two digits of each code identify a specific group such as alternators The last two digits of each code identify one specific option provided on your engine such as a 12 volt 55 amp alternator NOTE These option codes are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice If an engine is ordered without a particular component the last two digits of that fu
188. keys to scroll through the menu until Adjust Contrast STORED CODES 5 highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13161 UN 020CT03 Select Adjust Contrast OURGP11 00000AF 19 03SEP03 2 6 3 Once the Adjust Contrast menu item has been highlighted press the Enter key to activate the E Adjust Contrast function SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST Press Enter Key RG13185 UN 02OCT03 Continued on next page OURGP11 00000AF 19 03SEP03 3 6 15 12 PN 49 119 263 Operating the Engine 4 Use the Arrow keys to select the desired contrast intensity ADJUST CONTRAST RG13186 UN 29SEP03 Adjust Contrast Intensity OURGP11 00000AF 19 03SEP03 4 6 9 Press the Menu key to return to the main menu ADJUST CONTRAST 7 C gt A LLI 1 2 2 N lt O X Return To Main Menu OURGP11 00000AF 19 03SEP03 5 6 6 Press the Menu key to exit the main menu and return to the engine parameter display 1000 RPM 1800 RPM TSG TEMP 14 2 Psi RG13159 UN 26SEP03 Exit Main Menu OURGP11 00000AF 19 03SEP03 6 6 Selecting Units Of Measurement 98 1000 RPM LOA CAPM ENG 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the 1800 RPM 14 2 57 PSI Menu key BA
189. l drain Engine oil filter replace n Fuel filter replace Belt check tension and wear 300 Series and POWERTech with manual tensioner Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 74 19 22JAN07 1 1 10000 Hours of operation Engine oil drain Cooling system drain and flush Engine oil filter replace Valve clearance adjust POWERTech n Fuel filter replace Thermostat replace Check belt and tensioning system Vibration damper check Crankcase vent tube clean n Injection nozzles replace Air intake system check Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 75 19 22JAN07 1 1 02 11 PN 20 90 263 Serial Numbers PowerTech label A label is located on the rocker arm cover which identifies each engine as a John Deere PowerTech engine 4 5 liter RG8041 UN 15JAN99 DPSG CD03523 11 19 10JUL09 1 1 Engine serial number plate e 2 lt 0 B N i Z Z 5 1 N O Q c O 4045 and 6068 Engines 3029 and 4039 Engines Each engine has a 13 digit John Deere serial number The first two digits identify the factory that produced the engine Your engine s serial number plate A is located on the right hand side of cylinder block b
190. le electronically controlled engines DE10 HPCR have two fuel filters primary and final Both the primary and the final filters have to be replaced together at the same time Thoroughly clean fuel filter assembly and surrounding area Loosen drain plug C and drain fuel into a suitable container NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators 30 4 X9811 UN 23AUG88 ME JOHN DEE rapa JOHN DEF ri Er E ik p CD30930 UN 07FEB07 Fuel filters E Water separator bowl F Primary fuel filter element 3 Firmly grasp the retaining ring A and rotate it clockwise 1 4 turn Remove ring with filter element B IMPORTANT Do not dump the old fuel into the new filter element This could cause fuel injection problem A plug is provided with the new element for plugging the used element 4 Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation Install new filter element dry onto mounting base Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until
191. ler with a list of DTC s so that necessary repairs can be made 55 10 174 263 CD03523 0000192 19 02FEBO07 1 1 072209 PN 104 Troubleshooting Listing of Diagnostic Trouble Codes DTCs NOTE Not all of these codes are used on all OEM engine applications SPN 000028 000029 000084 000091 000094 000097 000100 000105 000107 000110 000111 000158 000160 000174 000174 000189 000190 000611 000620 FMI 03 04 03 04 31 03 04 09 03 04 10 13 17 00 03 04 16 01 03 04 18 00 03 04 16 00 00 03 04 15 16 01 17 02 00 03 04 16 00 00 16 03 04 03 04 Description of Fault Throttle 3 Signal Out of Range High Throttle Z3 Signal Out of Range Low Throttle 22 Signal Out of Range High Throttle 2 Signal Out of Range Low Vehicle Speed Signal Unreliable Throttle 1 Signal Out of Range High Throttle 1 Signal Out of Range Low Throttle 1 Communication Signal Erratic Low Pressure Fuel Signal Out of Range High Low Pressure Fuel Signal Out of Range Low Low Pressure Fuel Rate of Change Abnormal Low Pressure Fuel Out of Calibration High Pressure Fuel System Pressure Slightly Low Water in Fuel Continuously Detected Water in Fuel Signal Out of Range High Water in Fuel Signal Out of Range Low Water in Fuel Detected Engine Oil Pressure Signal Extremely Low Engine Oil Pressure Signal Out of Range High Engine Oil Pressure Signal Out of Range Low Engi
192. load or to increase the applied load possible for one speed variation turbo charged engines To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the lowest frequency in steady state Itis advised to use the LAM at 25 for load impacts gt at 7096 of the genset rated power 2 4 2 Gradual voltage return function During load impacts the function helps the genset to return to its rated speed faster thanks to a gradual increase in voltage according to the following principles if the speed drops between 46 Hz and 50 Hz the rated voltage follows a fast gradient as it is restored if the speed drops below 46 Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value N 46 Hz Time Drop N gt 46 Hz LEROY 6 SOMER 224 263 LEROY SOMER R250 A V R 2 5 Typical effects of the LAM with a diesel engine or without a LAM U F only 2 5 1 Voltage U f without LAM a Load on shaft kW LEROY SOMER 7 225 263 LEROY SOMER R250 A V R 3 INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wiring diagram Check that the position of the jumper corresponds to the operating frequency Check whether the ST
193. m filter bowls Check fuel filters C and D for water and debris as follows CD30929 UN 07FEBO7 Loosen drain plug s A at bottom of fuel filter s or bowl s two or three turns Drain fuel filter s Loosen air bleed plug s B two full turns and drain water into a suitable container A Drain plug C Primary fuel filter B Air bleed plug D Final fuel filter When fuel starts to drain out tighten drain plug s securely Bleed fuel system DPSG CD03523 27 19 07 7 4 4 072209 25 3 PN 70 140 263 Maintenance 500 hours Changing engine oil and filter IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications NOTE Change engine oil and filter for the first time after 100 hours maximum of operation then every 500 hours thereafter Change oil and filter at leat once a year Run engine approximately 5 minutes to warm up oil Shut engine off CD30758 UN 26AUG99 Open oil pan drain valve A Drain crankcase oil from engine while warm Continued on next page DPSG CD03523 29 19 01JUL09 1 3 072209 30 1 PN 71 141 263 Maintenance 500 hours 5 4 Oil filter 3029 4039 engines Oil filter on 4045 and 6068 engines 4 Replace oil filter 3029 and 4039 engines a b Remove and discard oil filter element B using a suita
194. mple LSA 43 2 M45 J6 4 e LSA name used in the PARTNER range M Marine C Cogeneration T Telecommunications e 43 2 machine type M45 model LSA Date N Hz Min 1 R P M fProtection Cos Q P F 1 ther Th class R gulateur A V R Alit m Masse Weight Rit AV D E bearing Rit AR N D E bearing Graisse Grease sd Valeurs excit Excit values en charge full load a vide atnoload e J excitation system AREP J SHUNT or PMG e 6 4 winding number number of poles 1 3 1 Nameplate So that you can identify your machine quickly and accurately we suggest you write its specifications on the nameplate below 1 4 Storage Prior to commissioning machines should be stored Away from humidity lt 90 after a long period of storage check the machine insulation section 3 2 1 To prevent the bearings from becoming marked do not store in an environment with significant vibration 1 5 Application These alternators are mainly designed to produce electricity in the context of applications involving the use of generators 1 6 Contraindications to use Use ofthe machine is restricted to operating conditions environment speed voltage power etc compatible with the characteri stics indicated on the nameplate amp Q WO ALTERNATORS PUISSANCE RATI
195. n In addition appendix D indicate the meaning of the code The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation OK HELP For JOHN DEERE JD PERKINS PE and VOLVO VO engines the codes displayed are SPN and FMI codes 6 3 4 5 Horn reset Depending on the settings made menu 363 HORN the activation of an alarm and or a fault leads to the horn sounding and the following screen appearing HORN STOP PRESS OK This screen will display first any messages relating to the alarms and faults that appear as soon as OK is pressed 25 12 2005 15 30 60 263 7 Maintenance schedule 7 1 Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule given as a guideline N B the environment in which the generating set is operating determines this schedule If the generating set is used in extreme conditions shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel oil and coolant which conform to the specifications given in this manual 7 2 Engine 2000 hrs 2500 hrs OPERATION VAR Loss n every every As required y yy 2 Inspect the engine compartment e oil fuel refrigerant levels indicator
196. n 61 Injector wiring status Injector wiring status AE Injector wiring shorted to power source o 4 ME Injector wiring shorted to ground Sensor power supply open short to power Sensor power supply open short to open short to B John Deere Sensor power supply short to ground Lr Start enable device intake heater ether _ Start enable device output short to B enable device Start enable device output short to B short to B a enable device output short to NOR USEC Wie CONTO panel is in charge of managing the ground start enable device nd Start enable device output open circuit Lj Powersupply CN votage problem For6125HFO7O only _ ECUunswitched power missing For 6068HF275 44 only voltage MemoryfaultinEMS2 fault in Memory faultinEMS2 EMEN OPUwachdogreseest alue _ and fueling ASIC RAMadWesstesalue Watchdog tip taire E EB ada e error 6068 475 VP44 Data setmemoryEEPROM Injection status Fuel shutoff error Pump position sensor cam position sensor input noise Permanent loss of signal High impedance of the position sensor or circuit open position in function of the type of injection Pump position sensor cam position sensor inp
