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User and maintenance manual for generating sets

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1. 6 Press the Menu key to exit the main menu and return U i to the engine parameter display M 1800 RPM i ETELE lt COOL TEMP z 4 D 2 G OR O OF CO zi g Exit Main Menu OURGP11 00000AC 19 03SEP03 6 6 Accessing Active Trouble Codes oh NOTE The engine does not need to be running to in navigate the diagnostic gauge screens If engine 1 start up is desired See Starting The Engine All COOL TEMP j Z of the engine values illustrated on the diagnostic a TS J gauge indicate the engine is running E Ce OL Ay 5 a eer SESS 8 For description of trouble codes see chart in Troubleshooting Section Normal Operation 1 During normal operation the single or four parameter screen will be displayed OURGP11 00000AD 19 03SEP03 1 7 2 When the diagnostic gauge receives a trouble code from an engine control unit the single or four WARNING parameter screen will be replaced with the Warning G SPN 34 FMI 18 message The SPN and FMI number will be displayed a NE Ww RyY PRESSURE along with a description of the problem and the CORRECTIVE ACTION a corrective action needed CHECK FEEL FILTER ANE IVES S 3 IMPORTANT Ignoring active trouble codes can T result in severe engine damage 5 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 tate WA
2. g ojol SPN CID SID PID PPID FMI 2 3 Description Comment E gt g gQ 2659 Flow level of the EGR valve 2 Calculated EGR flow not valid 15 Calculated EGR flow rather high 17 Calculated EGR flow rather low 2790 Air temperature at turbo compressor outlet 16 Temperature at compressor outlet moderately high 2791 19 Statuses of the EGR valve 2 Valve position signal not valid 3 Input voltage of the position sensor high Short to V 4 Input voltage of the position sensor low Short to V 7 Inability of the EGR valve to reach the expected position 13 The EGR valve is out of calibration 31 Error in position of the EGR valve 2795 Position of TGV actuator 7 The actuator does not respond or is not in the expected position 3509 Common supply voltage of the sensors output 1 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3510 Common supply voltage of the sensors output 2 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3511 Common supply voltage of the sensors output 3 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3512 Common supply voltage of the sensors output 4 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3513 Common supply voltage of the sensors output 5 3
3. 3 1 Unloading 3 1 1 Safety during unloading 3 1 2 Instructions for unloading 3 2 GHOICE OM IOCATION REE A EE T T aacdsetai das coasecta dutcagedadeaaadeas TT 3 3 Moving the genset sisman ase diene tien ee rene easly assets tae eel ince needle hein ee eee a 3 4 Connections 3 4 1 Connections general informatio ana i ae ie enaena idaraan ap aeae aen Aarte a aAa aaae a ae ea a aaa Paias 324 0 POWET Tl oE E E AE E E E E E A E E E E A E E A nlaettetel ate ha 3 4 3 Power connections 3 4 4 Battery installation 3 53 Protection for individuals ANd equipment eee eeeeeeeeeneeeeeeeneeeeeeaeeesenaeeeedneeeeeeaaeeeseaaeeeeeeaeeeeseaaeeseaeeeeseaeeeeeseaeeeseneeeeneneeeeee 3 5 1 Earth CONNECTION eseeeeseeeeeeeneeeeteneeees 3 5 2 Earthing system principle 3 5 3 TT SYSLOM eccceeesereeeeeeeeeee 3 5 4 Differential protection 3 5 5 Adjusting the genset differential protection 3 6 Connection summary 3 7 Special arrangements A MMAMOM celica ca cece EE 4 1 Neea Ee EE ETT AEAEE ATAT 4 2 Check before towing 4 3 Operation ceeeeeeeeeteeeeees 4 4 Unhitching the trailer 4 5 Implementation forinstallationis cca ega a e a aare a A aO aTa aE aeaaaee nea airal arenda irena 4 6 Break transmission adjustment 45 4 7 Faults and repairs n se 4 8 Electrical connection diagram 4 9 Complete wheels technical information 5 Preparation before operatin
4. Bolt or Screw Class 4 8 Class 8 8 or 9 8 Class 10 9 Class 12 9 Size Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry N m Ib in N m lb in N m Ib in Nem Ib in N m lb in Nem Ib in N m Ib in Nem b in M6 4 7 42 6 53 8 9 79 11 3 100 13 115 16 5 146 15 5 137 19 5 172 N m Ib ft Nem Ib ft N m Ib ft N m lb ft M8 11 5 102 14 5 128 22 194 27 5 243 32 23 5 40 29 5 37 27 5 47 35 N m lb ft N m lb ft N m lb ft M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70 N m lb ft M12 40 29 5 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190 M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300 M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410 M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580 M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800 M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000 M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475 M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750
5. 2 cceeeeeeeeeees 02 5 5000 Hours of operation cceeeeeeeees 02 6 5500 Hours of operation 0 ceeeeeeceeees 02 6 6000 Hours of operation cceeeeeeees 02 7 6500 Hours of operation 0 cceeeeeeeeeees 02 7 7000 Hours of operation 0 ceeeeeeees 02 8 7500 Hours of operation ccecceeeeeeeeees 02 8 8000 Hours of operation cceeceeeeerteees 02 9 8500 Hours of operation ccceceeeeeees 02 9 9000 Hours of operation cceeeeeeeeeees 02 10 9500 Hours of operation 0 cceeeeeeeeees 02 10 10000 Hours of operation ceceeeeeeees 02 11 Serial Numbers Record Engine Serial Number 3029 4045 and 6068 Engines ccceeeeereeees 03 1 Record Engine Serial Number 6090 ENGINe S ssi c tied dedia host E 03 1 Engine Option Codes ccceeeeeeeeeenteeeeeeeeee 03 2 Record fuel injection pump model number 03 3 Record Engine Control Unit ECU Serial NUMbE 2 eeeeeeeeeeeeeeeeeeeeeeeees 03 4 Record High Pressure Fuel Pump Model Numbet e cceeceeeeeeeeeeeeeneees 03 4 Safety escve fdeceseesuevics gles idee bene eden 05 1 Fuels Lubricants and Coolant Diesel Fuel si Gassner hrade 10 1 Handling and Storing Diesel Fuel 10 1 Diesel Engine Break In Oil n 10 2 Page Engine Oil and Filter Service Intervals
6. Danger Note Engines have two fuel filters primary and final equipped with a water sensor Depending on application an indicator light on the instrument panel signal the operator that water should be drained from filter bowls Check fuel filters C and D daily for water or debris and drain as necessary Loosen drain plugs A at bottom of both fuel filters two or three turns Loosen air bleed plugs B two full turns and drain water into a suitable container when tuel starts to drain out tighten drain plugs securely Bleed fuel system A Drain Plug B Air Bleed Plug C Primary Fuel Filter D Final Fuel Filter CD30929 37 260 6 2 Generator set with NEXYS control panel 6 2 1 Control panel presentation SO eOLV2OGOO OQ O Fig 6 1 View of the front side Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for starting up shutting down the module and RESET function Electronic card protection fuse Screen scroll button press successively to access the various screens which are available STOP button press to switch off the generating set START button press to switch on the generating set Normal operation LEDs and alarm and fault warning LEDs Slot reserved for panel fascia options Mounting bolt LCD for displaying alarms and faults operating states electrical and mechanical qua
7. e eee 60 4 Mixing IUDriCAnts ancara iia 10 4 M O Maintenance 1000 Hours Oil filter replacement Adjust speed droop governor 3029 engines 35 8 3029 engines agens e sgenhient AdcatenyatSitet Rasy abet enshiee 30 1 Check air intake System n 35 6 4045 or 6068 engines eee cette eeeeetteeeeeees 30 3 Check belt 3029 engines c ccceeeeceeeeee 35 1 6090 CNGINCS isis eileen 30 5 Check belt 4045 and 6068 engines Oil level with automatic tensioner PORNE TEER 35 2 GEC E EEE OE AEA E EA 25 1 Check belt 4045 and 6068 Engines Operating the engine with manual tensioner 0 ccceccsseseeeecereeeee 35 2 Break in Period ccccccceceeeeeseeeeeeeeneeeeeeenteeeeeeaas 15 25 Check belt 6090 engines with Changing Generator Frequency 2 0000 15 29 automatic tensioner ical innrshiianati 1111111111 35 3 Standby power units s ssesessisssessrreeerrreeressrreee 15 29 Check cooling SySteM c cccccesessesecesessseereneee 35 5 Starting the CNGiNG ec eceeeeeeeeeeeeeetetteeeeeeeee 15 25 Check crankshaft vibration damper Stopping the Engine ceceeeeeceeeeeeeetesetteaeees 15 29 6068 and 6090 Engines cccecececeeeeeeee 35 7 Using a booster battery or charger 15 28 Check engine speed 3029 engines 35 8 Check engine speed 4045 6068 and S 6090 engineS a sssesessssesserrnessrrssiinnnesnnnnnneennns 35 8 Replace crankcase v
8. 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 A Serial Number Label E Record Engine Control Unit ECU Serial Number RG14635 UN 13APR06 CD03523 0000189 19 06FEB07 1 1 Record High Pressure Fuel Pump Model Number Record the high pressure fuel pump model and serial number information found on the serial number plate A Model No RPM Manufacturer s No Serial No A Serial Number Plate RG13718 UN 11NOV04 Record High Pressure Fuel Pump Serial Number CD03523 000018A 19 O6FEBO7 1 1 03 4 99 260 020811 PN 21 Safety Recognize Safety Information This is a safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices T81389 UN 07DEC88 DX ALERT 19 29SEP98 1 1 Understand Signal Words A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual A DANGER
9. b 4045 or 6068 Engines Remove oil cooler housing drain plug B B Oil Cooler Housing Drain Plug ZX016192 UN 11JAN99 ZX016192 5 Oil Cooler Housing Drain Plug Continued on next page CD03523 00002CB 19 23DEC10 3 6 40 5 020811 PN 94 172 260 Maintenance 2000 Hours 2 Years A Pump Drain Valve c 6090 Engines Open coolant pump drain valve A and engine block drain valve B on left side of engine Drain all coolant from engine block B Block Drain Valve pe Cooling System Drain Valves RG13858 UN 17JAN05 CD03523 00002CB 19 23DEC10 4 6 10 Open radiator drain valve C Drain all coolant from radiator Close all drain orifices 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
10. Engine data Manufacturer model JOHN DEERE 4045HFS86 Type Turbo air air Cylinder configuration 4XL Cubic capacity 4 48 L Rotation speed 1500 Rpm Max emergency prime power at nominal speed 83 75 40 kW Adjustment type Electrical Fuel consumption 110 emergency power 21 80 L h 100 main power 19 80 L h Fuel Fuel type Diesel High autonomy fuel tank 516 L Lubrication Oil capacity 14 70 L Min Oil pressure 1 05 bar Nominal oil pressure 4 00 bar Oil consumption 100 load 0 05 L h Type of lubricant Genlub Cooling Fan power Max coolant temperature 110 C Refrigerant type Gencool Thermostat 82 95 C 13 260 Alternator data EN e Compliant with NEMA MG21 standards UTE NF C51 111 VDE 0530 BS 4999 IEC 34 1 CSA e The alternator is protected against short circuits e Vacuum impregnation epoxy winding IP23 protection rating Type LEROY SOMER LSA432L8 Number of phases 3 Power factor cos Phi 0 8 Number of poles 4 Excitation type AREP Insulation classe H Number of bearings 1 Coupling Direct Conirol unit s NEXYS Standard specifications Frequency meter Voltmeter Ammeter Alarms and faults Oil pressure Coolant temperature Fail to start Overspeed Alternator min max Fuel level low Emergency shutdown Engine parameters Working hours count
11. The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxi liary winding contact rating 16 A 250V A C Connection is identical for resetting the AVR internal protection In case of using the de excitation pro vide a forced excitation 3 2 3 3 R438 field forcing 400V WA Diode T oi lillike f a SS Battery B oo Exciter field Forced excitation B Volt Time Applications Guaranteed voltage build up Parallel operation de energized Parallel operation at standstill Frequency starting Sustained voltage on overload S SORER 1 241 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 3 3 Electrical faults Effect Check Cause Connect a new battery No voltage at of 4 to 12 volts to terminals E and E respecting the polarity for 2 to 3 seconds The alternator builds up and its voltage is still correct when the 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
12. Time setting potentiometer Current threshold adjustment potentiometer Two types of differential relay are fitted on the generating sets Type A Differential device for which operation is guaranteed v for residual sinusoidal alternating currents v for continuous pulsed residual currents y for continuous pulsed residual currents with a continuous component of 0 006 A with or without phase check independent of the polarity Type B Device for which operation is guaranteed as in the case of type A for residual sinusoidal currents up to 1000 Hz for residual sinusoidal currents superimposed on a pure continuous current for continuous pulsed currents superimposed on a pure continuous current for residual currents which could come from rectifier circuits i e three phase half wave rectifier or a three phase full wave bridge rectifier full wave bridge rectifier between phases with or without phase angle check independent of the polarity KASS Our residual current devices are factory set with an activation threshold of 30 mA and with automatic cut off Depending on the use if the residual current device is modified it is recommended to fit a seal to prevent any tampering when the generating set is being used 27 260 Identify its earthing system 3 6 Connection summary Mark the type of differential protection Fixed genset differential protection Adjustable genset differential protection No operation required
13. cable to a good ground on the engine frame and away from the battery 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 22JANO07 1 1 1 5 28 020811 PN 61 139 260 Operating the Engine Engine operation Warming engine Operate engine at high idle for 1 to 2 minutes before applying the load NOTE This procedure does not apply to standby generator sets where the engine is loaded immediately upon reaching rated speed Normal engine operation Compare engine coolant temperature and engine oil pressure with specifications below Specification Minimum oil pressure at full load rated speed Pressure Coolant temperature range Temperature 275 kPa 2 75 bar 40 psi 82 94 C 180 202 F Stop engine immediately if coolant temperature is above or oil pressure below specifications or if there are any signs of part failure Symptoms that may be early signs of engine problems could be e Sudden loss of power Oil at normal operating temperature of 115 C 240 F e Unusual noise or vibration e Excessive black exhaust e Excessive fuel consumption e Excessive oil consumption e Fluid leaks Recommendation for turbocharger engines Shou
14. 3000 H 3 Years 4500 H As Re quired Check engine oil and coolant level Check air filter restriction indicator Check fuel filter Water bowl Operate engine at rated speed and 50 70 load a minimum of 30 minutes Change engine oil and filter Replace fuel filter element s Check crankcase vent system Check engine mounts Check engine ground connection Check belt tension and automatic tensioner Check cooling system Check air intake system Replace crankcase vent filter optional Check crankshaft vibration damper 6 cyl Check and adjust engine speed Drain and flush cooling system Adjust valve clearance Replace crankshaft vibration damper 6 cyl Bleed the fuel system Clean or replace air filter element see note a Replace fan alternator belt Test thermostat and injection nozzles see your dealer Clean air filter element when restriction indicator is red Replace filter element after 6 cleanings or once a year For standby generator set only Change oil and filter after the first 100 hours of operation then every 500 hours maximum thereafter Change oil and filter at least once a year Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours 5 years Drain and flush cooling system every 3000 hours 3 years when John Deere COOL GARD II co
15. A WARNING TS187 19 30SEP88 A CAUTION DX SIGNAL 19 03MAR93 1 1 Do Not Open High Pressure Fuel System High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect or attempt repair of fuel lines sensors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform repairs See your John Deere dealer TS1343 UN 18MAR92 DX WW HPCR1 19 07JANO03 1 1 05 1 100 260 020811 PN 22 Safety Engine lifting procedure Fitton 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 NOTE If engine does not have lifting straps universal straps can be procured through service parts under part numbers JD 244 1 and JD 244 2 If not equipped install lifting straps and torque to 200 N m 145 lb ft Attach JDG23 Engine Lifting Sling A to engine lifting straps B and overhead hoist IMPORTANT Lifting straps are designed to lift the engine and
16. Close all drain orifices and fill the cooling system with specified coolant see Diesel Engine Coolant Continued on next page ail Radiator Drain Valve C Radiator Drain Valve CD30765 UN 27AUG99 Cooling system capacity Engine Model Cooling system capacity 3029 Engines 11 L 12 at 4045 Engines 20 L 21 5 qt 6068 Engines 27 L 29 qt 6090 Engines 36 L 38 5 qt CD03523 00002CB 19 23DEC10 5 6 40 6 173 260 020811 PN 95 Maintenance 2000 Hours 2 Years 11 When refilling cooling system loosen temperature sensor B or plug at the rear of cylinder head to allow air to escape except for 6090 engines 12 Run engine until it reaches operating temperature then check coolant level and entire cooling system for leaks B Coolant Temperature Sensor CD30643 UN 04MAY98 Coolant Temperature Sensor CD03523 00002CB 19 23DEC10 6 6 020811 40 7 PN 96 174 260 Maintenance As Required Additional Service Information This manual does not allow a complete repair of your engine If you want more detailed service information the following publications are available from your regular parts channel e PC10598 Parts Catalog for 4045HFU82 Engines e PC10600 Parts Catalog for 6068HFU82 Engines e PC10602 Parts Catalog for 3029TFU80 Engines e PC10604 Parts Catalog for 6090HFU84 Engines e CTM104
17. LAM action eliminated by cutting the ST5 jumper Voltage A Underspeed and LAM ST5 disconnected Un 4 l 0 85 UN gt 48 or 57 5 Hz Say ic N 50 or 60 Hz 2 3 2 Gradual voltage return function During load impacts the function helps the genset to return to its rated speed faster thanks to a gradual increase in voltage ac cording to the principle If the speed drops between 46 and 50 Hz the rated voltage follows a fast gradient as it is restored If the speed drops below 46 Hz since the engine needs more help the voltage follows a slow gradient as it returns to the reference value X Drop N lt 46 Hz Time Drop N gt 46 Hz 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only 2 4 1 Voltage Un Load on the shaft kW LEROY SOMER 7 237 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 2 5 R438 A V R options Current transformer for parallel operation of 1A 5 VACL 1 Remote voltage adjustment potentiometer 470 Q 0 5 W min adjustment range 5 range limited by internal voltage potentio meter P2 Remove ST4 to connect the po ten tiometer A 1 KQ potentiometer can also be used to extend the adjustment range For wiring up the external potentiometer the earth wires must be isol
18. Sensor short to ground Crank position Cam position out of synchronisation Crank position input missing Not informed by VOLVO Crank position sensor input pattern error 639 247 231 Communication status Bus Off error Passive bus error Data registers read back failure Loss of message error Bus CAN error 640 Engine shutdown vehicle status Engine shutdown vehicle request invalid Engine shutdown vehicle request 641 Status of the Turbo with variable geometry Supply voltage of the Turbo actuator low Error in communication between the ECU and the TGV actuator Error in position of the TGV Temperature of the actuator moderately high 251 260 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 651 651 Cylinder 1 injector status Injector outside specifications Recalibration of the injectors required Injector outside specifications Recalibration of the injectors required 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 652 652 Cylinder 1 circuit open Cylinder 1 circuit shorted Cylinder 1 balancing error mechanical failure Cy
19. im aru Active Trouble Code Condition RG13243 UN 010CT03 OURGP11 00000AD 19 03SEP03 7 7 15 8 020811 PN 41 Operating the Engine Engine Shutdown Codes 1 During normal operation the single or four parameter screen will be displayed COOL TEMP j i RG13172 UN 26SEP03 Normal Operation OURGP11 00000AE 19 03SEP03 1 6 When the diagnostic gauge receives a severe trouble code from an engine control unit the single or four vox SHUTDOWN parameter screen will be replaced with the Shutdown a SPN 100 FMI 1 message The SPN and FMI number will be displayed SAGINE Or PRESSURE TON along with a description of the problem and the CORRECTIVE ACTION E corrective action needed CHECK OL LEVEL 2 If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using 3 the arrow keys to scroll to the next trouble code 2 Shutdown Message OURGP11 00000AE 19 03SEP03 2 6 3 To acknowledge and hide the trouble code and return to the single or four parameter display press the Enter key IMPORTANT Ignoring the shutdown message can result in severe engine damage SHUTDOWN FMI 1 tafx SPN 100 FAULT ENGINE Olt PRESSURE LOW CORRECTIVE ACTION CHECK IL LEVEL NEXT HIDE JO Hide Trouble Code RG13239 UN 29SEP03 OURGP11 00000AE 19 03SEP03 3 6 4 The display will re
20. 30NOV10 Oil Dipstick Filler Cap Crosshatch Area on Oil Dipstick Filler Cap A Oil Dipstick Filler Cap B Crosshatch Area on Oil Dipstick Filler Cap 10 Close oil pan drain valve c Reinstall dipstick then tighten by hand 11 Remove oil dipstick filler cap A and fill engine d Again remove dipstick and check oil level crankcase with correct John Deere engine oil IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase to full mark or within crosshatch area on dipstick B whichever is present DO NOT overfill To determine the correct oil fill quantity for your engine see the Specifications Section 12 Start engine and run to check for possible leaks To check oil level proceed as follows 13 Stop engine and check oil level after 10 minutes Oil a Remove oil dipstick filler cap A level reading should be on upper mark of dipstick b Wipe dipstick blade to remove oil CD03523 00002B6 19 23DEC10 2 2 30 6 020811 PN 74 152 260 Maintenance 500 Hours Change Fuel Filter Element 3029 Engines Boer Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applyin
21. 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 3 INSTALLATION Personnel undertaking the various operations discussed in this section must wear the appropriate personal protective equipment for mechanical and electrical hazards 3 1 Assembly All mechanical handling operations must be undertaken using approved equipment and the machine must be horizontal Check how much the alternator weight see 4 9 before choosing the lifting tool During this operation do not allow anyone to stand under the load 3 1 1 Handling The generously sized lifting rings are for handling the alternator alone They must not be used to lift the genset The choice of lifting hooks or handles should be determined by the shape of these rings Choose a lifting system that has regard for the integrity and environment of the alternator 3 1 2 Coupling 3 1 2 1 Single bearing alternator Before coupling the alternator and the heat engine check they are compatible by undertaking a torsional analysis of the transmission on both units checking the dimensions of the flywheel and its housing the flange coupling discs and offset CAUTION When coupling the alternator to the prime mover the holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Do not use the alternator fan to turn the rotor Make sure the alternator is securely bedded in position during coupling Tighten the
22. Align Marks RG7382 UN 28NOV97 RG7381 UN 28NOV97 CD03523 00002BD 19 10DEC10 2 2 35 4 163 260 020811 PN 85 Maintenance 1000 Hours 1 Year Check 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 to relieve pressure before removing completely Test Radiator Cap 1 Remove radiator cap and attach to D05104ST tester as shown 2 Pressurize cap to specification listed Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable If gauge does not hold pressure replace radiator cap Specification Radiator Cap Calibration PreSSure c ccccccceeeeteeeeeeeeeeeneeeteeees 100 kPa 1 00 bar 14 5 psi for 10 seconds minimum 3 Remove the cap from gauge turn it 180 and retest cap to confirm measurement Test Cooling System NOTE Engine should be warmed up to test overall cooling system RG6557 UN 20JAN93 RG6558 UN 20JAN93 Test Cooling System 1 Allow engines to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level IMPORTANT DO NOT apply excessive pressure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck Pressu
23. Potentiometer LAM Supply LAM voltage drop amplitude U f function bend position 13 or 25 function Delivrery position Quadrature droop operation with C T Voltage Stability Excitation current ceiling 2 2 Frequency compared with voltage without LAM Voltage i Bend 57 5 Hz 48 HZ 4 y 100 U UN 50 Hz a 60 Hz Frequency 60 Hz Hz ee 2 3 LAM Load Acceptance Module characteristics 2 3 1 Voltage drop The LAM system is integrated in the R 438 AVR as standard Role of the LAM Load Adjustment Mo dule On application of a load the rotation speed of the generator set decreases When it passes below the preset frequency thres hold the LAM causes the voltage to drop by approximately 13 or 25 and conse quently the amount of active load applied is reduced by approximately 25 to 50 until the speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its dura tion for a given applied load or to increase the applied load possible for one speed va riation turbo charged engine To avoid voltage oscillations the trip thres hold for the LAM function should be set ap proximately 2 Hz below the lowest frequen cy in steady state EROY g SOMER 236 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R
24. Temperature in the EGR extremely high Input voltage of the temperature sensor high Short to V Input voltage of the temperature sensor low Short to V 15 Temperature in the EGR high 16 Temperature in the EGR moderately high 443 443 ENGINE RUN output status Engine run output open short to B Engine run output short to B 523 Gear selection 608 250 Gear selection invalid Data link faulty J1587 Start Stop redundancy J1939 communication bus Not possible with Genset application 608 132 Redundancy of the accelerator 608 98 Redundancy of the Stop start information 611 Injector wiring status Injector wiring shorted to power source Injector wiring shorted to ground 620 262 232 5 Volt sensor power supply FMI not VOLVO informed by Sensor power supply open short to B 626 45 Sensor power supply short to ground Start enable device intake heater and ether Start enable device output short to B Start enable device output short to ground Start enable device output open circuit Not used the control panel is in charge of managing the start enable device 627 Power supply Injector supply voltage problem For 6125HF070 only ECU unswitched power missing For 6068HF275 VP44 o