197. n Engine parameters Working hours counter Engine speed Battery voltage Fuel Level Air Preheating Standard specifications Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage 20 263 2 3 Fuel and consumables All specifications product features are given in the motor and alternator maintenance manuals attached to this manual In addition we recommend the consumables to be used in the specifications section 2 3 1 Specifications 2 5 1 1 grades Type John Deere PLUS 50 MITSUBISHI GenPARTS GENLUB TDX 15W40 GenPARTS GENLUB 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 injector pumps v All types of use can cope with the most demanding applications Yv Depolluted engines complies with EURO 2 and EURO 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 e
198. n DIESEL ENGINE COOLANT Check entire cooling cause serious burns system for leaks Only remove filler cap when engine is cold or when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely DPSG CD03523 27 19 07FEBO07 2 4 3 filter has a dust unloader valve C squeeze valve tip to release any trapped dirt particles 4 Check air intake restriction indicator D When indicator is red air filter needs to be cleaned IMPORTANT Maximum air intake restriction is 6 25 kPa 0 06 bar 1 0 psi 25 in 2 A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine 5 Make a thorough inspection of the engine compartment RG4687 UN 20DEC88 NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination CD30757 UN 26AUG99 Continued on next page DPSG CD03523 27 19 07 7 3 4 072209 25 2 PN 69 139 263 Maintenance Daily or every 10 hours 6 NOTE Engines with mechanical fuel system have a single fuel filter while electronically controlled engines DE10 and HPCR fuel systems have two fuel filters primary and final Moreover these electronically controlled engines may be equipped with a water sensor at the fuel filters An indicator light on the instrument panel will signal the operator that water should be drained fro
199. nctional group option code will be 99 00 or XX The list on the next page shows only the first two digits of the code numbers For future reference such as ordering repair parts it is important to have these code numbers available To ensure this availability enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page NOTE NOTE Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory If option code label is lost or destroyed consult your servicing dealer or engine distributor selling the engine for a replacement Option Description Option Description Codes Codes Engine Base Code Rocker Arm Cover 50 Oil Pump 12 Oil Filler Neck 51 Cylinder Head With Valves 13 Crankshaft Pulley 52 Auxiliary Gear Drive 14 Flywheel Housing 53 Fuel Heater 15 Flywheel o4 ___ Oil heater 16 Fuel Injection Pump DO or Shipping stand 17 Air inlet 56 __ Paint Option 18 Soo Coolant Inlet 19 59 __ Oil Cooler 20 Coolant pump 60 Add on Auxiliary Drive Pulley 21 Thermostat Cover 62 Alternator Mounting 22___ Thermostat 63 Low Pressure Fuel Line Continued on next page 03 3 93 263 DPSG CD03523 14 19 22JAN07 1 2 072209 PN 23 Serial Numbers Record fuel injection pump model number Description Fan Drive Fan Belt
200. nctions and trouble codes DTCs The gauge is linked to the electronic control NOTE Engine parameters which can be accessed system and its sensors This allows the operator to will vary with the engine application Six monitor engine functions and to troubleshoot the engine languages for readouts are available and can systems when needed be selected during setup of gauge Press the menu key B to access the various engine The diagnostic gauge includes a graphical backlit Liquid functions in sequence The displays can be selected as Crystal Display LCD screen The display can show either customary English or metric units The following either a single parameter or a quadrant display showing menu of engine parameters can be displayed on the four parameters simultaneously The diagnostic gauge diagnostic gauge window uses two arrow keys C for scrolling through the engine parameter list and viewing the menu list and an enter key D for selecting highlighted items The red E and amber F lights are used to signal active trouble code received by the diagnostic gauge Engine hours Engine rom e System voltage Percent engine load at the current rpm CD03523 000018B 19 22JAN07 1 1 Main Menu Navigation 1000 RPM ENG EP NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine 14 2 57 PSI start up is desired See Starting The Engine All BAT VOLT of the engine values illustrat
201. ne Oil Pressure Signal Moderately Low Intake Manifold Air Temperature Signal Extremely High Intake Manifold Air Temperature Signal Out of Range High Intake Manifold Air Temperature Signal Out of Range Low Intake Manifold Air Temperature Signal Moderately High Air Filter Pressure Differential Extremely High Engine Coolant Temperature Signal Extremely High Engine Coolant Temperature Signal Out of Range High Engine Coolant Temperature Signal Out of Range Low Engine Coolant Temperature Signal Slightly High Engine Coolant Temperature Signal Moderately High Engine Coolant Level Low ECU Power Down Error Internal ECU Problem Axle Speed Signal Unreliable Fuel Temperature Signal Extremely High Fuel Temperature Signal Out of Range High Fuel Temperature Signal Out of Range Low Fuel Temperature Signal Moderately High Engine Speed Derate Condition Exists Engine Speed Extremely High Engine Speed Moderately High Injector Shorted to Power Injector Shorted to Ground Sensor Supply 2 Voltage High Sensor Supply 2 Voltage Low Continued on next page 55 11 175 263 Trouble Codes Corrective Action Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Switch and Wiring Check Switch and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer
202. ne Position Sensor Signal Missing Engine Position Sensor Signal Rate of Change Abnormal Engine Timing Sensor Signal Unreliable Engine Timing and Position Sensors Out of Sync Engine Timing Sensor Signal Missing Engine Timing Signal Rate of Change Abnormal CAN Bus Error Communication network problem Injector Number 1 Circuit Has High Resistance Injector Number 1 Circuit Has Low Resistance Injector Number 1 Not Responding Injector Number 2 Circuit Has High Resistance Injector Number 2 Circuit Has Low Resistance Injector Number 2 Not Responding Injector Number 3 Circuit Has High Resistance Injector Number 3 Circuit Has Low Resistance Injector Number 3 Not Responding Injector Number 4 Circuit Has High Resistance Injector Number 4 Circuit Has Low Resistance Injector Number 4 Not Responding Injector Number 5 Circuit Has High Resistance Injector Number 5 Circuit Has Low Resistance Injector Number 5 Not Responding Injector Number 6 Circuit Has High Resistance Injector Number 6 Circuit Has Low Resistance Injector Number 6 Not Responding Vehicle Speed or Torque Message Unreliable External Shutdown Commanded External Fuel Derate Switch Active Tire Size Invalid Tire Size Error Sensor Supply 1 Voltage High Sensor Supply 1 Voltage Low Fuel Rail Pressure Sensor Supply Voltage High Fuel Rail Pressure Sensor Supply Voltage Low Engine Protection Shutdown Warning Engine Protection Shutdown High Pressure Fuel Pump Control Valve Signal Out o
203. ne for 24 hours in a drying oven at a temperature of 110 without the regulator b Blow hot air into the air intake having made sure that the machine is rotating with the exciter field disconnected Note Prolonged standstill In order to avoid these problems we recommend the use of space heaters as well as turning over the machine from time to time Space heaters are only really effective if they are working continuously while the machine is stopped WARNING Ensure that the alternator has the degree of protection matching the defined environmental conditions 3 2 2 Mechanical checks Before starting the machine for the first time check that all fixing bolts and screws are tight the cooling air is drawn in freely the protective grilles and housing are cor rectly in place Connection codes L L voltage the standard direction of rotation is clock wise as seen from the shaft end phase rotation in order 1 2 3 For anti clockwise rotation swap 2 and 3 the winding connection corresponds to the site operating voltage see section 3 3 3 3 Terminal connection diagrams To modify the connection change the position ofthe stator cables on the terminals The winding code is specified on the nameplate 3 3 1 Terminal connection 12 wire The connection accessories are detailed in section 5 3 3 Any intervention on the alternator terminals during reconnection or checks should be
204. nector vicinity looking for wires that have pulled out of connectors poorly positioned terminals damaged connectors and corroded or damaged splices and terminals Look for broken wires Electromagnetic interference EMI from an improperly damaged splices and wire to wire shorts Use good installed 2 way radio etc can cause faulty signals to judgement if component replacement is thought to be be sent to the ECU required Suggestions for diagnosing intermittent faults e Faulty connection between sensor or actuator harness Faulty contact between terminals in connector Faulty terminal wire connection NOTE Refer also to generator documents for more NOTE The engine control unit ECU is the component information about connections and wirings LEAST likely to fail CD03523 0000193 19 O5FEBO7 1 1 95 13 PN 107 177 263 Storage Engine storage guidelines 1 John Deere engines can be stored outside for up to three 3 months with no long term preparation IF COVERED BY WATERPROOF COVERING John Deere engines can be stored in a standard overseas shipping container for up to three 3 months with no long term preparation John Deere engines can be stored inside warehoused for up to six 6 months with no long term preparation Preparing engine for long term storage The following storage preparations are good for long term engine storage up to one year After that the engine should be started w
205. ned 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 conditions some of these periods will be shorter Ensure that all repairs and adjustments are carried o