25. Warning high temperature risk of burns Battery level must be checked Earth A A Warning rotating or moving parts risk of getting caught in the machinery Lifting point required Warning corrosive product Figure 1 1 Pictograms and their meanings 4 260 Battery isolating switch on Fuel IN OUT e y External fuel connections inspection hatch E T Retention container h P drainage i Fuel drainage Oil filling s Coolant filling lifting Forklift required for AVA Buk tank level high Fuel supply selection valves Ly During any operation on the batteries wear protective glasses and protective clothing Rinse any splashes of acid on the skin or in the eyes using clean water Consult a doctor immediately Contaminated clothes must be washed with water ventilated area Important refer to the documentation accompanying the generating set Warning emission of toxic exhaust gases Do not use in a confined or badly Figure 1 1 continued Pictograms and their meanings 5 260 EN 1 3 Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows Y
26. flash one time short pause flash eight times long pause flash three times short pause flash three times long pause flash five times short pause flash three times CD03523 00002D9 19 22DEC10 1 1 50 2 184 260 020811 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 Other intermittent faults may be set only under certain operating conditions such as heavy load extended idle etc When diagnosing intermittent faults take special note of the condition of wiring and connectors since a high percentage of intermittent problems originate here Check for loose dirty or disconnected connectors Inspect the wiring routing looking for possible shorts caused by contact with external parts for example rubbing against sharp sheet metal edges Inspect the connector vicinity looking for wires that have been pulled out of connectors poorly positioned terminals damaged connectors and corroded or damaged splices and terminals Look for broken wires damaged splices and wire to wire shorts Use good judgement if component replacement is thought to be required NOTE The engine control unit ECU is the component LEAST likely to fail Suggestions for diagnosing intermittent faults e If the problem is
27. keys to scroll through the menu until Adjust Backlight pd E ERTEAN is highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY o S ADJUST BACKLIGHT 8 2 T Select Adjust Backlight Continued on next page OURGP11 0000237 19 210CT03 2 6 15 10 PN 43 121 260 Operating the Engine 3 Once the Adjust Backlight menu item has been z highlighted press the Enter key to activate the SAREE panded Adjust Backlight function ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT COG 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 RG13183 UN 29SEP03 Adjust Backlight Intensity OURGP11 0000237 19 210CT03 4 6 5 Press the Menu key to return to the main menu ADJUST CONTRAST Om i410 RG13184 UN 26SEP03 Return To Main Menu Continued on next page OURGP11 0000237 19 210CT03 5 6 15 11 an 122 260 Operating the Engine 6 Press the Menu key to exit the main menu and return U Yi to the engine parameter display 1800 RPM ETELE lt COOL TEMP Ti ge OE E ED Exit Main Menu RG13159 UN 26SEP03 OURGP11 0000237 19 210CT03 6 6 Adjusting Contrast 1 Turn the key switch to the ON position Starting at S the single or four engine parameter display press t
28. the low glycol formulation has been modified to provide the same level of corrosion inhibitor as John Deere COOL GARD II Premix 50 50 COOL GARD is a trademark of Deere amp Company IMPORTANT Water may be used as coolant in emergency situations only Foaming hot surface aluminum and iron corrosion scaling and cavitation will occur when water is used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible DX COOL6 19 03NOV08 1 1 10 4 020811 PN 33 111 260 Operating the Engine Using Diagnostic Gauge to Access Engine Information Optional equipment RG13132 UN O9SEP03 Diagnostic Gauge A Diagnostic Gauge B Menu Key C Arrow Keys D Enter Key NOTE Generator sets powered by an electronically controlled engine DE10 or HPCR fuel system can be optionally equipped with the diagnostic gauge shown Depending on the generator set manufacturer other instrumentations can be used Refer to the generator set documentation for more information The diagnostic gauge A allows the operator to view many readouts of engine functions and trouble codes DTCs The gauge is linked to the electronic control system and its sensors This allows the operator to monitor engine functions and to troubleshoot the engine systems when needed Press the menu key B to access the various engine funct
29. Add differential protection No operation required Add differential protection terminal circuits protected set to 30 mA to the terminal terminal circuits protected set to circuit output s 30 mA to the terminal circuit output s Earth the generating set Connect to the power supply 28 260 EN 3 7 Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 4 Trailer 4 1 Trailer linkage Before attaching the trailer check the trailer hook on the tow vehicle it should fit the trailer ring perfectly Trying to tow a trailer with a non matching device bar wires cords etc could lead to serious accidents Also check no incipient fractures or excessive wear on the hitching system Warning locking system is operating properly To 0000000 hitch the trailer proceed as follows Lock the wheels to stop the trailer from moving Lift up the rear trailer supports and lock them Release the parking brake Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook Hitch the trailer remove the locks on each side of the wheels then lift up the front wheel fully using its handle
30. Battery cabling incorrect Tighten the ends of the battery cables or replace them if necessary One or two cells release a lot of gas at high charge Cell s faulty Fit a new battery The battery discharges very quickly Charge status too low Short circuit in the current circuit High self discharge through electrolyte contamination etc Sulphation storage of discharged battery Check the load Replace the battery Short service life Incorrect battery part no Repeated deep discharging Battery stored too long without charge Define the correct battery part no for the recommended use It is recommended to charge the battery using a regulator High water consumption Overload Charging voltage too high Check the charger voltage regulator The battery explodes Spark after battery charging Short circuit Connection or disconnection during charging Internal fault and low electrolyte level Replace the battery Ventilate well 74 260 EN 9 Appendix 9 1 Appendix A Engine user and maintenance manual 75 260 76 260 User guide and maintenance manual JOHN DEERE Engine 4045HFS86 4045HFS87 4045HFS88 6068HFS85 6068HFS86 OMCD16510 23 12 2010 33522921101_0_1 77 260 78 260 Engines amp Power Units for Generator Sets Stage Ill A Saran Built OPERATOR S MANUAL Engines amp Power Units for Generator
31. CD31255A UN 06DEC10 Oil Filter Header D Outer Seal E Sealing Surfaces F Dust Seal CD03523 00002B5 19 23DEC10 1 2 30 3 149 260 020811 PN 71 Maintenance 500 Hours we e mme naanin eee CD30761 UN 24SEP99 2 gt O z i z 5 N A oO ra O CD31243 Oil Filler Cap and Dipstick on 4045 6068 Engines 6 Fill engine crankcase with correct John Deere engine oil through opening on rocker arm cover C or on the side of the engine B Oil Filler Cap on Rocker Arm Cover 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 area on dipstick A whichever is present DO NOT overfill 7 Start engine and run to check for possible leaks FD000047 UN 13MAR96 FDOO0047 8 Stop engine and check oil level after 10 minutes If necessary top up Crosshatch Area on Oil Dipstick A Oil Dipstick C Oil Filler Cap on Rocker B Oil Filler Cap on Side of Arm Cover Engine CD03523 00002B5 19 23DEC10 2 2 020811 30 4 PN 72 150 260 Maintenance 500 Hours Change Engine Oil and Filter 6090 Engines 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
32. Cetane number greater than 47 is preferred especially for temperatures below 20 C 4 F or elevations above 1500 m 5000 ft Cold Filter Plugging Point CFPP should be at least 5 C 9 F below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature Fuel lubricity should pass a maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 Sulfur Content for Interim Tier 4 and EU Stage IIIB Engines e Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates e Use ONLY ultra low sulfur diesel ULSD fuel with a maximum of 0 0015 15 mg kg sulfur content Sulfur Content for Other Engines e Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates e Use of diesel fuel with sulfur content less than 0 10 1000 mg kg is STRONGLY recommended e Use of diesel fuel with sulfur content 0 10 1000 mg kg to 0 50 5000 mg kg may result in REDUCED oil and filter change intervals Refer to table in Diesel Engine Oil and Filter Service Intervals e BEFORE using diesel fuel with sulfur content greater than 0 50 5000 mg kg contact your John Deere dealer IMPORTANT Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel Improper fuel additive usage may cause damage on fuel inject
33. D counterclockwise Forma sh En L kinalikiter Packing CCW to remove F Primary Filter Packing 5 Once primary filter canister D is removed pull primary filter element E down to remove from primary i filter header A 10 Screw canister D into filter header A and turn clockwise CW Tighten until canister lip G snugly 6 Inspect primary filter header A and primary filter mates with header lip H canister D sealing surfaces Clean as required l 7 11 Turn filter additional 3 4 turn after seal contact with 7 Place new packing F on primary filter canister D header 8 Place thin film of fuel on primary filter packing F 12 Connect water in fuel sensor connector C IMPORTANT Do NOT pre fill filter with fuel This may NOTE Be sure to also replace final fuel filter and introduce debris into the fuel system then prime system see following 9 Place new primary filter element E in canister D with tangs on bottom going into canister Continued on next page CD03523 00002B9 19 23DEC10 2 3 30 11 PN 79 157 260 Maintenance 500 Hours Remove and Install Final Fuel Filter AA OTON Due to High Pressure Common Rail system design fuel in filter is likely to be under high pressure To avoid possible personal harm open valves B and J on bottom of filters to relieve pressure prior to removing each filter NOTE Engines are equipped with a primary fuel filter A and a final fuel filter I Both fue
34. Figure 2 1 2 General description of the generating set 1 Radiator access hatch 4 Air filtration 2 Coolant drainage 5 Alternator 3 Starter battery 6 Battery isolating switch 11 260 Control S TT r aa Figure 2 1 3 General description of the generating set i Control unit 2 Emergency stop 3 Socket control panel Working hours counter Power circuit breaker Connection terminal block Oo Note Photo presented with the Nexys control unit 12 260 2 2 Technical specifications EN Range Generating set type RENTAL POWER R90C3 Weights and Dimensions Dimensions with high autonomy tank Dimensions x w x h 2860mm x 1150mm x 1995mm Hood M3129 Output Emergency 2 Voltage Hz Phase Load factor Mens current A power T A kW kVA 400 230 50 3 0 8 130 72 90 66 82 1 ESP Stand by output available for emergency use under variable charge up to 200hrs per year as per ISO 8528 1 no overload available under these service conditions 2 PRP Main output available continuously under variable load for an unlimited time period per year as per ISO 8528 1 an overload of 10 one hour every 12 hours is available as per ISO 3046 1 Term of use Standard reference conditions ESP PRP 40 409 Air Intlet Temp 1000m 1000m mA S L 60 relative humidity
35. IMMEDIATELY Date and time depending on settings 24 08 2005 13 12 WARNING Operating mode generating set in Auto Mode with AUTOMATIC Start programmed start G5 19 min 30 sec Countdown to micro disconnection delay or EJP notice delay for France only Date and time depending on settings 24 08 2005 Generating set start up gra Screen Data displayed START UP O inah i i ing ph IN PROGRESS perating phase generating set in starting phase 24 08 2005 Date and time depending on settings 58 260 EN Screen Screen Data displayed no AIR PREHEATING Operating phase air preheating prior to starting G7 generating set 10 seconds 24 08 2005 Countdown for air preheating delay Date and time depending on settings Generating set started Screen Screen Data displayed no AVAILABLE POWER Operating phase generating set in operation oe 75 stable voltage and frequency Default Dout TT avziiabie power Date and time depending on settings 24 08 2005 AUTOMATIC STOP Operating mode operation in Auto Mode IN PROGRESS Opening of power supply device motorised circuit breaker or source changeover switch controlled by G9 TELYS nir SUPPRESSION Countdown for the mains return delay OR the load min 30 sec test delay Date and time depending on settings 24 08 2005 13 12 AUTOMATIC STOP Operating mode operation in Auto Mode IN PROGRES
36. Maintenance Records 1000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Engine speed check and adjust Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 0000296 19 O3JAN11 1 1 1500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 0000297 19 22DEC10 1 1 02 2 020811 PN 8 86 260 Maintenance Records 2000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check or drain and flush if COOL GARD II is not used o Engine speed check and adjust a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Valve clearance adjust