206. nformation is of a general nature Corrected See also the generator documentation for a complete information of your application A reliable program for troubleshooting engine problems should include the following basic diagnostic thought process CD03523 000018D 19 08FEBO7 1 1 072209 55 1 PN 95 165 263 Troubleshooting Engine Wiring Layout Electronic Fuel System With Stanadyne DE10 Injection Pump RG12201 UN 24MAY02 A Coolant Temperature Sensor G Starter Relay Connector M Remote ON OFF Connector S Fuel Heater Connector Connector H Oil Pressure Sensor N CAN Network Diagnostic T Manifold Air Temperature B Fuel Temperature Sensor Connector Connector MAT Sensor Connector Connector I Main System Fuse 10 amp O Instrument Panel Connector U Alternator Ignition Connector C Injection Pump Solenoid J Power and Ground Battery Harness V Optional Instrument Panel or Connector Connections P 23 pin Optional Feature Generator Instrument Panel D SAE 1939 CAN Connector K Fuse Holder Connector Extended feature E Crankshaft Position Sensor L Transient Voltage Protection ECU only Connector TVP Module Connector Q 21 pin Instrument Panel F ECU Connector Connector R Engine Wiring Harness CD03523 000018E 19 02FEBO07 1 1 072209 55 2 PN 96 166 263 Troubleshooting Engine Wiring Layout Electronic Fuel System With Denso High Pressure Common Rail E 2 9 2 7
207. ng and selection wheel to scroll through ALARM 25 12 05 15 30 the list of faults Low Fuel Level GDS 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 58 263 6 3 4 4 Engine fault codes display Certain alarms and engine faults generate specific fault codes These codes are standardised according to the J1939 and or J1587 standards except for MTU engines that have a specific transmission protocol see appendix if applicable Terminology used by the SAE CAN J1939 standard SPN Suspect Parameter This represents the system or component at fault for example SPN 100 Number indicates an oil pressure problem or a problem with the oil pressure sensor This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault Terminology used by VOLVO FMI Failure Mode identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more particularly to an assembly of components for example the injection system SID System Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN However this term corresponds more
208. ng 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 64 263 8 5 Faults and remedies Fault observed Probable origin Measures or observations The acid heats up when a new battery is ncorrect storage Load med Prolonged storage in a damp place Check the acid density 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 Insufficient charge Short circuit in the power circuit Consumption fault Recharge Check the electrical installation Acid level too low Incorrect operation from start up Reduce the acid level by filling with distilled water Repeat the operation if necessary The battery has been filled with acid ne desit OON instead of battery fluid Battery empty Starting problems A da Recharge the battery Capacity too low Starting test incorrect Battery sulphated Fita new battery ncorrect electrical connection Tighten the ends of the battery Battery terminals melted Battery cabling incorrect cables or replace them if necessary One or two cells release lot of gas at Cell s faulty Fita new battery high charge Charge status too low Short circuit in the current circuit
209. nsioning system Crankcase vent tube clean Cooling system drain and flush if COOL GARD is not used Valve clearance adjust POWERTech Air intake system check Vibration damper check Number of hours Job done by Observation Dealer or distributor stamp DPSG CD03523 67 19 22JAN07 1 1 02 7 86 263 072209 PN 16 Maintenance Records 6500 Hours of operation Engine oil drain Engine oil filter replace n Fuel filter replace manual tensioner Valve clearance adjust 300 Series Belt check tension and wear 300 Series and POWERTech with Number of hours Job done by Observation Dealer or distributor stamp 7000 Hours of operation DPSG CD03523 68 19 22JAN07 1 1 Engine oil drain Engine oil filter replace n Fuel filter replace Check belt and tensioning system Crankcase vent tube clean Air intake system check Number of hours Job done by Observation Dealer or distributor stamp 02 8 87 263 DPSG CD03523 69 19 22JAN07 1 1 072209 17 Maintenance Records 7500 Hours of operation Engine oil drain Cooling system drain and flush if COOL GARD is used Engine oil filter replace n Fuel filter replace Belt check tension and wear 300 Series and POWERTech with manual tensioner Valve clearance adjust 300 Series
210. ntrol module whose voltage remains at a high level when the ECM commands it to low Broadcast of data value is substituted with the error indicator value FMIZ4 VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE a A voltage signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose voltage remains at a low level when the ECM commands it to high Broadcast of data value is substituted with the error indicator value FMIZ5 CURRENT BELOW NORMAL OR OPEN CIRCUIT a A current signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose current remains off when the ECM commands it on Broadcast of data value is substituted with the error indicator value FMIZ6 CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT a A current signal data or otherwise is above the predefined limits that bound the range Hegion e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose current remains on when the ECM commands it off Broadcast of data value is substituted with the
211. ock nuts instructions are given for the specific application wheel bolts or wheel nuts unless different instructions are given for the specific application 24 ubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or M20 and larger fasteners with JDM F13C zinc flake coating f Dry means plain or zinc plated without any lubrication or M6 to M18 fasteners with JDM F13B zinc flake coating DX TORQ2 19 24 9 1 1 072209 65 9 PN 117 187 263 Specifications 65 10 PN 118 188 263 Index Page Page A Engine wiring layout With Denso High Pressure Common 55 3 Air filter With Stanadyne DE10 55 2 Clean or replace one piece 50 3 Clean or replace 50 4 F Air intake system 35 1 Fuel ER 10 1 Handling and 10 1 Fuel filter Belt FRE DIAC EIMIOC cR T 30 4 Check automatic tensioner 35 2 Fuel pump model 03 5 Check tension 30 5 Fuel system Replace 4045 and 6068 50 5 50 5 Bolt and screw torque values n 65 9
212. ode bridge 330410713 Varistor 330410335 For all technical assistance or spare part requests contact your nearest SDMO agent lt Pd Y p lt 248 263 9 4 Appendix D List of John Deere Volvo and Perkins fault codes o SPN CID SID PID PPID FMI E Description Comment m S UC HB a roe votase shono j ThrottewPostion TweteVotepehgh hotioVe EE TwoweVolegelowshorioV J jJVhileseed 4o Oo 4 J Vehicle invalid or missing Not possible with Genset 31 Vehicle speed mismatch application e FMI not determined for all B a Accelerator pedal position VOLVO s Throttle Voltage high short to E Throttle Voltage low short to V Throttl libration invalid PWM throttle abnormal pulse width application codes declared Throttle invalid CAN value by the CAN 1587 for VOLVO Throttle voltage out of range low Throttle calibration aborted Throttle voltage out of range a a Fuel supply pressure extremely low Fuel rail pressure input voltage high Short to V Fuel rail pressure input voltage low Short to V Fuel rail pressure sensor open circuit Fuel rail pressure lost detected Fuel rail pressure higher than e
213. onomy and service life from your engine ensure service is carried out according Deere oils and coolants have been formulated to this present manual and recorded in the following to give maximum protection and performance to your pages It is recommended that your engine Distributor engine We recommend only genuine John Deere service or your Dealer carry out this service work and stamp the Products and replacement parts appropriate case To protect your rights under the warranty ensure all Keeping an accurate account of all service performed on scheduled services are carried out and recorded If your your engine will give more value to the machine when engine Is covered by extended warranty it is Important to maintain this record for the duration of the warranty DPSG CD03523 6 19 22JAN07 1 1 100 Hours of operation Engine oil drain Engine oil filter replace Hose connections check Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 7 19 22JANO7 1 1 0 2 1 072209 PN 10 80 263 Maintenance Records 500 Hours of operation Engine oil drain Engine oil filter replace n Fuel filter replace Belt check tension and wear 300 Series and POWERTech with manual tensioner Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG
214. ontacts damper outer circumference With engine at operating temperature rotate crankshaft using JDG820 or JDE83 Flywheel Turning Tool Note dial indicator reading If runout exceeds specifications given below replace vibration damper Specification Damper Maximum radial uer Dc eae asics 1 50 mm 0 060 in RG7508 UN 23NOV97 DPSG CD03523 40 19 22JAN07 1 1 072209 40 4 PN 85 155 263 Maintenance 2500 hours 3 years Drain and flush cooling system NOTE Drain and flush cooling system every 2500 hours 3 years when John Deere COOL GARD coolant is used Otherwise every 2000 hours 2 years Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 DPSG CD03523 41 19 15JUL09 1 5 1 Slowly open the radiator cap 2 Remove engine block drain plug A Lu 1 2 2 x o O x DPSG CD03523 41 19 15JUL09 2 5 3 On POWERTech engines remove oil cooler housing drain plug B ZX016192 UN 11JAN99 ZX016192 Continued on next page DPSG CD03523 41 19 15JUL 09 3 5 072209 45 1 PN 86 156 263 Maintenance 2500 hours 3 years 10 11 12 13 Open radiator drain valve C Drain all coolant from radiator Close all drain o
215. ontrol Unit Connectors Clean IMPORTANT Do not open control unit and do not clean with a high pressure spray Moisture dirt and other contaminants may cause permanent damage Keep terminals clean and free of foreign debris Moisture dirt and other contaminants may cause the terminals to erode over time and not make a good electrical connection RG16946 UN 31MARO09 If a connector is not in use put on the proper dust cap or an appropriate seal to protect it from foreign debris and moisture X o he wiring harness terminals and connectors for Control units are not repairable electronic control units are repairable Since control units are the components LEAST likely to fail isolate failure before replacing by completing a diagnostic procedure See your John Deere dealer DX WW ECUOA 19 11JUN09 1 1 072209 50 2 PN 89 159 263 Maintenance As required Clean or replace air filter one piece Clean air filter when restriction indicator is red Air filter can be cleaned up to six times Thereafter or at least once a year it must be replaced Proceed as follows 1 Thoroughly clean all dirt around air filter area 2 Loosen clamp B then remove air filter IMPORTANT Never reinstall an air filter which shows evidence of bad condition punched dented allowing no filtered air to enter the engine CD30766 UN O6SEP99 3 Clean air filter with compressed air working from clean to dir