37. Min 1 R P M Protection Cos P F Cl ther Th class R gulateur A V R Altit m Masse Weight Rit AV D E bearing Rit AR N D E bearing Graisse Grease Valeurs excit Excit values en charge full load a vide at no load S aLternateuRs 21 Ia P ALTERNATORS PUISSANCE RATING D e v Ph Connex Continue kVA Continuous kW 40C i Secours kVA Std by kW 27C LEROY 4 LS SOMER 214 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 2 TECHNICAL 2 2 Mechanical characteristics CHARACTERISTICS Steel frame 2 1 Electrical characteristics PARTNER LSA 43 2 44 2 alternators are generators without sliprings or revolving field brushes wound as 2 3 pitch 12 wire the insulation is class H and the field excitation system is available in either SHUNT AREP or PMG versions see AVR manual 2 1 1 Options Stator temperature detection probes Space heaters Interference suppression conforms to standard EN 55011 group 1 class B Europe 2 1 2 SHUNT system with R 250 AVR Other version R 251 AVR for dedicated single phase or R 448 for additional function Cast iron end shields Protected ball bearings greased for life M
38. Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 0000298 19 O3JAN11 1 1 2500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace a Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 0000299 19 22DEC10 1 1 02 3 020811 PN 9 87 260 Maintenance Records 3000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check or drain and flush if COOL GARD II is used a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Engine speed check and adjust Number of hours Observation Dealer or distributor stamp Date Job done by CD03523 000029A 19 03JAN11 1 1 3500 Hours of operation a Engine oil drain o Crankcase vent system clean a Engine oil filter replace a Engine mounts check o Fuel filter elements replace a Engine ground connection check Number of hours Observation Dealer or distributor stamp Date Job done by CD03523 000029B 19 22
39. On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine TS218 UN 23AUG88 DX SERV 19 17FEB99 1 1 Work In Ventilated Area Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area TS220 UN 23AUG88 DX AIR 19 17FEB99 1 1 05 6 020811 PN 27 105 260 Safety Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body 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 in English from Deere amp Company Medical Department in X9811 UN 23AUG88 Moline Illino
40. cables must be parallel with each other and as perpendicular as possible with the upper edge of the generating set pump unit or lighting column If other equipment fitted on the generating set pump unit or lighting column alters its centre of gravity special lifting devices may be necessary to maintain correct balance and completely safe working conditions The ground must be able to withstand the load of the generating set pump unit or lighting column and its lifting machinery without stress otherwise put down beams of sufficient strength in a stable configuration Position the generating set pump unit or lighting column as close as possible to its place of use or transport in a clear space with free access Never perform work on a generating set pump unit or lighting tower just hanging from a lifting device 1 3 8 Risks related to noise A Dangerous noise Risk of hearing loss Important Prolonged exposure to a noise level above 80dB A can lead to permanent hearing damage Therefore it is recommended that ear defenders are used when working in close proximity to a generating set which is in operation 9 260 2 General description 2 1 Description Overview Figure 2 1 1 General description of the generating set e Control unit 2 Product information plate 3 Forklift grooves Protective grille Charging alternator Oil drainage pump Oo 10 260
41. check the resistance Voltage too low Check the drive speed Correct speed Check the AVR connections AVR may be faulty Field windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the AVR voltage pot P2 before running at the correct speed Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Voltage oscillations potentiometer Adjust AVR stability If no effect try normal fast recovery modes ST2 Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F bend set too high Voltage correct at no load and too low when on load Run at no load and check the voltage between E and E on the AVR Voltage between E and E SHUNT lt 20 V AREP PMG lt 10V Check the speed or U F bend set too high Voltage between E and E SHUNT gt 30V AREP PMG gt 15V Faulty rotating diodes Short circuit in the main field Check the resistance Faulty exciter armature Caution For single phase operation check that the sensing wires comin operating terminals g from the AVR are correctly connected to the Voltage disappears during operation components Check the AVR the surge suppressor the rotating diodes
42. 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 63 260 EN 6 3 4 3 Activation of an alarm and a fault The appearance of an alarm and a fault causes gt The yellow and red LEDs to flash gt the related screen to be displayed example below FAULTS 1 2 Emergency Stop If several faults are present the number of faults is 25 12 05 15 30 displayed at the top of the screen Esc RESET OK LIST The faults list can be accessed by pressing OK of the scrolling and selection wheel examples below FAULTS Press Esc to return to the previous screen FAULT 25 12 05 15 30 Press OK to go to the HELP screen help on the highlighted fault Emergency Stop Use the scrolling and selection wheel to scroll through ALARM 25 12 05 15 30 the list of faults Low Fuel Level GS OK HELP Esc Check Emerg Stop Pos Connector s Esc If the alarm is no longer active it is reset automatically cause disappears Press Esc to reset a fault reset acknow
43. 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 260 260
44. required 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 655 655 Cylinder 4 circuit open Cylinder 4 circuit shorted Cylinder 4 balancing error mechanical failure Cylinder 4 unknown error mechanical failure Cylinder 5 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B 656 656 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 Cylinder 6 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required Short circuit high side to B Short circuit high side to low side or low side to B 676 39 Short circuit high or low side to ground Cylinder 6 circuit open Cylinder 6 circuit shorted Cylinder 6 balancing error mechanical failure Cylinder 6 unknown error mechanical failure Glow plug relay
45. 1 1 35 6 165 260 020811 PN 87 Maintenance 1000 Hours 1 Year Replace Crankcase Vent Filter Optional ae gt E CD31259 Crankcase Vent Filter A Side Cap DO NOT REMOVE C Filter Element B Top Cap D Blow Off Valve IMPORTANT Do not remove the cap A otherwise crankcase vent filter will be irremediably destroyed 1 2 Clean filter canister Remove top cap B and filter element C CD31259 UN 15DEC10 CD31262 CD31262 UN 15DEC10 Install New Crankcase Vent Filter Element E Filter Element O Ring F Cap O Ring 3 Check blow off valve D for proper operation Install a new filter element with O ring E Install new O ring F onto top cap B and then reinstall the cap Tighten securely CD03523 00002C1 19 23DEC10 1 1 Check Crankshaft Vibration Damper 6068 and 6090 Engines 1 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 Remove belts shown removed Check vibration damper radial runout by positioning a dial indicator so probe contacts damper outer circumference With engine at operating temperature rotate crankshaft using JDG820 or JDE83 Flywheel Turning Tool Note dial i
46. 12 Fuel Cold weather operation Sn hte Rn ha te te 15 26 Diesel E ETET TEPEE A A taints 10 1 Configuration data viewing eeeeeseeeeeeeeeeeseeeeeee 15 3 Handling and Storing sssssssessssessseetiee 10 1 Coolant Fuel filter Diesel engine e a a eer ee 10 4 Check E E A E EEC A TRE DC E AE NENE E E AEN 25 3 Warm temperature climates 0 ceeeee 10 4 Fuel filter replacement Coolant level 3029 CNGINGS vicechsccteleete E T 30 7 Checks E PE A a danimans jana ACAD OF COGS ENNES sosrensiisa ia ad Da Cooling system 6090 Engi oiea EEEREN 30 10 CHECK rea A I TAT 35 5 Fuel pump model NUM Er ssssssiirsrsnntirsennr ttnet 03 4 Drairand flush nieri Aedes aeaa 40 5 Fuel system Crankcase vent system BIGOCING occ ncnia e ai AS 45 6 CHOCK ecesanta AEE cheated 30 12 Replace filter cceeeceeceeccececeeeeeeeeeeeeceeeeeeeees 35 7 H Crankshaft vibration damper OCG AE E EA baatets fetes tense A 35 7 Hardware torque values Metric Tiai Sis eet airaa ide dara eau ae 60 4 D Unified iNCh mron aida 60 3 Diagnostic ProCeCure eeeeceeeseteeeeeeetteeeeeteteeeeeees 50 1 I Intermittent fault diagnostics eee 50 3 Using diagnostic QaUuge ccccscecesstseseeeeeeeeees 15 1 Instrument panel Diagnostic trouble codes DTCS ceseseeseseseeeee 50 4 Adjust backlighting ceceeeeeeeeeeeeeeeeeeneees 15 10 Active engine service codes viewing ee Aeon eee 15 7 Adjust contra
47. 15 13 6090 engines V Valve clearance adjustment 3029 ENJE Ee ea aasta EERE 40 1 Index 3 205 260 020811 PN 3 Index Index 4 Nea 206 260 EN 9 2 Appendix B Alternator user and maintenance manual 207 260 208 260 User guide and maintenance manual LEROY SOMER Alternator 43 2 amp 44 2 SHUNT AREP amp PMG 33522059401_6_1 3434 i 01 10 2010 209 260 210 260 LEROY SOMER 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS Installation and maintenance 211 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i This manual concerns the alternator which you have just purchased The latest addition to a whole new generation of alternators this range benefits from the experience of the world s leading manufacturer using advanced technology and incorporating strict quality control SAFETY MEASURES Before using your alternator for the first time it is important to read the whole of this installation and maintenance manual All necessary operations and interventions on this alternator must be performed by a qualified technician Our technical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommendations or symbols to alert the user to potential risk of accident It is vital that
48. 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow wu we GO TO 1 UP DISPLAY keys to scroll through the menu until Stored Codes is STORED CODES highlighted ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS 3 ADJUST BACKLIGHT 9 O ji 5 1 Select Stored Codes Continued on next page OURGP11 00000AC 19 03SEP03 2 6 15 5 PN 38 116 260 Operating the Engine 3 Once the Stored Codes menu item has been highlighted press the Enter key to view the stored codes GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13169 UN 020CT03 Enter Key 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 tafx SPN 94 FMI 18 FAULT FUEL DF Ww gt RyY PRESSURF TIVE ACTION SZL FILTER ANC LoS 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 tafx FAULT ENSIN COC _ANT TEMCRATO RE St CORRECTIVE ACTIO TECK COOLING amp Y RENUSE PovFa 2 Q O N ji z T oO vt N oO 10 ia Return To Main Menu Continued on next page OURGP11 00000AC 19 03SEP03 5 6 1 5 6 020811 PN 39 117 260 Operating the Engine
49. 500g of bicarbonate of soda diluted in 4 litres of water The bicarbonate of soda solution should be added until the reaction has finished lather The remaining liquid should be rinsed off with water and left to dry v Dry batteries do not require any servicing v Batteries ready for use must be recharged at the latest when the acid density drops below 1 20 8 1 Storage and transport v Batteries ready for use must be stored in a cool and dry place frost free protected from the sun self discharge v Batteries must be transported and stored vertically risk of acid spillage v Leave the terminal cover on the positive terminal 71 260 EN 8 2 Battery setting into service Batteries filled with acid have a density of 1 28 g ml and are charged In the case of dry batteries fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates Let the battery rest for 20 minutes Before fitting the battery stop the engine and any power consumer clean the terminals and give them a light coating of grease When connecting connect the positive terminal first and then the negative terminal Temperature when activated gt 10 C Fill with acid to the mark or about 1 cm above the edge of the plates battery becomes hot wait 5 to 20 mins Voltage check charge 10 mins Fit on the set 72 260 EN 8 3 Check Acid density
50. CD03523 00002D4 19 22DEC10 1 2 50 4 186 260 020811 PN 108 Troubleshooting SPN 000620 000627 000629 000636 000637 000639 000651 000652 000653 000654 000655 000656 000898 000970 000971 001069 001079 001080 001109 001110 001347 001568 001569 002000 FMI 03 04 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 Sensor Supply 2 Voltage High Sensor Supply 2 Voltage Low All Injector Currents Are Low ECU Programming Error Engine Position Sensor Signal Unreliable Engine Position Sensor Signal Missing Engine Position Sensor Signal Rate of Change Abnormal Engine Timing Sensor Signal Unreliable Engine Timing and Position Sensors Out of Sync Engine Timing Sensor Signal Missing Engine Timing Signal Rate of Change Abnormal CAN Bus Error Communication network problem Injector Number 1 Circuit Has High Resistance Injector Number 1 Circuit Has Low Resistance Injector Number 1 Not Responding Injector Number 2 Circuit Has High Resistance Injector Number 2 Circuit Has Low Resistance Injector Number 2 Not Responding Injector Number 3 Circuit Has High Resistance Injector Number 3 Circuit Has Low Resistance Injector Number 3 Not Responding Injector Number 4 Circuit Has High Resistance Injector Number 4 Circuit H