216. oor load distribution Check the load distribution Damage to slide or to guide rings Replace the faulty parts and grease Remove the corrosion and grease When starting the trailer holds back the Tie rod damaged We ied DOE soldat due settings towing vehicle Replace the damaged parts and adjust Linkage damaged or incorrectly set the settings Adjust the setting Parking braking too weak Notched sector damaged ieu Aoust SUIS Lever ratchet worn Replace the lever and adjust the setting Cable ruptured Replace the cable and adjust the setting 33 263 4 8 Electrical connection diagram 2 white side lights on 2 two coloured flexible support side marker lights 2 x 6 function rear lights depending on model depending on model depending on model i 7 metal pin male plug 2 x 2 conductor cables 2 plate lights Metal socke connector c 7 conductor cable _ 2x2 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 TYRES COMPLETE WHEELS Dimensions Indices Diameter mm Cross section Radius under Load Pressure mm load Kg bar mm 165814 98N G2 172 28 650 38 155 70 R12 100 N 525 155 244 650 6 25 800 185 14 102 P 650 188 316 675 45 850 195 R 14
217. or 25 2 1 2 Setting potentiometers function Delivrery position Quadrature droop operation with 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 60 Hz 2 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 2596 to 5096 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 in steady state LEROY 6 SOMER 236 263 LEROY SOMER Installation and maintenance RA38 A V R LAM action eliminated by cutting the ST5 2 4 Typical effects of the LAM with jumper a diesel engin
218. or mixing with ethylene glycol and propylene glycol base engine coolant concentrate A 50 mixture of propylene glycol engine coolant in water provides freeze protection to 33 C 27 F If protection at lower temperatures is required consult your John Deere dealer for recommendations Water quality The coolant concentrate shall be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system John Deere COOL GARD meets this IMPORTANT Do not use cooling system sealing requirement additives or antifreeze that contains Freeze protection sealing additives 50 mixture of ethylene glycol engine coolant in water IMPORTANT Do not mix ethylene glycol and provides freeze protection to 37 C 34 F propylene glycol base coolants DX COOLS8 19 16NOV01 1 1 072209 10 3 PN 36 106 263 Fuels Lubricants and Coolant Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol IMPORTANT Water may be used as coolant base engine coolants emergency situations only Always use a recommended glycol base engine coolant even when operating in geographical areas where freeze protection is not required Foaming hot surface aluminum and iron corrosion scaling and cavitation will occur when water is used as the coolant even when John Deere COOL GARD II Premix is available in a coolant conditioners are added concentration of 50 ethylene gl
219. orage Engine storage guidelines Preparing engine for long term storage Removing engine from long term storage Specifications General engine pack specifications Non Emission Certified Engines General engine pack specifications Stage 1 Emission Certified Engines Page General engine pack specifications EPA Tier 2 Emission Certified Engines 65 6 General engine pack specifications EPA Tier 3 Emission Certified Engines 65 7 Unified Inch Bolt and Screw Torque Values 65 8 Metric Bolt and Screw Torque Values 65 9 76 263 072209 PN 2 Identification Views Identification views 2 5 2 2 T CD30840 30290 128 Continued on next page DPSG CD03523 3 19 22JAN07 1 3 072209 01 1 PN 7 77 263 Identification Views L a M Te i Y i a E d 1 1 M id E 2 lt 3 i D I CD30841 z 4045HF158 Continued on next page DPSG CD03523 3 19 22JANO07 2 3 072209 01 2 PN 8 78 263 Identification Views CD30842 CD30842 UN 10JAN03 6068HF258 DPSG CD03523 3 19 22JAN07 3 3 072209 0 1 3 PN 9 79 263 Maintenance Records Using maintenance records To obtain the best performance ec
220. ortable loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine TS206 UN 23AUG88 DX WEAR 19 10SEP90 1 1 Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises TS207 UN 23AUG88 DX NOISE 19 03MAR93 1 1 072209 05 4 PN 29 99 263 Safety Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with John Deere equipment include such items as lubricants coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques Check the MSDS before you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment TS1132 UN 26NOV90 See your John Deere dealer for MSDS s on chemical products used with John Deere equipment DX MSDS NA 19 03MAR93 1 1 Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all times M
221. orted Cylinder 1 balancing error mechanical failure Cylinder 1 unknown error mechanical failure 255 263 Po 9 Cylinder 2 injector status BE Injector outside the specifications Recalibration of the injectors required Injector outside the specifications required Short circuit high side to low side or low side to Short circuit high or low side to ground CID Volvo Cylinder 2 circuit open Cylinder 2 circuit shorted Cylinder 2 balancing error mechanical failure Cylinder 2 unknown error mechanical failure Cylinder 3 injector status Recalibration of the injectors required Recalibration of the injectors required Injector outside the specifications Injector outside the specifications Short circuit high side to Short circuit high side to low side or low side to Short circuit high or low side to ground Cylinder 3 circuit open Cylinder 3 circuit shorted Cylinder 3 balancing error mechanical failure Cylinder Z3 unknown error mechanical failure Cylinder 4 injector status Injector outside the specifications e edo required Injector outside the specifications RECANO ANON Re required Short circuit high side to side to Cylinder 4 circuit open Cylinder 4 circuit shorted failure failure mem NEM NEM oco 256 263 9 Cylinder 5 injector status BE Injector outsi
222. ould 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 Dry batteries do not require any servicing Batteries ready for use must be recharged at the latest when the acid density drops below 1 20 8 1 Storage and transport 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 Leave the terminal cover on the positive terminal 62 263 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 Ge Temperature when activated gt 10 C Fill with acid to the mark or about 1 cm above the edge of the plates yes battery becomes hot wait 5 to 20 mins charge 10 mins 8 3 Check EE e
223. ove 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 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 4 6 7 Accessing the main field and stator 4 6 7 1 Dismantling Follow the procedure for dismantling the bearings see sections 4 6 5 1 and 4 6 6 1 Remove the coupling disc single bearing alternator or the DE shield two bearing alternator and insert a tube of the corresponding diameter on the shaft end Rest the rotor on one of its 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
224. peed and non starting fault pictograms are used to display the fault The battery pictogram is used to display the alternator charge fault and to indicate the battery voltage VVVV 39 263 6 2 2 Manual starting Check that the generating set circuit breaker has triggered Connect the generating set battery Turn the key switch to the ON position without forcing it All of the LEDs light up for 2 seconds to confirm that they are operating correctly If the LEDs do not light up check the protection fuse and replace it if necessary All the items on the screen are displayed for 2 seconds Only the ON LED remains lit to indicate that the module is powered up The following screen appears hob S E The first line displays motor speed in RPM i The second line displays the battery voltage in volts V Check the battery voltage min 12 V e Press once briefly the green START button v fthe motor is equipped with an air preheating system there is a 10 second delay before the motor starts preheating activation period v The EM screen appears 1000 The third line displays the air preheating time 11 remaining with pictograms representing a iu 5 resistor and an hourglass v fthe motor is not fitted with an air preheating system or once the preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to start up the engine v
225. performed with the machine stopped Factory connection Winding 6 7 3 phases 50 Hz R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 110 V gt T2 Winding 3 phases 60 Hz 190 208 190 240 380 415 380 480 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 380 V gt T2 LEROY SOMER 201 263 LSA 43 2 44 2 4 POLES ALTERNATORS Winding 50Hz 60Hz 220 240 220 240 R 250 voltage sensing 0 gt T1 110 V gt T4 R 438 voltage sensing 0 gt T10 220 V gt T1 220 240 220 240 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 R 250 voltage sensing 0 gt 8 110 V gt T11 R 438 voltage sensing 0 gt T3 110 V gt T2 Winding Winding FOR LSA 44 2 THE COUPLING IS NOT POSSIBLE Connection not 50 Hz 60 Hz 6 220 240 220 240 R 250 voltage sensing 0 gt 8 110 V gt T11 R 438 voltage sensing LM voltage 1 2 LL voltage 0 gt T3 220 V gt T2 LEROY 8 SOMER 202 263 15 43 2 44 2 4 POLES ALTERNATORS SINGLE PHASE 4 WIRE type M or M1 DEDICATED WINDING SERIAL CONNECTION PARALLEL CONNECTION Not possible with LSA 44 2 T3 T4 Voltage 50 60Hz 115 2 3 2 3 120 251 voltage sensing 0 gt T1 110 V gt T2
226. power plant s and frequency gensets Warning message for setting offset on all of the power plant s generating sets G 13 1 Esc 54 263 6 3 2 Starting Check that the generating set circuit breaker has triggered Connect the generating set battery Turn the key switch to the ON position without forcing it to the ON position the ON lamp will light up if the lamp does not light up check and replace the fuse if necessary Test the Alarm and Fault LEDs menu 15 TEST LAMPS 1 ACTIONS 1 5 11 MANUAL AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS GS OK Esc Press Esc several times to return to the following home menu OPERATION MANUAL Press START to start 24 08 2005 G Check the battery voltage Q Press START AVAILABLE POWER AIR PREHEATING START UP 100 096 10 seconds 24 08 2005 24 08 2005 24 08 2005 13 12 The following pictogram is displayed f the engine is equipped with Warning the number of successive air preheating system there is and automatic starting attempts is delay adjustable before the limited to 3 engine starts preheating 2 SP activation period The following pictogram will flash The following information is displayed f the motor is not fitted with an air preheating system or once the m Speed of rotation preheating delay has elapsed the engine starts up start of a