51. Charge status Voltage when idle 1 27 100 Above 12 60 V 1 25 80 12 54 V 1 20 60 12 36 V From 50 recharge 1 19 40 12 18 V Risk of sulphation 1 13 20 Under 11 88 V Unusable 8 4 Load preconization v Highly discharged or sulphated batteries formation of whitish lead sulphate deposit on the plates which becomes hard and insoluble to acid this deposit reduce the active surface of the plates and increases their internal resistance can no longer regenerate or be charged in a generating set A A discharged battery should be recharged immediately or else it will suffer irreparable damage Important Battery charge When several batteries are connected together the following points should be checked v v v v 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 KASS 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery is short 30 Ah and this must be recharged Charge factor 1 2 Ah x 1 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required Recharging is complete when the battery voltage and the acid density stop increasing The charging current must always be 1 10 of the nominal capaci
52. Continued on next page CD03523 00002B9 19 23DEC10 1 3 30 10 156 260 020811 PN 78 Maintenan ce 500 Hours Remove and Install Primary Fuel Filter Element Fhe biog Due to High Pressure Common Rail system design fuel in filter is likely to be under high pressure To avoid possible personal harm open valves B and J on bottom of filters to relieve pressure prior to removing each filter NOTE Engines are equipped with a primary fuel filter A and a final fuel filter I Both fuel filters have to be replaced together at the same time Replace fuel filter elements anytime audible alarm sounds and trouble codes indicate plugged fuel filters low fuel pressure If no alarm sounds during the 12 month gt service interval replace elements at that time or after 500 hours operation whichever comes first Z l 1 Thoroughly clean primary filter header A and g surrounding area to prevent dirt and debris from b getting into fuel system 2 Connect a fuel drain line to primary filter drain valve f B on bottom of filter and drain all fuel from the aan ae Header G Primary Filter Canister Dip filter canister D Primary ilter Canister H Primary Filter Header Lip primary ti Drain Valve I Final Fuel Filter Header C Water In Fuel Sensor J Final Filter Drain Valve Disconnect water in fuel sensor connector C Connector K Final Fuel Filter 4 Turn primary filter canister
53. John Deere Plus 50 Il John Deere Plus 50 or other diesel engine oil as recommended in this manual DX ENOIL4 19 0O3AUG09 1 1 10 2 109 260 020811 PN 31 Fuels Lubricants and Coolant Engine Oil and Filter Service Intervals tTier 3 and Stage Ill A Engines Recommended oil and filter service intervals are based on a combination of oil pan capacity type of engine oil and filter used and sulfur content of diesel fuel Actual service intervals also depend on operation and maintenance practices Use oil analysis to evaluate the condition of the oil and to aid in selection of the proper oil and filter service interval Contact your John Deere dealer for more information on engine oil analysis Change the oil and oil filter at least once every 12 months even if the hours of operation are fewer than the otherwise recommended service interval Diesel fuel sulfur content affects engine oil and filter service intervals e Use of diesel fuel with sulfur content less than 1000 mg kg 1000 ppm is RECOMMENDED e Use of diesel fuel with sulfur content 1000 5000 mg kg 1000 5000 ppm REDUCES the oil and filter change interval e BEFORE using diesel fuel with sulfur content greater than 5000 mg kg 5000 ppm contact your John Deere dealer e DO NOT use diesel fuel with sulfur content greater than 10 000 mg kg 10 000 ppm IMPORTANT To avoid engine damage e Reduce oil and filter service interval
54. Sets Stage Ill A Saran Built OMCD16510 ISSUE LO 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 Additional Proposition 65 Warnings can be found in this manual John Deere Usine De Saran European Edition PRINTED IN GERMANY 79 260 Introduction Foreword THIS MANUAL COVERS the following Stage III A engines for generator sets Engine Pack CD3029TFU80 Mechanical Fuel System CD4045HFU82 HPCR System 2 Valve Head CD6068HFU82 HPCR System 2 Valve Head RG6090HFU84 HPCR System 4 Valve Head Bare Engine CD4045HFS86 HPCR System 2 Valve Head CD4045HFS87 HPCR System 2 Valve Head CD4045HFS88 HPCR System 2 Valve Head CD6068HFS85 HPCR System 2 Valve Head CD6068HFS86 HPCR System 2 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 ME
55. Trouble Codes DTCS Jarrin orni E T 50 2 Using Blink Code Method for Retrieving Diagnostic Trouble Codes DTO s 50 2 Intermittent Fault Diagnostics With Electronic Controls J enseiiininaiiikaaa 50 3 Listing of Diagnostic Trouble Codes DTCs 50 4 Page Engine Wiring Harness Layout 4045 and 6068 Engines 50 6 Engine Wiring Harness Layout 6090 ENGINCS cites vicneewecdesaigvsnetia tensa mateasmbi ness 50 7 Engine Troubleshooting ccccecceeeeeeeeeee 50 9 Electrical Troubleshooting ccceereeeeee 50 13 Storage Engine Storage Guidelines c cece 55 1 Prepare Engine for Long Term Storage 55 1 Remove Engine from Long Term Storage 55 1 Specifications General Engine Pack Specifications 60 1 General Bare Engine Specifications 60 2 Unified Inch Bolt and Screw Torque Values 60 3 Metric Bolt and Screw Torque Values 60 4 82 260 020811 PN 2 Identification Views Identification Views 4045HFU82 Continued on next page CD31238 UN 04NOV10 CD03523 0000294 19 04NOV10 1 2 01 1 83 260 020811 PN 5 Identification Views Oo gt f rA 3 2 2D Q S CD31239 a 8 6090HFU84 CD03523 0000294 19 04NOV10 2 2 020811 01 2 PN 6 84 260 Maintenance Records Using maintenance records To obtain t
56. add John Deere Break In or Break In Plus Engine Oil respectively as needed to maintain the specified oil level Operate the engine under various conditions particularly heavy loads with minimal idling to help seat engine components properly Change the oil and filter at 100 hours maximum for Break In Oil or 500 hours maximum for Break In Plus Oil during the initial operation of a new or rebuilt engine After engine overhaul fill the engine with either John Deere Break In or Break In Plus Engine Oil If John Deere Break In or Break In Plus Engine Oil is not available use a 10W 30 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 e ACEA Oil Sequence E2 e ACEA Oil Sequence E1 Break In is a trademark of Deere amp Company Plus 50 is a trademark of Deere amp Company IMPORTANT Do not use Plus 50 Il Plus 50 or engine oils meeting any of the following for the initial break in of a new or rebuilt engine API CJ 4 API Cl 4 PLUS API Cl 4 API CH 4 API CG 4 API CF 4 API CF 2 API CF These oils will not allow the engine to break in properly ACEA E9 ACEA E7 ACEA E6 ACEA E5 ACEA E4 ACEA E3 John Deere Break In Plus Engine Oil can be used for all John Deere diesel engines at all emission certification levels After the break in period use
57. and replace any defective The voltage does not return to the rated value Exciter winding open circuit Faulty exciter armature Faulty AVR Main field open circuit or short circuited Caution Internal protection may be activated overload open circuit short circuit Warning after operational testing replace all access panels or covers 12 LEROY SOMER 242 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 4 SPARE PARTS 4 1 Designation Description Code A V R AEM 110 RE 017 4 2 Technical support service Our technical support service will be happy to provide any information you require When ordering spare parts you should in dicate the complete machine type its serial number and the information indicated on the nameplate 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 243 260 13 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 NOTES 14 LEROY SO
58. and TELYS and vice versa 2 Connection for microcomputer DEVICE gt file transfer between PC and TELYS and vice versa gt main module power supply 3 _ Protective cover 51 260 EN 6 3 1 2 Description of the screen The screen is backlit and requires no contrast adjustments This screen is divided into 4 zones IA O BRRR RPE ID BARRA ODOL WHERE Aa SERIAL No 08030010000 s r SOFTWARE 5 3 5 NOMINAL VOLTAGE 400V l FREQUENCY 50Hz i I D gt NOMINAL KW 320kW EARTH SYSTEM TNS Fig 6 7 description of the screen example Zone 1 in this zone the status of the generating set is displayed Zone 2 in this zone pictograms relating to dimensions measured are displayed as well as Alarm and Fault pictograms Zone 3 in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4 in this zone messages relating to the control of the generating set and the menus are displayed Note the information displayed on measurements alarms and faults as well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set Certain screens may therefore not be present 52 260 EN 6 3 1 3 Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms Display Activation conditions Fixed TELYS in manua
59. cap on the container and store in a cool protected location Do not incinerate or puncture a starting fluid container TS1356 UN 18MAR92 DX FIRE3 19 16APR92 1 1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine TS206 UN 23AUG88 DX WEAR 19 10SEP90 1 1 Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises TS207 UN 23AUG88 DX NOISE 19 03MAR93 1 1 05 4 020811 PN 25 103 260 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 bef
60. dealer DX READ 19 16JUN09 1 1 05 2 020811 PN 23 101 260 Safety Prevent Machine Runaway Avoid possible injury or death from machinery runaway Do not start engine by shorting across starter terminals Machine will start in gear if normal circuitry is bypassed NEVER start engine while standing on ground Start engine only from operator s seat with transmission in neutral or park TS177 UN 11JAN89 DX BYPAS1 19 29SEP98 1 1 Handle Fuel Safely Avoid Fires Handle fuel with care 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 TS202 UN 23AUG88 DX FIRE1 19 03MARQ3 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 03MARQ3 1 1 05 3 102 260 020811 PN 24 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
61. defaults scroll to and highlight Use Defaults Press the Enter key to activate the Use Defaults function RESTORED TO A message indicating the display parameters are DEFAULTS reset to the factory defaults will be displayed then the display will return to the Setup 4 Up Display menu ise i a w 7 vt z O D D 0 ia Restored To Defaults Continued on next page OURGP11 00000B2 19 03SEP03 5 14 1 5 22 020811 PN 55 133 260 Operating the Engine 6 Custom Setup To perform a custom setup of the USE DEFAULTS CUSTOM SETUP 4 Up Display use the arrow buttons to scroll to and highlight Custom Setup on the display RG13227 UN 26SEP03 Custom Setup OURGP11 00000B2 19 03SEP03 6 14 7 The quadrant with the highlighted parameter value is the current selected parameter Use the Arrow Seen 125 F 1000 RFM keys to highlight the value in the quadrant you wish to change to a new parameter COOL TEMP ENG RPM 57 PSI BAT VOLT OIL PRES Select Parameters RG13228 UN 26SEP03 OURGP11 00000B2 19 03SEP03 7 14 8 Press the Enter key and a list of engine parameters will be displayed 425 F 1000 RPM COOL TEMP ENG RPM 8 th 12 S 4 7 S S 0 a List Of Engine Parameters Continued on next page OURGP11 00000B2 19 03SEP03 8 14 020811 15 23 PN 56 134 260 Operating the Engine 9 The parameter that
62. diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation power of the machine see the genset nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field supply current by adjusting the rheostat or the Variac and measure the output voltages on L1 L2 L3 checking the excitation voltage at no load see machine nameplate or ask for the factory test report When the output voltage is at its rated value and balanced within 1 for the rated excitation level the machine is in good working order The fault therefore comes from the AVR or its associated wiring ie sensing auxiliary windings Variac 6 Exciter field 5 Diode 1A DC 12 V 220 V Assembly B 4 6 Dismantling reassembly see sections 5 4 1 5 4 2 amp 5 4 3 During the warranty period this operation should only be carried out in an LEROY SOMER approved workshop or in our factory otherwise the warranty may be invalidated Whilst being handled the alternator should remain horizontal translational movement of rotor not locked Check how much the alternator weighs see section 4 9 before choosing the lifting method The choice of lifting hooks or handles should be determined by the shape of the lifting rings 12 LEROY SOMER 222 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10
63. display press the 1800 RPM i Menu key ETELE lt COOL TEMP i T i i a GOO ooe z Menu Key OURGP11 00000B2 19 03SEP03 1 14 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Setup 4 Up Display is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUF 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13225 UN 020CT03 Select Setup 4 Up Display Continued on next page OURGP11 00000B2 19 03SEP03 2 14 15 21 ae 132 260 Operating the Engine 3 Once the Setup 4 Up Display menu item has been highlighted press the Enter key to activate the akkedis aore Setup 4 Up Display menu ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13226 UN 020CT03 Press Enter Key OURGP11 00000B2 19 03SEP03 3 14 4 Two options are available for the 4 Up Display USE DEFAUI TS a Use Defaults This option contains the following CUSTOM SETUP engine parameters for display Engine Speed Battery Voltage Coolant Temperature and Oil Pressure b Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters RG13244 UN 020CT03 Select Factory Defaults OURGP11 00000B2 19 03SEP03 4 14 5 To reset the display parameters to the factory
64. 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 Maximum resistance value of the earth socket R Q according to the differential unit operational current operation time should not be longer than 1 second R Ul An An differential Earth R Q UI 50 V Earth R Q UI 25 V lt 30 mA 500 gt 500 100 mA 500 250 300 mA 167 83 500 mA 100 50 1A 50 25 3A 17 8 5A 10 5 10A 5 2 5 The UI value 25 V is required for work site installations and livestock buildings etc 24 260 EN For a default voltage of 25 V and a default current of 30 mA this rod must be of a minimum length of see table below Length of Nature of ground rod in metres Thick arable land 1 moist compact ballast Lean arable land 1 Gravel coarse ballast Bare stony soils dry sand To obtain an equivalent length you can use several earthing rods impermeable rock 3 6 connected in parallel and set apart by at least their length Example 4 interconnected 1 metre rods separated by 1 metre Note For the United States National Electrical Code reference NFPA 70 The generating set must be earthed To do this use a copper wire with a minimum cros
65. fault finding module has encountered problems on the CAN Bus and it tries to automatically re establish the network connection 49 260 6 3 Generator set with TELYS control panel 6 3 1 Control panel presentation 6 3 1 1 View of the front panel _ CONDO RWND ee Cae gN Shu mal f AII aue Hz Fig 6 4 View of the front panel Emergency stop button AU for switching off the generating set in the event of a fault which could endanger personnel or damage equipment Key switch for switching the module on off Electronic board protection fuse Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel STOP button 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 50 260 ON G o Fig 6 5 Description of the LEDs A lit LED indicates 1 Alarm activated flashing yellow 2 Fault found flashing red 3 Module on green on continuously Fig 6 6 Close up of USB ports 1 USB key connection HOST file transfer between USB key
66. fines or other penalties per EPA regulations or other local emission laws 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 Fuel System A High Pressure Fuel Pump if Ti A TS1343 UN 18MAR92 RG 13735 UN 11NOV04 CD03523 00002CD 19 20DEC10 1 1 45 1 175 260 020811 PN 97 Maintenance As Required Welding Near Electronic Control Units IMPORTANT Do not jump start engines with arc welding equipment Currents and voltages are too high and may cause permanent damage 1 Disconnect the negative battery cable s 2 Disconnect the positive battery cable s 3 Connect the positive and negative cables together Do not attach to vehicle frame 4 Clear or move any wiring harness sections away from welding area 5 Connect welder ground close to welding point and away from control units 6 After welding reverse Steps 1 5 TS953 UN 15MAY90 DX WW ECU02 19 14AUG09 1 1 Keep Electronic Control Unit Connectors Clean IMPORTANT Do not open control unit and do not clean with a high pressure spray Moisture dirt and other contaminants may cause permanent damage 1 Keep terminals clean and free of foreign debris Moisture dirt and other contaminants may cause the terminals to erode over time and not make a good e
67. for the first time after 100 hours maximum of operation then every 500 hours thereafter Change oil and filter at least once a year 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Open oil pan drain valve A 3 Drain crankcase oil from engine while warm NOTE Do NOT remove plug B Plug B is not an oil drain Oil in filter will drain down automatically as filter cap is loosened 4 Loosen filter cap C one half turn with wrench Wait 30 seconds to allow oil filter housing to drain Remove cap and filter assembly 5 While holding cap strike filter element against solid surface as shown to unfasten filter from cap Discard used filter CD31257 B 6 Remove O ring seal and replace with new O ring provided with new filter element 7 Press new filter element into cap until it snaps into place 8 Insert cap and filter assembly into oil filter housing Screw cap into place 9 Tighten cap to specifications Specification Top Load Oil Filter Gap lorque seassa a aai 45 N m 33 lb ft A Oil Pan Drain Valve C Oil Filter Cap B Plug DO NOT REMOVE Continued on next page CD31257 UN 06DEC10 CD31256 UN 06DEC10 RG11628 UN 01FEB01 i Remove Filter Element from Cap CD03523 00002B6 19 23DEC10 1 2 30 5 151 260 020811 PN 73 Maintenance 500 Hours CO31245 Oo gt O z O T z 5 t N 2 ra O CD31245 UN
68. i Inlet air temperature 172 172 172 Ambient air temperature sensor sensor for PERKINS 3 Ambient air temperature sensor input Inlet air temperature sensor voltage high input voltage high 4 Ambient air temperature sensor input Inlet air temperature sensor voltage low Ambient air temperature sensor open circuit input voltage low High Inlet air temperature alarm warning 16 Fuel temperature sensor High Inlet air temperature alarm action alert Fuel temperature high most severe Fuel temperature sensor input voltage high Fuel temperature sensor input voltage low Fuel temperature high Fuel temperature moderately high Fuel temperature sensor faulty 175 Oil temperature sensor Oil temperature extremely high Oil temperature sensor input voltage high Oil temperature sensor input voltage low Oil temperature sensor open circuit 177 Transmission oil temperature sensor Transmission oil temperature invalid Not possible with Genset application 189 Rated engine speed Engine speed de rated Engine speed de rated 248 260 EN Warning output open circuit
69. intake valves 3 A Front of Engine E Exhaust Valve Valve Clearance Adjustment on 4045 Engines B No 1 Piston at TDC I Intake Valve Compression Stroke C No 4 Piston at TDC Compression Stroke Continued on next page CD03523 00002C9 19 23DEC10 3 4 40 2 PN 91 169 260 Maintenance 2000 Hours 2 Years 6068 Engine NOTE Firing order is 1 5 3 6 2 4 1 2 Lock No 1 piston at TDC compression stroke B Adjust valve clearance on No 1 3 and 5 exhaust valves and No 1 2 and 4 intake valves Rotate flywheel 360 Lock No 6 piston at TDC compression stroke C 3 4 Adjust valve clearance on No 2 4 and 6 exhaust valves and No 3 5 and 6 intake valves E Exhaust Valve I Intake Valve A Front of Engine B No 1 Piston at TDC Compression Stroke C No 6 Piston at TDC Compression Stroke Valve Clearance Adjustment on 6068 Engines RG4777 UN 310CT97 CD03523 00002C9 19 23DEC10 4 4 Check and Adjust Engine Valve Cl Lock Engine at Top Dead Center A Flywheel Turning Tool B Timing Pin Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 2 Remove rocker arm cover and crankcase vent tube Using JDE83 or JDG820 Flywheel Turning Tool A rotate engine flywheel in running direction clockwise viewed from water pump until No 1 piston front CD31264 UN 16
70. intermittent try to reproduce the operating conditions that were present when the diagnostic trouble code DTC was set e f a faulty connection or wire is suspected to be the cause of the intermittent problem clear DTCs then check the connection or wire by wiggling it while watching the diagnostic gauge to see if the fault resets Possible causes of intermittent faults e Faulty connection between sensor or actuator harness e Faulty contact between terminals in connector e Faulty terminal wire connection e Electromagnetic interference EMI from an improperly installed 2 way radio etc can cause faulty signals to be sent to the ECU NOTE Refer also to generator documents for more information about connections and wirings CD03523 00002DA 19 22DEC10 1 1 50 3 020811 PN 107 185 260 Troubleshooting Listing of Diagnostic Trouble Codes DTCs NOTE Not all of these codes are used on all OEM engine applications Diagnostic Trouble Codes SPN 000028 000029 000084 000091 000094 000097 000100 000105 000107 000110 000111 000158 000160 000174 000174 000189 000190 000611 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 Description of Fault Throttle 3 Signal Out of Range High Throttle 3 Signal Out of Range Low Throt
71. is highlighted is the selected parameter for the screen Use the arrow keys to highlight the new parameter to be placed in the 4 Up Display ENGINE SPEED 37 ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 The tuma 53 Ihe ro i Gl the D2 ams nct Ihe Quadratt Nahin t 4 asaya BATTERY POTENTIAL 1 Japer tel Ohadenl ENGINE OIL TEMPERATURE Ee arai ealas t 3 e Upper age Gueceent distin Roli Rialia Select Desired Engine Parameter RG13230 UN 26SEP03 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 OIL 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 Setup screen ENGINE SPEED 3 ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL TEMPERATURE ENGINE OIL PRESSURE Mola tre nuyrdaber 10 hea riya ol she se ctles p2m eter sd cating thal the parzmater it acw assigned ta that display negation 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 Continued on next page 125 F COGL TEMP 1000 RPM ENG RPM RG13153 UN 24SEP03 4 Up
72. lamp does not light up check and replace the fuse if necessary Test the Alarm and Fault LEDs menu 15 TEST LAMPS 1 ACTIONS 5 11 MANUAL lt gt AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS Go OK Esc Press Esc several times to return to the following home menu OPERATION MANUAL Press START to start 24 08 2005 Check the battery voltage my Press START D Ta AVAILABLE POWER AIR PREHEATING START UP 100 0 IN PROGRESS 10 seconds 24 08 2005 24 08 2005 24 08 2005 The following pictogram is displayed If the engine is equipped with an Warning the number of successive air preheating system there is a and automatic starting attempts is loKTH delay adjustable before the limited to 3 engine starts preheating Paerrren activation period The following pictogram will flash The following information is displayed If the motor is not fitted with an air preheating system or once the eta Y Speed of rotation preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to w Coolant temperature start up the engine 2 r lt Oil pressure S ok O Oil Temperature 61 260 EN 6 3 3 Switching off Open the circuit breaker gt manually OR gt by selecting menu 12 CONTROL LOAD rtr The following display will disappear supply stopped Nal gt gt gt gt gt Pre
73. 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 SSS SS annNN e Yg RPI The first line displays the motor speed in RPM The second line displays the battery voltage in volts V v Check the battery voltage min 12 V Press once briefly the green START button v Ifthe motor is equipped with an air preheating system there is a 10 second delay before the motor starts preheating activation period v The following screen appears oo RM HR J The third line displays the air preheating time l bv remaining with pictograms representing a CI iz Ht 5 resistor and an hourglass v Ifthe motor is not fitted with an air preheating system or once the preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to start up the engine v The following screen appears 0000 RM A The number of successive and automatic starting attempts is limited to 3 Warning Note the LED flashes as soon as the START button is pressed and continues to flash until the frequency stabilises if a measurements card has not been inserted and until the frequency and voltage stabilise if a measurements card has been inserted Following s
74. must only be entrusted to personnel with the necessary skills Failure to follow these instructions in any way could result in malfunction or very serious accidents Danger 5 1 Installation checks e Check that the general recommendations from section Installation ventilation exhaust connections etc are followed Carry out level checks oil coolant diesel battery Ensure that the generating set is correctly earthed earthing rod Ensure that the electrical connections have been made properly Ensure that the fuel connection has been made properly valve position if the generating set is equipped with the three way valve option enabling external supply 5 2 Checks after starting the generating set e Carry out the mechanical checks oil pressure water temperature absence of noise etc e Carry out the electrical checks voltage current frequency rotary field etc e Carry out the safety checks emergency shutdown oil pressure coolant temperature etc e Carry out the check on Normal Emergency Inverter switching or coupling if fitted 35 260 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 Important Do not top up the oil if the oil
75. 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 FMI 6 CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT a A current signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data 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 error indicator value FMIl 7 MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of a mechanical system that with a reasonable confidence level is not caused by an electronic or electrical system failure This type of fault may or may be directly associated with the value of general broadcast information FMI 8 ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD To be considered in cases of FMI 4 and 5 Any frequency or PWM signal that is outside the predefined limits which bound the signal range for frequency or duty cycle outside Region b or the signal definition Also if the signal is an ECM output any signal whose frequency or duty cycle is not consistent with th