227. 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 o 38 263 Figure 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 OF 6 2 1 1 Introduction to pictograms The pictograms are as follows Operating temperature oymbols for electric and mechanical sizes Overspeed Non starting fault Battery a Starting on external command 0 Preheating __ gt Air intake Oil pressure Figure 6 3 View of pictograms The fuel level pictogram is used to display the fault the alarm and the fuel level The operating temperature and oil pressure pictograms are used to display the fault and analog value The overs
228. r Fan Exciter field Fixing screws Exciter field fixing 44 2 only Screw Earth terminal Exciter armature DE shield Diode crescent support Terminal block support AREP Shield on exciter end Terminal block Tie rod 43 2 Voltage regulator Tie rod 44 2 AVR Cover front panel AVR damper seal Cover rear panel Terminal block Cover top panel Hub 43 2 L7 amp 44 2 Fixing screws Coupling disc Fixing screws 43 2 Fixing screws 44 2 Clamping washer 43 2 S1 to L6 Spacer shim 43 2 L7 amp 44 2 only Bearing retainer fixing Diode bridge screw assembly Cable gland washer 43 2 only Circlips O ring Inner bearing retainer End shield Rotor assembly Air outlet grille Air intake grille Inspection door DE bearing Surge suppressor LEROY SOMER 21 215 263 15 43 2 44 2 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006 42 CE dated 17 May 2006 MOTEURS LEROY SOMER MLS HOLICE STLO SRO MOTEURS LEROY SOMER Boulevard Marcellin Leroy SLADKOVSKEHO 43 1 rue de la Burelle 16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517 France Czech Republic 45800 St Jean de Braye France Declares hereby that the electric generators of the
229. rch Remove paint before heating Remove paint a minimum of 100 mm 4 in from area to be affected by heating If paint cannot be removed wear an approved respirator before heating or welding e f you sand or grind paint avoid breathing the dust Wear an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating Do not use a chlorinated solvent in areas where welding Will take place X9811 UN 23AUG88 DX FLUID 19 03MAR93 1 1 lt gt 1 2 2 0 H DX TORCH 19 10DEC04 1 1 TS220 UN 23AUG88 Do all work in an area that is well ventilated to carry toxic fumes and dust away Dispose of paint and solvent properly 05 7 102 263 DX PAINT 19 24JUL02 1 1 072209 PN 32 Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer Components in products that m
230. re 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 243 263 13 LEROY SOMER R438 NOTES LEROY 14 SOMER 244 263 LEROY SOMER R438 NOTES LEROY SOMER 15 245 263 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOUL ME CEDEX FRANCE 338 567 258 RCS ANGOULEME S A au Capital de 62 779 000 www leroy somer com 246 263 9 3 Appendix Common spare parts GenPARTS Starter motor solenoid 330361644 Radiator cap 31802000304 Alternator diode 330360144 Fan belt 330360183 Thermostat 330360012 Thermostat seal 330361286 Alarm oil pressure sensor 330360059 Alarm water temperature sensor 330360060 330910115 GENLUB 330910095 330910098 330910099 GENCOOL 330910100 247 263 330570116 330570115 330560552 330510015 330560613 Di
231. release to reset indicator 3 Thoroughly clean all dirt from inside canister 7 Check air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM DPSG CD03523 58 19 22JAN07 1 1 072209 90 4 91 161 263 Maintenance As required Replacing fan and alternator belt 4045 and 6068 Engines NOTE Refer to CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR for additional information on the belt tensioner Inspect belts for cracks fraying or stretched out areas Replace if necessary On engines with automatic belt tensioner release tension on belt using a breaker bar and socket on tension arm On engines with manual tensioner loosen cap screws holding the alternator CD30769 UN 01SEP99 Remove poly V belt from pulleys and discard belt Installation on 4045 engines Install new belt making sure belt is correctly seated in all pulley grooves Refer to routing at right for your application Apply tension to belt See CHECKING BELT T Start engine and check belt alignment ALT Alternator I Idler Pulley CP Crank Pulley T Tensioner FD Fan Drive WP Water Pump O O A 0 gt 1 2 2 we O Installation on 6068 engines DPSG CD03523 45 19 31JAN07 1 1 Bleeding the fuel system CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines
232. removing the terminal box lid 48 To access the AVR adjustment potentiometers the side plate 367 should be removed 4 6 5 Replacing the NDE bearing 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 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 4 6 5 2 Reassembly Heat the inner slipring of a new bearing by induction or in a drying oven at 80 C do not use an oil bath and fit itto the machine Place the preloading wavy washer 79 in the shield and fit a new O ring seal 349 Refitthe NDE shield and pass the bundle of wires between the top bars of the shield Refit the fixing clamps on the cables the R 791 module and the connector Refit the air intake grille 51 Replace the terminal box lid 48 LEROY 14 SOMER 208 263 LSA 43 2 44 2 4 POLES ALTERNATORS NDE shield Rotor Screw rod WARNING When dismantling the shields you will need to change the antifriction bearings the ring seal the preloading wavy washer and adhesive paste 4 6 6 Replacing the DE bearing 4 6 6 1 Dismantling Uncouple the alternator from the prime mover Remove the 8 assembly screws Rem
233. rifices after coolant has drained Fill the cooling system with clean water Run engine until water passes through the thermostat to stir up possible rust or sediment Stop engine and immediately drain the water from system before rust and sediment settle After draining water close all drain orifices and fill the cooling system with cleaning product such as PMCC2610 or PMCC2638 Cooling System Cleaners available from your John Deere Dealer Follow manufacturer s directions on label After cleaning the cooling system drain cleaner and fill with water to flush the system Run engine until water passes through the thermostat then drain out flushing water Check cooling system hoses for proper condition Replace as necessary Close all drain orifices and fill the cooling system with specified coolant see DIESEL ENGINE COOLANT When refilling cooling system loosen temperature sensor B or plug at the rear of cylinder head to allow air to escape Run engine until it reaches operating temperature then check coolant level and entire cooling system for leaks 45 2 157 263 CD30765 UN 27AUG99 Cooling system capacity Engine Model Cooling system capacity 3029DF 128 3029TF120 3029TF158 3029 570 3029TF270 3029 570 3029HFU70 3029TFU70 14 5 L 15 5 qt 4039DF008 4039TF008 16 5 L 17 5 qt 4045DF 158 20 L 21 qt 4045TF120 4045TF158 4045TF220 4045TF258 4045HFS8
234. rious 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 ofthe 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 232 263 LEROY SOMER Installation and maintenance R438 A V R CONTENTS PY 8 4 1 1 AREP excitation system 4 1 2 PMG excitation 556 5 1 3 SHUNT or separate excitation 5 M 6 Ale GN R 6 2 2 Frequency compared with voltage 6 2 3 LAM Load Acceptance Module 6 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only T 2
235. ror Pump detected communication error O ECU Pumptimingstatus timing status ECU Pump timing moderately out synchronisation BN ECU Pump timing speed synchronisation 34 NN ECU Pump timing extremely out of synchronisation Hes x Sensor supply volage 8 Vor Analog trot reference sensor Sensor supply voltage pressure Coolant temp fuel pressure 5V sensor supply 2 DTT shutdown es E anoj J O 0 DH amj 268 JChekpaametes 0 0 Lo p 136 151 ECU Temperature NH eveseseesmewm Ecu temperature 1172 Input temperature of the TGV compressor za voltage of the temperature sensor chort to V HI M low Turbine temperature moderately high ShottoV 1189 173 Exhaust gas temperature sensor O Z o Z Status of the pressure system of the common rail w L Pwmeeonmolvavestaus Pomp conroivave curenthign Pump contol valve enormi ra pressure controleror Oooo Pump control valve fuel fow notdetected John Deere Volvo 19
236. s DTCs Intermittent fault diagnostics 05 13 Active engine service codes viewing 15 7 Stored service codes viewing 15 5 L Diagnostic Trouble Codes DTOs 55 11 181 N 55 10 Listing of DITOS oo unco oe be eie us 05 11 Diesel engine 10 2 Lubricant TUG lucite LE 10 1 MIKINO meet 10 3 DTCs Diagnostic Trouble Codes SOFAS NEED 10 3 View active service 15 7 View stored service 15 5 M E Maintenance 1000 hours 1 year Engine Check and adjust valve clearance 3029 Op ratiO E c e PUMP MAL EA E 15 29 and 4099 engllieS imperia 35 3 Engine Control Unit ECU serial 03 5 Checking air intake system 35 1 Engine oil Checking automatic belt tensioner 10 2 4045 6068 Engines 35 2 RE ERE 10 2 Cleaning crankcase vent tube 35 1 30 1 Pressure testing cooling system 35 5 Engine speed Mechanical fuel system 40 3 Continued on next page Index 1 E 189 263 2000 hours 2 years Engine option codes 03 3 Adjust spee
237. s for Generator Sets Saran Built OMCD16564 ISSUE 69 ANGLAIS CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The State of California requires the above two warnings John Deere Usine De Saran This manual replaces OMCD16564 F8 European Version PRINTED IN GERMANY 71 263 Foreword THIS MANUAL COVERS the following engines for generator sets Non Emission Certified Engines Mechanical Fuel System CD3029DF 120 CD3029DF 128 CD3029TF120 CD3029TF158 CD4039DF008 CD4039TF008 CD4045DF 158 CD4045HF 120 CD4045HF 158 CD4045TF120 CD4045TF158 CD4045TF220 CD4045TF258 CD6068HF 120 CD6068HF 158 CD6068HF 258 CD6068TF158 CD6068TF220 CD6068TF258 Emission Certified Engines Stage Il according to Directive 97 68 EC CD3029HFS 70 Mechanical Fuel System CD3029HFU70 Mechanical Fuel System CD3029TFS70 Mechanical Fuel System CD3029TFU70 Mechanical Fuel System CD4045HFS 72 DE10 Fuel System CD4045HFS73 HPCR System 2 Valve Head CD4045HFU72 DE10 Fuel System CD4045HFU79 HPCR System 2 Valve Head CD4045TFS70 Mechanical Fuel System CD4045TFU70 Mec
238. several different methods for displaying both stored and active DTCs from the ECU via a fault lamp or a diagnostic gauge on the electronic instrument panel 2 DIGIT CODES The FMI identifies the type of failure that has occurred Some engines display Service Codes or DTCs as 2 digit for example FMI 03 indicates value above normal codes read from a fault lamp which gives blink codes Combining SPN 000110 with FMI 03 yields engine coolant temperature input voltage too high or the equivalent of SPN FMI CODES 2 digit fault code 18 Stored and active diagnostic trouble codes are output on If diagnosing an application that shows DTCs as SPNs the diagnostic gauge on the Deere electronic instrument FMISs using the following list determine the equivalent panel according to the J1939 standard as a two part code 2 digit code and have your dealer use the diagnostic as shown on the tables on the following pages procedure in the component technical manual for that 2 digit code The SPN identifies the system or the component that has the failure for example SPN 000110 indicates a failure in the engine coolant temperature circuit The first part is a six digit Suspect Parameter Number SPN followed by a two digit Failure Mode Identifier FMI Always contact your servicing dealer for help in correcting code In order to determine the exact failure both parts diagnostic trouble codes which are displayed for your SPN and of the code are n
239. sing the wheel STOP button press to switch off the generating set START button press to switch on the generating set Power ON LEDs and alarm fault warning LEDs Location of USB ports Mounting bolt LCD for displaying alarms and faults operating statuses electrical and mechanical quantities ESC button for returning to the previous selection and for default RESET function MENU button for accessing the menus Lighting for the emergency stop button 43 263 Figure 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 Figure 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 file transfer between PC and TELYS and vice versa main module power supply Protective cover 44 263 6 3 1 2 Description of the screen The screen is backlit and requires no contrast adjustments This screen is divided into 4 zones 4 Cu 888844 OR xc unn SERIAL 08030010000 SOFTWARE 5 3 5 r NOMINAL VOLTAGE 400V FREQUENCY 50Hz NOMINAL KW 320kW EARTH SYSTEM TNS Figure 6 7 description of the screen example Zone 1 O Zone 2 Zone 3 in this
240. specifications Non Emission Certified Engines ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight Engine oil quantity Engine coolant quantity With Fan Approximate ITEM Number of Cylinders Fuel Bore Stroke Displacement Compression Ratio POWER 1500 rpm Prime POWER 1500 rpm Standby POWER 1800 rpm Prime POWER 1800 rpm Standby Width overall Length overall Height overall Weight Engine oil quantity Engine coolant quantity With Fan UNIT OF MEASURE mm mm kW hp kW hp kW hp kW hp mm mm mm kg UNIT OF MEASURE mm mm kW hp kW hp kW hp kW hp mm mm mm kg 3029DF120 Diesel 106 5 110 2 9 17 2 1 27 36 30 41 30 41 35 47 519 716 819 316 6 14 5 40390 008 Diesel 106 5 110 3 9 17 8 1 35 48 38 52 41 56 47 64 588 1016 960 475 12 16 5 3029DF128 Diesel 106 5 110 2 9 17 2 1 26 35 30 41 30 41 34 46 582 888 931 345 6 14 5 4039TF008 Diesel 106 5 110 3 9 17 8 1 55 75 61 83 67 91 73 99 588 1016 979 487 12 16 5 3029 120 Diesel 106 5 110 2 9 17 2 1 3
241. ssor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage Y Engine with air preheating starting components never use starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube causing bodily injury Do not touch the lighting column lights when they are switched on Maintenance v Follow the maintenance table and its instructions 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 Goggles should be worn when carrying out maintenance operations and watches bracelets etc should be removed Fit only original parts Y Disconnect the battery and the pneumatic starter if fitted before undertaking any repairs to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt to start 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 Clean off any trace of oil fuel or coolant using a clean cloth Do not use a soapy solution containing either chlorine or ammonia as these two chemicals prevent bub
242. stem every 2500 hours 3 years when John Deere COOL GARD coolant is used Otherwise every 2000 hours 2 years Contact your dealer when thermostat or injection nozzles are suspected to be defective Replace injection nozzles every 5000 hours and thermostat every 10000 hours DPSG CD03523 26 19 25JAN07 1 1 072209 20 1 67 137 263 Maintenance Daily or every 10 hours Daily prestarting checks O O O O 2 2 S S 1 E z z 1 e LO LO N N e e e 3029 and 4039 engines O T 7 2 5 5 LO N 54 3 e e FDOO0047 A Do the following BEFORE STARTING THE ENGINE for IMPORTANT DO NOT fill above the crosshatch area the first time each day Oil levels anywhere within crosshatch are IMPORTANT DO NOT add makeup oil until the oil considered in the acceptable operating range level is BELOW the add mark 1 Check engine oil level on dipstick A Add as required using seasonal viscosity grade oil See DIESEL ENGINE OIL Add oil at rocker arm cover filler cap B Continued on next page DPSG CD03523 27 19 07FEB07 1 4 25 1 072209 PN 68 138 263 Maintenance Daily or every 10 hours TS281 UN 23AUG88 CD30756 UN 26AUG99 Remove radiator cap E and check coolant level which should be at bottom of filler neck Fill radiator A Explosive release of fluids with proper coolant solution if level is low See from pressurized cooling system ca
243. tall rocker arm cover and crankcase vent tube 4 Cylinder Engine NOTE Firing order is 1 3 4 2 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves c Rotate flywheel 360 Lock No 4 piston at compression stroke C d Adjust valve clearance on No 2 and 4 exhaust valves and No 3 and 4 intake valves 6 Cylinder Engine NOTE Firing order is 1 5 3 6 2 4 a Lock No 1 piston at TDC compression stroke B b Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves c Rotate flywheel 360 Lock No 6 piston at compression stroke C d Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves A Front of engine E Exhaust valve B No 1 Piston at TDC I Intake valve compression stroke C No 6 Piston at TDC compression stroke im iur A Front of engine B No 1 Piston at TDC compression stroke C No 4 Piston at TDC compression stroke RG7409 UN O6AUG96 RG4776 UN 310CT97 E Exhaust valve I Intake valve 40 2 153 263 RG4777 UN 310CT97 DPSG CD03523 36 19 31JAN07 2 2 072209 PN 83 Maintenance 2000 hours 2 years Checking engine speed Mechanical fuel system NOTE Most engines for generator set application 1500 rpm for 50 Hz or 1800 rpm for 60 Hz run only
244. tector must be important returned to its factory settings and this must be checked by trained personnel Any modification to this setting could endanger personnel Any modification would render the user liable and 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 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 The resistance value is calculated in the following way Er Maximum resistance value of the earth socket R O according to the differential unit operational current operation time should not be longer than 1 second An RE R R differential Ul V Ul e V 100 mA 300 mA 500 mA The UI value 25 V is required for work site installations and livestock buildings etc For a default voltage of 25 V and a default current of 30 mA this rod must be of a minimum length of see table below Length of Nature of ground rod in metres qm moist compact ballast emma Gravel coarse ballast Bare stonv soils drv sand To obtain an equivalent length you can use several earthing rods y ud 3 6 connecte
245. tered and patents applied for LEROY 2 SOMER 196 263 LEROY SOMER Installation and maintenance LSA 43 2 44 2 4 POLES ALTERNATORS CONTENTS imc 4 1 1 Standards and safety 4 iE PRENNENT 4 OC CMGI ARNO Marlo TT T o 4 4 4 10 12 9 4 2 TECHNICAL CHARACTERISTICS ava uiuo rig adus 5 2 1 Ele trical characteristiCS reus 5 2 2 5 SEN TN 6 SEE Tia UU 6 3 2 Checks prior to first use T E T 3 3 Terminal connection T 3A COMMISSIONING NUES 10 E 10 4 SERVICING 11 4 1 Safety measures Se UNE Da 11 4 2 Routine maintenance 11 4 3 Fault GOTO COM we MM 11 4 4 Mechanical defects 2 12 4 5 EIS ETSI C
246. tery ies RG4698 UN 14DEC88 24 Volts System 6 Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first A 12 Volt Machine battery C Booster cable ies D Cable to starter motor B 12 Volt Booster battery ies DPSG CD03523 20 19 22JAN07 1 1 15 28 PN 65 135 263 Operating the Engine Engine operation Warming engine Operate engine at high idle for 1 to 2 minutes before applying the load NOTE This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed Normal engine operation Compare engine coolant temperature and engine oil pressure with specifications below Specification Minimum oil pressure at full load rated speed 275 kPa 2 75 bar 40 psi Coolant temperature range Temperature 82 94 C 180 202 F Stop engine immediately if coolant temperature is above or oil pressure below specifications or if there are any signs of part failure Symptoms that may be early signs of engine problems could be e Sudden loss of power at normal operating temperature of 115 C 240 F Standby power units To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 0 load for 30 minutes every 2 Stopping the engine 1 Before stopping run engine
247. tion data ENGINE SPEED PT 1 1000 RPM A o o 1 2 NU O X Use Arrow Keys To Scroll OURGP11 00000AB 19 03SEP03 4 6 5 Press the Menu key to return to the main menu ENGINE SPEED PT 1 1000 RPM RG13167 UN 29SEP03 Return To Main Menu Continued on next page OURGP11 00000AB 19 03SEP03 5 6 072209 15 4 PN 41 111 263 Operating the Engine 6 Press the Menu key to exit the main menu and return 1000 RPM to the engine parameter display s 1800 RPM TEMP 14 2 PSI RG13159 UN 26SEP03 Exit Main Menu OURGP11 00000AB 19 03SEP03 6 6 Accessing Stored Trouble Codes 1000 RPM ENG EP NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine 14 2 57 PSI start up is desired See Starting The Engine All VOLT PENES of the engine values illustrated on the diagnostic gauge indicate the engine is running RG13159 UN 26SEP03 For description of trouble codes see chart in Troubleshooting Section Menu Key 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AC 19 03SEP03 1 6 The main menu will be displayed Use the Arrow keys to scroll through the menu until Stored Codes is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKL
248. tions Sulfated or worn out batteries Solution Remove accessories or install higher output alternator Increase engine rpm when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections oee your authorized servicing dealer or engine distributor otretched poly V belt or defective belt Adjust belt tension or replace belts tensioner Engine under load Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse Low battery output Crankcase oil too heavy Loose or corroded connections Faulty battery connection Continued on next page 55 8 172 263 Remove load Clean and tighten loose connections oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor Replace fuse oee your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections Clean and tighten connections DPSG CD03523 50 19 22JAN07 1 2 072209 PN 102 Troubleshooting Symptom Problem Solution Sulfated or worn out batteries oee your authorized servicing dealer or engine distributor Blown fuse Replace fuse DPSG CD03523 50 19 22JAN07 2 2 Displaying Of Diagnostic Trouble Codes DTCs There are