76. of tensioner as shown d Measure 21 mm 0 83 in from mark A and put a mark B on tensioner mounting base e Install torque wrench 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 f Record torque wrench measurement and compare with specification below Replace tensioner assembly as required RG7977 UN 14NOV97 Specification SPriNGQ FOrce eee eee cess eeseeeeeeeneeeeeeees 18 22 N m 13 16 lb ft A Mark on Swing Arm B Mark on Tensioner Mounting Base RG12054 UN 08JAN02 Align Marks CD03523 00002BC 19 10DEC10 2 2 Check Belt 6090 Engines with Automatic Tensioner NOTE With the belt loosened inspect pulleys and bearings Rotate and feel for hard turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer 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 RG7380 UN 28NOV97 Automatic Belt Tensioner e Check belt wear The belt tensioner is designed to operate within the limit of arm movement provided by the cast stops A A Tensioner Stop B Fixed Stop and B when correct belt length and
77. or oil vapour absorption and accelerated engine speed On load tests It is recommended to conduct an on load test on the generating set monthly for a period of around 1 hour after stabilisation of the parameters The load must be greater than 50 of nominal power ideally 80 to ensure unchoking of the engine and to obtain a decent picture of the generating set operation Off load test no load This test is not recommended it must not exceed 10 minutes and must not be repeated without a monthly on load test This test only allows you to check for correct engine start up It does not allow you to check that the generating set is working properly 70 260 EN 8 Battery Fit the battery so that it is properly ventilated Maintenance should only be carried out by qualified personnel If replacing the batteries use the same type of batteries Do not throw the old battery in the fire Only use insulated tools the operator should not be wearing a watch chain or any metal object Never use sulphuric acid or acid water to top up the electrolyte level Use an approved battery fluid Batteries release oxygen and hydrogen gas which are flammable Never bring flames or sparks near the battery risk of explosion Discharge any static electricity before handling the batteries by first touching an earthed metal surface Do not use the battery when the fluid level is below the minimum required level Using a battery with a low electrolyt
78. 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 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 8 260 EN If the protective plates blanking covers need to be removed to route cables the protector blanking cover must be refitted when the operations are finished Due to high mechanical stresses use only strong flexible wiring with rubber sheathing compliant with IEC 245 4 or equivalent wiring 1 3 6 Dangers presented by electric currents first aid First aid In the event of an electric shock shut off the power immediately and activate the emergency stop on the generating set or lighting column If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid di
79. poles 1 3 1 Nameplate So that you can identify your alternator quickly and accurately we suggest you fill in its specifications on the non contractual nameplate below 1 4 Storage Prior to commissioning machines should not be stored in humid conditions at relative humidity levels greater than 90 the machine insulation can drop very rapidly to just above zero at around 100 The state of the anti rust protection on unpainted parts should be monitored For storage over an extended period the alternator can be placed in a sealed enclosure heatshrunk plastic for example with dehydrating sachets inside away from significant and frequent variations in temperature to avoid the risk of condensation during storage If the area is affected by vibration try to reduce the effect of these vibrations by placing the generator on a damper support rubber disc or similar and turn the rotor a fraction of a turn once a fortnight to avoid marking the bearing rings 1 5 Applications These alternators are designed mainly to produce electricity in the context of applications involving the use of generators 1 6 Contra indications to use Use of the alternator is restricted to operating conditions environment speed voltage power etc compatible with the characteristics indicated on your genset RERO SOMER S LSA Date N Hz
80. products and dust v The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements v Facilities must be operated under the constant supervision of a qualified person who must regularly check that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply v Apart from the combustion devices it is prohibited to use fire in any form This restriction must be clearly displayed 6 260 N 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 ca
81. set at the fac tory When first used with no load make sure that the drive speed is correct and stable see the nameplate After opera tional testing replace all access panels or covers The only possible adjustments to the machine should be made on the AVR 3 2 1 R438 settings AREP or PMG system Before any intervention on the A V R make sure that the ST9 jumper is closed with AREP excitation and disconnected with PMG or SHUNT or separate excita tion a Initial potentiometer settings see table below Remote voltage adjustment potentiometer centre ST4 jumper removed Action Factory setting Pot 400V 50Hz 7 t Voltage R z n minimum fully anti clockwise Put apo 4 0 380 V 5 Not set raa tabili ot se FE Stability centre position Voltage quadrature droop Not set operation with C T fully anti 0 quadrature loop fully clockwise KP19 anti clockwise Stability adjustments in standalone operation Excitation ceiling Limit of excitation and 10A short circuit current maximum minimum fully anti clockwise b Install a D C analogue voltmeter needle dial cal 50V on terminals E E and an A C voltmeter cal 300 500 or 1000V on the alternator output terminals c Make sure that the ST3 jumper is positio ned on the desired frequency 50 or 60 Hz d Voltage potentiometer P2 at minimum fully anti clockwise e Stability pot
82. speed sensor circuit open 6 Sensor shorted to earth Short to V 8 Speed signal invalid 31 Intermittent problem with speed information 105 105 Manifold air temperature sensor 0 Manifold air temperature extremely high 3 Manifold air temperature sensor input voltage high 4 Manifold air temperature sensor input voltage low 5 Manifold air temperature sensor open circuit 15 Air temperature very high 16 Manifold air temperature moderately high 106 106 Air inlet pressure sensor 0 Air inlet pressure above normal 3 Air inlet pressure sensor input voltage high 5 Air inlet pressure sensor open circuit 246 260 EN SPN CID SID PID PPID John Deere Description Comment 107 107 Air filter differential pressure sensor Air filter restriction high Air filter differential pressure sensor input voltage high Air filter differential pressure sensor input voltage low Air filter differential pressure sensor open circuit Air filter restriction high 108 274 108 Barometric pressure sensor Not use with EDC Ill and EMS2 Air pressure invalid High barometric pressure sensor short to high High barometric pressure sensor short to low High barometric pressure ECM option connected sensor not 110 110 110 Coolant temperature sensor Coolant temperature extremely high Coo
83. thin layer of oil to protect it from rust Never top up the oil or coolant if the generating set pump unit or lighting column is running or if the engine is hot A generating set can only operate when stationary and cannot be installed on a vehicle or other mobile equipment without a prior study taking into account the various specific features of using the generating set 1 3 5 Risks related to electrical networks v v ANN ANN 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
84. to the alternator In this case disconnect the blue wire of the R 791 interference suppression module linking the neutral Any protective devices in place have not tripped If there is an external AVR the connections between the alternator and the cubicle are made in accordance with the connection diagram There is no short circuit between phase or phase neutral between the alternator output terminals and the generator set control cabinet part of the circuit not protected by circuit breakers or cubicle relays The alternator has been connected with the busbar separating the terminals as shown in the terminal connection diagram aot ano The equipotential earth links have been implemented correctly cross section and continuity of the earths 3 4 Commissioning The alternator can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The alternator is tested and set in the factory When first used with no load make sure that the drive speed is correct and stable see the genset nameplate On application of the load the alternator should achieve its rated speed and voltage however in the event of abnormal operation the alternator setting can be altered follow the adjustment procedure see section 3 5 If the operation is still incorrect the cause of the malfunction must be located see section 4 4 amp 4 5 3 5 Setting up The
85. 0 046 2 51 18 4 0 5 S7 0 036 2 91 18 4 0 5 4 9 Table of weights S75 0 036 2 91 18 4 0 5 L12 0 019 3 66 18 4 0 5 S1 220 76 S15 220 76 Field excitation current i exc A 400 V 50 Hz S25 220 76 i exc excitation current of the exciter field S35 240 80 LSA 44 2 no load on load M45 270 90 L65 290 102 VS3 0 5 1 8 L8 330 120 VS45 0 5 2 1 S7 0 5 1 9 S75 0 5 2 1 M95 0 6 2 LSA 44 2 Total weight kg Rotor kg L12 0 5 1 9 VS3 405 140 VS45 405 140 S7 460 165 4 8 5 3 phase LSA 44 2 4 pole AREP S75 460 165 excitation M95 515 185 Resistances at 20 C 9 Ete ai 210 LSA 44 2 Stator Rotor ie A Field Armat VS3 0 046 2 51 0 3 0 5 4 9 0 5 VS45 0 046 2 51 0 3 0 5 4 9 0 5 S7 0 036 2 91 0 21 0 32 4 9 0 5 S75 0 036 2 91 0 21 0 32 4 9 0 5 M95 0 024 3 32 0 17 0 28 4 9 0 5 L12 0 019 3 66 0 16 0 21 4 9 0 5 LEROY SOMER 15 225 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 5 SPARE PARTS 5 1 First maintenance parts Emergency repair kits are available as an option They contain the following items Ref Designation Qty LSA 43 2 44 2 SHUNT Code R 250 AEM 110 RE 019 198 AVR 1 R 251 AEM 110 RE 021 343 Diode bridge assembly 1 LSA 432 9 100 ALT 432 KD 001 347 Surge suppressor 1 LSA 432 1 13 AEM 000 RE 126 AVR fuse 1 250 V 8 A slow blow Ref Desi
86. 00 A Engine Base Code In addition to the serial number plate OEM engines have an engine option code label affixed to the rocker arm cover These codes indicate which of the engine options were installed on your engine at the factory When in need of parts or service furnish your authorized servicing dealer or engine distributor with these numbers An additional sticker may be also delivered in a plastic bag attached to the engine or inserted in the machine documentation It is recommended to stick this option code list sticker either e On this page of your Operator s manual below this section or e 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 OPTION CODES CD31242 UN 24NOV10 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 availabl
87. 03 94 127 112 152 Prime POWER at 1500 rpm kW hp 83 113 103 140 123 167 Standby POWER at 1800 rpm kW hp 78 106 96 131 115 156 Prime POWER at 1800 rpm kW hp 86 117 106 144 126 171 Standby Width overall mm 612 612 612 Length overall mm 860 860 860 Height overall mm 1039 1039 1039 Weight dry kg 491 491 491 Engine oil quantity L 14 14 14 With Fan Approximate ITEM UNIT OF MEASURE 6068HFS85 6068HFS86 Number of Cylinders 6 6 Fuel Diesel Diesel Bore mm 106 5 106 5 Stroke mm 127 127 Displacement L 6 8 6 8 Compression Ratio 19 0 1 19 0 1 POWER at 1500 rpm kW hp 139 189 184 250 Prime POWER at 1500 rpm kW hp 153 208 202 275 Standby POWER at 1800 rpm kW hp 142 193 193 262 Prime POWER at 1800 rpm kW hp 157 214 212 288 Standby Width overall mm 657 657 Length overall mm 1123 1123 Height overall mm 1036 1036 Weight dry kg 608 608 Engine oil quantity L 20 32 With Fan Approximate CD03523 00002DF 19 23DEC10 1 1 60 2 199 260 PN 121 Specifications Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAY03 O O OOO 8 Bolt or Screw SAE Grade 1 SAE Grade 2 SAE Grade 5 5 1 or 5 2 SAE Grade 8 or 8 2 Size Lubricated Dry Lubricated Dry Lubricated Dry Lubric
88. 11 Press the Enter key to deselect the selected parameter removing it from the list of parameters ENGINE SPEED being displayed on the 1 Up Display PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE CO Deselect Parameters RG13219 UN 26SEP03 OURGP11 00000B1 19 03SEP03 11 18 12 Use the Arrow keys to scroll and highlight the desired ENGINE SPEED parameter that has not been selected for display PERCENT LOAO AT CURRENT RPM 2 parameter without a number to right of it ENGINE OIL PRESSURE 4 Note Load Vie nun Yers ENGINE COOLANT TEMP War v dicare the rew arder oi c pky it she 2289 nel RG13151 UN 24SEP03 Select Desired Parameters 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 14 Continue to scroll through and select additional ENGINE OIL PRESSURE 1 parameters for the custom 1 Up Display Press the Menu key at any time to return to the Custom Setup ENGINE COOLANT TEMP menu S W 9 Ko i Zz S N N f 0 a Select Parameters For Display Continued on next page OURGP11 00000B1 19 03SEP03 13 18 1 5 1 9 020811 PN 52 130 260 Operating the Engine 15 Automatic Scan Selecting the scan function will allow the 1 Up Display to scroll through the selected USE D