249. tions observing the voltage between E and E approx 10V D C LEROY SOMER 9 239 263 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 1590 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 51 52 Potentiometer P1 quadrature droop in centre position Apply the rated load cos 0 8 inductive The voltage should drop by 2 to 3 If it in creases check that V and W and also 51 and S2 have not been reversed The no load voltages should be identical for all the alternators intended to run in pa rallel Couple the machines in parallel By adjusting the speed try to obtain 0 KW power exchange By altering the voltage setting P2 on one of the machines try to cancel or minimise the current circulating between the machines From now on do not touch the voltage set tings m Apply the available load the setting is only correct if a reactiv
250. to relieve pressure before removing completely Test Radiator Cap 1 Remove radiator cap and attach to 0051045 tester as shown Pressurize cap to specification listed Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable If gauge does not hold pressure replace radiator cap Specification Radiator Cap 70 kPa 0 7 bar 10 psi for 10 seconds minimum 3 Remove the cap from gauge turn it 180 and retest cap to confirm measurement Test Cooling System NOTE Engine should be warmed up to test overall cooling system 35 5 RG6557 UN 20JAN93 RG6558 UN 20JAN93 Test cooling system 1 Allow engines to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level IMPORTANT DO NOT apply excessive pressure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck Pressurize cooling system to specification listed for radiator cap With pressure applied check all cooling system hose connections radiator and overall engine for leaks If leakage is detected correct as necessary and pressure test system again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket Have your engine d
251. tor stamp DPSG CD03523 63 19 22JAN07 1 1 02 5 84 263 072209 PN 14 Maintenance Records 4500 Hours of operation Engine oil drain Vibration damper replace 6 cyl n Fuel filter replace Belt check tension and wear 300 Series and POWERTech with manual tensioner Valve clearance adjust 300 Series Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 64 19 22JAN07 1 1 5000 Hours of operation Engine oil drain Injection nozzles replace Engine oil filter replace n Air intake system check Fuel filter replace Cooling system drain and flush if COOL GARD is used Check belt and tensioning system Crankcase vent tube clean Number of hours Observation Dealer or distributor stamp Job done by DPSG CD03523 65 19 22JAN07 1 1 0 2 6 072209 15 85 263 Maintenance Records 5500 Hours of operation Engine oil drain Engine oil filter replace n Fuel filter replace manual tensioner Valve clearance adjust 300 Series Belt check tension and wear 300 Series and POWERTech with Number of hours Job done by Observation Dealer or distributor stamp 6000 Hours of operation DPSG CD03523 66 19 22JAN07 1 1 Engine oil drain Engine oil filter replace n Fuel filter replace Check belt and te
252. ttons To Scroll Quadrant Display OURGP11 00000A9 19 03SEP03 5 5 Engine Configuration Data 98 1000 RPM ENG NOTE The engine configuration data is a read 1800 RPM TEMP 14 2 PSI only function NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine 1 running Menu Key RG13159 UN 26SEP03 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AB 19 03SEP03 1 6 The main menu will be displayed Use the Arrow GO TO 1 UP DISPLAY keys to scroll through the menu until Engine Config is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS RG13164 UN 070CT03 Select Engine Configuration Continued on next page OURGP11 00000AB 19 03SEP03 2 6 072209 15 3 PN 40 110 263 Operating the Engine 3 Once Engine Config menu item has been highlighted TO 1 UP DISPLAY 7 TO 1 UP DISPLAY press the Enter key to view the engine configuration STORED CODES data ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13165 UN 020CT03 Oc Enter Key OURGP11 00000AB 19 03SEP03 3 6 4 Use the Arrow keys to scroll through the engine configura
253. ty side NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi Mark air filter to keep track of each cleaning operation Fully depress air restriction indicator reset button and release to reset indicator Check air system entirely for proper condition see CHECKING AIR INTAKE SYSTEM RG9912 UN 25FEB99 DPSG CD03523 44 19 22JAN07 1 1 072209 50 3 PN 90 160 263 Maintenance As required Clean or replace air filter element CD30772 UN 27AUG99 A Primary element B Secondary safety element restriction indicator D Wing nut Clean air filter when restriction indicator C is red Replace both primary A and secondary B filter elements after primary element has been cleaned six times or at least once a year IMPORTANT If primary element shows evidence of bad condition punched dented replace both the primary and the secondary elements Proceed as follows 4 Clean primary element with compressed air working from clean to dirty side 1 Thoroughly clean all dirt around air filter area NOTE Compressed air pressure must not exceed 2 Remove wing nut D and remove primary element 600 kPa 6 bar 88 psi A from canister IMPORTANT Do not attempt to clean the secondary 5 Mark air filter to keep track of each cleaning operation safety element B It must be only 6 Fully depress air restriction indicator reset button and replaced as recommended
254. ty of cyclic irregularity Loose terminals Faulty A V R Speed too low on load or U F gradient set too high Voltage correct at no load and too low when on load Run at no load and check the voltage between E and E on the A V R Check the speed or U F gradient set too high Faulty rotating diodes Short circuit in the main field Check the resistance Faulty induced excitaion Warning For single phase operation check that the sensing wires coming from the A V R are correctly connected to the operating terminals see the alternator manual Voltage disappears during operation Check the A V R the surge suppressor the rotating diodes and replace any defective components The voltage does not return to the rated value Exciter winding open circuit Faulty induced excitation Faulty A V R Main field open circuit or short circuited Warning after setting up or trouble shooting replace all access panels or covers LEROY SOMER 227 263 LEROY SOMER R250 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 019 4 2 Technical support service Our technical support service willbe pleased to help you with any information needed For replacement part orders it is necessary to indicate the type and the code number of the A V R Please contact your usual correspondant An extensive net
255. types LSA 36 37 40 42 2 43 2 44 2 46 2 47 2 49 1 50 2 51 2 as well as their derivatives manufactured by Leroy Somer or on Leroy Somer s behalf comply with the following International Standards and Directive EN and IEC 60034 1 and 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with the Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the following International Directives Machinery Directive Nr 2006 42 CE dated 17 May 2006 EMC Directive Nr 2004 108 CE dated 15 December 2004 as intrinsic levels of emissions and immunity are concerned WARNING The here above mentioned generators should not be commissioned until the corresponding Gen Sets have been declared in compliance with the Directives Nr 2006 42 CE et 2004 108 CE as well as with the other relevant Directives Leroy Somer undertakes to transmit in response to a reasoned request by the national authorities relevant information on the generator Technical Managers P Betge J Begu 4152 en 2010 11 d LEROY 22 SOMER 216 263 15 43 2 44 2 4 POLES ALTERNATORS LEROY SOMER 23 217 263 LEROY SOMER
256. uctions so as to avoid the risk of accidents and to maintain the machine 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 personal protective equipment appropriate for mechanical and electrical hazards Before any intervention on the machine ensure that it cannot be started by a manual or automatic system and that you have understood the operating principles of the system 4 2 Routine maintenance 4 2 1 Checks after start up After approximately 20 hours of operation check that all fixing screws on the machine are still tight plus the general state of the machine various electrical connections in the installation 4 2 2 Bearings The bearings are permanently greased and they have a life of 20 000 hrs or 3 years As an option they are regreasable for the LSA 44 2 It is advisable to lubricate the alternator during operation and when it is first commissioned The lubrication characteristics are given in the table below NDE DE bearing 6315 C3 6309 C3 30grorcm 15grorcm Quantity of grease Lubrication interval 6000 h 10000h 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
257. uel filter s must only be bled when the engine is stopped and cold Note Engines with a mechanical supply circuit have a single fuel filter whilst electronically controlled engines DE10 and high pressure common rail fuel circuits have two fuel filters primary and final In addition fuel filters in electronically controlled engines may be fitted with a water presence sensor An indicator on the instrument panel warns the operator that the water must be drained from the filter cup Inspect fuel filters C and D as follows in order to detect any traces of water or debris Place a suitable container under the drain plug s A at the bottom of the fuel filter s or cup s Undo the drain plug s A at the bottom of the fuel filter s or cup s by two or three turns Loosen the air drain plugs s B by two full turns and drain the water into the container When the fuel begins to flow out tighten the drain plugs Bleed the supply circuit A Drain plug Air bleed plug C Main fuel filter D Final fuel filter 37 263 6 2 Generator set with NEXYS control panel 6 2 1 Control panel presentation MICS on amp A A ERI Figure 6 1 View of the front side Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for starting up shutting down the module and RESET function Electronic card
258. unctioning Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oll level Continued on next page 55 5 169 263 Solution Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Have authorized servicing dealer or engine distributor check injectors Remove and check thermostat Check gauge sender and connections Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat oee your authorized servicing dealer or engine distributor Have authorized servicing dealer or engine distributor check injectors oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor oee your authorized servicing dealer or engine distributor Clean or replace fuel hose oee your authorized servicing dealer or engine distributor Add oil DPSG CD03523 49 19 22JANO07 2 4 072209 PN 99 Troubleshooting Symptom High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Engine overheats Problem Improper type of oil Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Improper type of fuel Low engine temperature De
259. using the activation of the control unit performing insulation the generating set stops immediately Underspeed fault indicates an incorrect rotation speed below 1000 rpm Emergency stop or external emergency stop fault 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 Low fuel level alarm Indicates the need to fill up with fuel Alternator charging fault alarm indicates a problem affecting the alternator charging rate EN List of faults which will cause the generating set to stop and generate a fault code Associated message 42 263 Associated message Associated message Associated message Associated message Associated pictogram 01 Associated pictogram 6 3 Generator set with TELYS control panel 6 3 1 Control panel presentation 6 3 1 1 View of the front panel OON OD O12 C 9 9 9 8 Figure 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 pres
260. ut 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 sets some engines may be fitted with specific electrical wiring different to that described in the
261. ut missing Not informed by VOLVO Pump position sensor cam position sensor input pattern error o 254 263 e Description Comment Crank position sensor Speed sensor flywheel Crank position input noise 63 a go Permanent loss of signal High impedance of the position sensor or open circuit Sensor short to ground Crank position Cam position out of synchronisation Crank position input missing r Not informed by VOLVO Crank postion sensorinputpatiem enor reso mr ze Communicationstatus SCS 2 gg ev e Mj 6 lossotmessagecnor Engine shutdown vehiciestatus Nl engine shutdown vehiclerequest OOo jSwyvotagofheTuboacwaorlow a and the actuator OSS S 07 L j Faswmpy 35 Short circuit to earth ENN g ele Recalibration of the injectors required Recalibration of the injectors required Injector outside specifications Injector outside specifications Short circuit high side to B Short circuit high side to low side or low side to B Short circuit high or low side to ground Cylinder 1 circuit open Cylinder 1 circuit sh
262. verned by standard NFC 15 100 France or by the standards in the relevant country based on international standard IEC 60364 6 61 They must also adhere to the regulations in the NFC 15 401 application guide France or to the regulations and standards in the relevant country b Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose The cable cross section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation The choice of conductors must comply with international standard IEC 30364 5 52 Three phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors or single conductor joined when precision 4X 1 Cable type PVC 70 e g HO7RNF Ambient temperature 30 Circuit breaker Cable sizes calibre 51 100m 101 150m mm AWG 4 10 6 9 6 9 10 7 10 7 16 5 16 5 25 3 25 35 2 4 1 50 0 1 4 1 50 0 4 1 50 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 2250MCM 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 h
263. with the original one Monitor the temperature rise in the bearings see section 4 4 4 2 3 Electrical servicing Commercially available volatile degreasing agents can be used WARNING Do not use trichlorethylene perchlo rethylene trichloroethane or any alkaline products These operations must be performed ata cleaning station equipped with a vacuum system that collects and flushes out the products used The insulating components the impregnation system are not at risk of damage from solvents Avoid letting the cleaning product run into the slots Apply the product with a brush sponging frequently to avoid accumulation in the housing Dry the winding with a dry cloth Let any traces evaporate before reassembling the machine 4 2 4 Mechanical servicing WARNING Cleaning the machine using water or a highpressure washer is strictly prohi bited Any problems arising from such treatment are not covered by our warranty Degreasing Use a brush and detergent suitable for paintwork Dusting Use an air gun Ifthe machine is fitted with air inlet and outlet filters the maintenance personnel should clean them routinely at regular intervals In the case of dry dust the filter can be cleaned using compressed air and or replaced if it is clogged After cleaning the alternator itis essential to check the winding insulation see sections 3 2 and 4 8 4 3 Fault detection If when commissioned the
264. work of service centres is available to rapidly supply any necessary parts In order to ensure the correct operation and safety of our machines strongly recommend that original manufacturer s spare parts are used Failure to do so will discharge the manufacturer from liabilty in the case of damage LEROY 10 SOMER 228 263 LEROY SOMER R250 A V R LEROY SOMER 11 229 263 LEROY SOMER MOTEURS LEROY SOMER 16015 ANGOULEME CEDEX FRANCE 338 567 258 RCS ANGOULEME S A au Capital de 62 779 000 www leroy somer com 230 263 LEROY SOMER 3971en 2010 11 f l T1 T7 T4 710 R438 A V R Installation and maintenance 231 263 LEROY SOMER R438 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your A V R you can look forward to many years of trouble free operation SAFETY MEASURES Before using your machine for the first time itis important to read the whole of this instal lation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional infor mation you may require The va
265. xpected EN Fuel rail pressure not developed HE Fuel supply pressure moderately low Water in fuel sensor Water in fuel continuously detected Fuel supply pressure moderately high NENNEN Waterinfueldetecea _ Waterinfueldeteced Oil level sensor Oil level value below normal Oil level sensor input voltage high Short to Oil level sensor input voltage low Short to V Oil level sensor open circuit EMEN 249 263 Oil pressure sensor Engine oil pressure extremely low 7 Oil pressure sensor voltage high Short to V Engine oil pressure moderately low EE Oil pressure sensor input voltage low Short to V E L Ol pressure detected motor stopped Manifold air pressure sensor eee betow 2 Incoherent measurement of the oil pressure pressure sensor eHortioME COET pressure sensor Shorttov a I to peed sensor ign 1 O E O O TT speed signativaia Intermittent problem with speed T information voltage high voltage low a NEN input circuit Air inlet pressure sensor input voltage high Air inlet pressure sensor open circuit 250 263 Volvo Air filt
266. ycol However there are situations in warm temperature climates where a coolant with lower glycol concentration approximately 20 ethylene glycol has been approved In these cases the low glycol formulation has been modified to provide the same level of corrosion inhibitor as John Deere COOL GARD II Premix 50 50 Drain cooling system and refill with recommended glycol base engine coolant as soon as possible COOL GARD is a trademark of Deere amp Company DX COOL6 19 03NOVO08 1 1 1 0 2 4 072209 PN 37 107 263 Operating the Engine Using Diagnostic Gauge to Access Engine Information Optional equipment 2 Diagnostic Gauge A Diagnostic Gauge C Arrow Keys E Red STOP ENGINE B Menu Key D Enter Key Indicator Light F Amber WARNING Indicator Light NOTE Generator sets powered by an electronically e Coolant temperature controlled engine DE10 or HPCR fuel system Oil pressure can be optionally equipped with the diagnostic e hrottle position gauge shown Depending on the generator ntake manifold temperature set manufacturer other instrumentations Current fuel consumption can be used Refer to the generator set Active service diagnostic codes documentation for more information e Stored service diagnostic codes from the engine e Set the units for display The diagnostic gauge A allows the operator to view e View the engine configuration parameters many readouts of engine fu
267. ypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors Cable type PVC 70 e g HO7RNF Ambient temperature 30 mms m Cable sizes 101 150m mme AWG 10 7 16 5 25 3 25 3 35 2 50 0 50 0 70 2 0 __ 80 393572 OO 95 4 0 95 4 0 120 2250MCM 27 263 C Battery cables Install the battery or batteries in the immediate vicinity of the electric starter motor The cables will be connected directly from the battery terminals to the starter motor terminals The primary instruction to follow is to ensure that the polarities between the battery and starter motor match Never reverse the positive and negative battery terminals when connecting them This could cause severe damage to the electrical equipment The minimum cross section of the cables will be 70 It varies according to the power of the starter motor but also the distance between the batteries and the set voltage drops on the line d Safety guidelines References NFC 15 100 2002 France IEC 60364 5 54 In order to protect personnel against electric shocks this generating set is equipped with a differential residual current protector factory set to trigger instantly with a sensitivity of 30 mA must only be performed by qualified and authorised personnel When the generating set is disconnected from a facility after use the master differential pro
268. zone the status of the generating set is displayed in this zone pictograms relating to dimensions measured are displayed as well as Alarm and Fault pictograms in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4 in this zone messages relating to the control of the generating set and the menus are displayed Note the information displayed on measurements alarms and faults as well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set Certain screens may therefore not be present 45 263 6 3 1 3 Description of the pictograms in zone 1 Zone 1 pictograms Display Activation conditions TELYS in manual mode MAN Flashing For 5 seconds when switching from MAN mode AUTO to MAN mode Fixed AUTO Flashin For 5 seconds when switching from MAN to AUTO mode Flashing Genset starting Fixed Genset started AUTO mode Genset stabilised voltage Fixed frequency SP constant The genset is generating and in use movement from left to right 9 9 9 Fixed Usage supplied Not used Fixed Synchronisation Flashing Fixed Genset synchronised or coupled 46 263 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

Generating set R110 - User manual - SDMO

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