89. 124 202 260 Page Page A E Air filter Checka sted cae eae aad 25 3 Engine Clean or replace one piece Sent ee CRE eee 45 3 Operation Lomita gations Roady Aaa E ane ake 15 29 Clean or replace element 45 4 Engine Control Unit ECU serial number 03 4 Air intake system Engine electrical ground connections Checking nAra eee ae a e a sta 35 6 ChecK eer A r O A 30 13 Engine mounts B CHECK iea TA AN AAE 30 13 Engine oil Belt Break In tive ii ie a aae einai 10 2 Check tension 3029 engines c sssessseessseeeee 35 1 Engine oil and filter service intervals eee 10 3 Check tension 4045 and 6068 engines enone seed with automatic tensioner Es Me te ane Oa eR a 35 2 3029 Engines sina EE stats sitenaenedenreesnscenrectaaanerdets 35 8 Check tension 4045 and 6068 engines eee wane Ae ENGINES cece eee ee cece eee 35 8 with manual tensioner ceeeeeeeeeeeeeeeeeeeneeees 35 2 l Check tension 6090 engines with 4045 and 6068 ENGINES cece cece eee eect eeeeeees 50 6 automatic tenSionel ssecsssssecssesessesesseessseeeeees 35 3 6090 engines ennaa aiae a 50 7 Replace 4045 6068 and 6090 engines 45 5 Bolt and screw torque values F Methi Cesi eaaa a ea ees 60 4 Unified inchi enianagn nnna aae 60 3 Final filter Break in engine Ol ccccccsssesescsescesseeteeseseeesees 10 2 Remove and install Replace Cc Install neniigi ae ied neediest 30
90. 19 25NOV10 1 1 15 29 020811 PN 62 140 260 Maintenance Observe service intervals Using hour meter as a guide perform all services at the hourly intervals indicated on following pages At each scheduled maintenance interval perform all previous maintenance operations in addition to the ones specified Keep a record of hourly intervals and services performed using charts provided in Maintenance Records Section IMPORTANT Recommended service intervals are for normal operating conditions Service MORE OFTEN if engine is operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the engine DPSG CD03523 24 19 22JAN07 1 1 Use correct fuels lubricants and coolant IMPORTANT Use only fuels lubricants and coolants meeting specifications outlined in Fuels Lubricants and Coolant Section when servicing your John Deere Engine ayy teat Meet Consult your John Deere engine distributor servicing 8 dealer or your nearest John Deere Parts Network for recommended fuels lubricants and coolant Also 1 available are necessary additives for use when operating 7 engines in tropical arctic or any other adverse conditions 8 p DPSG CD03523 25 19 22JAN07 1 1 020811 20 1 PN 63 141 260 Maintenance Maintenance Interval Chart Item 10 H Daily Every 2 Weeks 500 H 1000 H 1 Year 2000 H 2 Years
91. 2 2 1xa za e E ov s10 220 320 Installation and maintenance 231 260 140 mm LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R This manual concerns the alternator A V R which you have just purchased We wish to draw your attention to the contents of this maintenance manual By following certain important points during installation use and servicing of your A V R you can look forward to many years of trouble free operation SAFETY MEASURES Before using your machine for the first time itis important to read the whole of this instal lation and maintenance manual All necessary operations and interventions on this machine must be performed by a qualified technician Ourtechnical support service will be pleased to provide any additional infor mation you may require The various operations described in this manual are accompanied by recommen da tions or symbols to alert the user to potential risks of accidents It is vital that you unders tand and take notice of the following warning symbols This A V R can be incorporated in a ma chine marked C E Warning 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
92. 2 Slol SPN CID SID PID PPID FMI z 2 x Description Comment lt gt 2 gQ 190 190 190 Engine speed sensor 0 Overspeed extreme 2 Engine speed sensor data intermittent 9 Engine speed sensor abnormal update 11 Engine speed sensor signal lost 12 Engine speed sensor signal lost 15 Overspeed 16 Overspeed moderate 228 261 Speed sensor calibration 13 a Engine timing abnormal calibration 252 252 Software 11 Incorrect engine software 234 253 Check system parameters 2 Incorrect parameters 281 281 Action alert output status 3 Action alert output open short to B 4 Action alert output short to ground 5 Action alert output open circuit 282 282 Overspeed output status 3 Overspeed output open short to B 4 Overspeed output short to ground 285 285 Coolant temperature output status 3 Stata temperature lamp open short to 4 Coolant temperature lamp short to ground 286 286 Oil pressure output status 3 Oil pressure output open short to B 4 Oil pressure output short to ground Oil pressure output open circuit 323 323 Shutdown output status 3 Shutdown output open short to B 4 Shutdown output short to ground 5 Shutdown output open circuit 324 324 Warning output status 3 Warning output open short to B 4 Warning output short to ground 249 260 EN SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 412 Temperature sensor in the EGR valve
93. 23 00002C6 19 23DEC10 1 1 Check Engine Speed 4045 6068 and 6090 Engines If equipped with a tachometer A on the instrument panel observe tachometer reading to verify engine speeds Refer to Specifications Section later in this manual If engine speed adjustment is required see your authorized servicing dealer or engine distributor A Tachometer RG13728 UN 11NOV04 Using Tachometer to Check Engine Speeds CD03523 00002C7 19 23DEC10 1 1 020811 35 8 PN 89 167 260 Maintenance 2000 Hours 2 Years Check and Adjust Engine Valve Clearance 3029 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 D has reached top dead center TDC on compression O X stroke Insert timing pin JDE81 4 B into flywheel bore Lock Engine at Top Dead Center CD30544 UN 19MAY98 A Flywheel Turning Tool B Timing Pin CD03523 00002C8 19 23DEC10 1 2 3 Check and adjust valve clearance to specifications according to the following procedure 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 val
94. 260 Operating the Engine Using a booster battery or 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 T AARE Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn charger off Make last connection and first disconnection at a point away from battery Always connect NEGATIVE cable last and disconnect this cable first TS204 UN 23AUG88 IMPORTANT Be sure polarity is correct before making connections Reversed polarity will damage electrical system Always connect positive to positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems and 24 volt booster battery ies for 24 volt electrical systems RG4678 UN 14DEC88 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine 2 Connect one end of jumper cable to the POSITIVE post of the booster battery 3 Connect the other end of the jumper cable to the POSITIVE post of battery connected to starter 4 Connect one end of the other jumper cable to the NEGATIVE post of the booster battery 5 ALWAYS complete the hookup by making the last connection of the NEGATIVE
95. 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 lock nuts instructions are given for the specific application wheel bolts or wheel nuts unless different instructions are given for the specific application I ubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or M20 and larger fasteners with JDM F13C F13F or F13J zinc flake coating Dry means plain or zinc plated without any lubrication or M6 to M18 fasteners with JDM F13B F13E or F13H zinc flake coating DX TORQ2 19 12JAN11 1 1 020811 PN 123 60 4 201 260 Specifications 60 5 020811 PN
96. 43 2 44 2 WHERE REBBERREI TEN YW N j PY 227 260 N Nbr Description N Nbr Description 1 1 Stator assembly 120 1 Terminal block support AREP 4 1 Rotor assembly 124 1 Terminal block 15 1 Fan 198 1 Voltage regulator AVR 16 6 Fixing screws 44 2 only 207 1 AVR damper seal 28 1 Earth terminal 217 1 Terminal block 30 1 DE shield 290 1 PMG housing 33 1 Air outlet grille 291 1 Adaptation shaft 36 1 Shield on exciter end 292 1 Magnetic rotor 37 4 Tie rod 293 1 Stator 41 1 Cover front panel 294 2 Fixing screws 47 1 Cover rear panel 295 1 Tie rod 48 1 Cover top panel 296 1 Cable gland washer nut 49 34 Fixing screws 297 1 End plate 51 1 Air intake grille 320 1 Hub 43 2 L7 amp 44 2 only 59 3 Inspection door 322 1 Coupling disc 70 1 NDE bearing 323 Fixing screws 79 1 Preloading wavy washer 324 1 Clamping washer 43 2 S1 to L6 90 1 Exciter field 325 gt Spacer shim 43 2 L7 amp 44 2 only 91 4 Exciter field fixing screw 343 1 Diode bridge assembly 100 1 Exciter armature 347 1 Surge suppressor 107 1 Diode crescent support 349 1 O ring LEROY SOMER 17 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 5 4 2 Two bearing LSA 43 2 44 2 PM
97. 5 5 Check Air Intake System ns 35 6 Replace Crankcase Vent Filter Optional 35 7 Check Crankshaft Vibration Damper 6068 and 6090 Engines ceeee 35 7 Check Engine Speed 3029 Engines 35 8 Adjust Speed Droop Governor 3029 ENGINGS azsctscncs pecans A T 35 8 Check Engine Speed 4045 6068 and 6090 ENgineS ccccescccccrtesececeeteseceettseeeees 35 8 Maintenance 2000 Hours 2 Years Check and Adjust Engine Valve Clearance 3029 Engines ieee 40 1 Check and Adjust Engine Valve Clearance 4045 and 6068 Engines 40 2 Check and Adjust Engine Valve Clearance 6090 Engines cceeeeee 40 3 Drain and Flush Cooling System ceee 40 5 Maintenance As Required Additional Service Information 45 1 Do Not Modify Fuel System cc eeeeeeeeee 45 1 Welding Near Electronic Control Units 45 2 Keep Electronic Control Unit Connectors Clean 0 eeecceeeeeeeeeeeeetteeeeeeenaes 45 2 Clean or Replace Air Filter One Piece 45 3 Clean or Replace Air Filter Element 45 4 Replace Fan Alternator Poly V Belt 4045 6068 and 6090 Engines 45 5 Bleed the Fuel System ecceeeeeseeeeeeeneee 45 6 Troubleshooting General Troubleshooting Information 50 1 Using Diagnostic Gauge for Retrieving Diagnostic Trouble Codes DTC s 4 50 1 Displaying Of Diagnostic
98. 50 0 4X 1X70 2 0 160 1 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 250 1 4X 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 400 1 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 630 1 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM Single phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C eee Cable sizes cali tyr a 0 50m 51 100m 101 150m mm2 AWG mm2 AWG mm2 AWG 10 4 10 10 7 10 7 16 6 9 10 7 16 5 20 10 7 16 5 25 3 25 10 7 16 5 25 3 32 10 7 25 3 35 2 40 16 5 35 2 50 0 50 16 5 35 2 50 0 63 25 3 50 0 70 2 0 80 35 2 50 0 95 4 0 100 35 2 70 2 0 95 4 0 125 50 0 95 4 0 120 2250MCM 22 260 EN 3 4 3 Power connections Disconnect the battery leads or use the battery isolating switch before carrying out any operations on the generating set To disconnect the battery disconnect the negative lead first Warning Open the access hatch to the power section Feed the power cables through the access hatch on the genset control unit Connect the power cables to the bars N LO L1 L2 L3 or N2 R2 S2 T2 Connect the power cables to the installation ensuring the live and neutral wires are correctly connected PONS C S
99. 755 755 Length overall mm 888 1359 1359 1359 Height overall mm 1005 1155 1155 1155 Weight dry kg 363 598 598 598 Engine oil quantity 8 15 15 15 Engine coolant 11 20 20 20 quantity With Fan Approximate ITEM UNIT OF 6068HFU8Z2 6068HFU8Z2 6090HFU84 6090HFU84 MEASURE 150 kVA 200 kVA 250 kVA 300 kVA Number of 6 6 6 6 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 118 4 118 4 Stroke mm 127 127 136 136 Displacement L 6 8 6 8 9 0 9 0 Compression Ratio 19 0 1 19 0 1 16 0 1 16 0 1 POWER at 1500 kW hp 139 189 184 250 233 317 277 376 rpm Prime POWER at 1500 kW hp 153 208 202 274 256 348 304 413 rpm Standby POWER at 1800 kW hp 142 193 193 262 237 321 282 378 rpm Prime POWER at 1800 kW hp 156 212 212 288 260 353 315 428 rpm Standby Width overall mm 819 819 1072 1072 Length overall mm 1524 1524 1755 1755 Height overall mm 1387 1387 1625 1625 Weight dry kg 750 750 1089 1089 Engine oil quantity 20 32 40 40 Engine coolant 27 27 36 36 quantity With Fan Approximate CD03523 00002DE 19 23DEC10 1 1 60 1 020811 198 260 PN 120 Specifications General Bare Engine Specifications ITEM UNIT OF MEASURE 4045HFS86 4045HFS87 4045HFS88 Number of Cylinders 4 4 4 Fuel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 Stroke mm 127 127 127 Displacement L 4 5 4 5 4 5 Compression Ratio 19 0 1 19 0 1 19 0 1 POWER at 1500 rpm kW hp 76 1
100. ASUREMENTS 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 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
101. CD03523 00002B3 19 23DEC10 2 3 6090 Engines NOTE Depending on application the primary fuel filter is equipped with a sensor that detects the presence of water in the fuel filter element This sensor will illuminate the red STOP ENGINE warning light on the diagnostic gauge and also sound an audible alarm A Diagnostic Trouble Code DTC a description of the trouble code and the corrective action needed will be displayed on the diagnostic gauge Check fuel filters A and B daily for water or debris and drain as necessary 1 Loosen drain plugs C at bottom of both fuel filters two or three turns 2 Drain water into a suitable container Retighten drain plugs securely 4 Turn ignition key to ON for 60 seconds to prime the fuel system before starting engine RG13845 UN 11JANO5 Drain Water from Fuel Filters A Primary Fuel Filter B Final Fuel Filter C Drain Plugs CD03523 00002B3 19 23DEC10 3 3 25 4 146 260 020811 PN 68 Maintenance 500 Hours Change Engine Oil and Filter 3029 Engines CD31250 CD31250 UN 06DEC10 Oil Pan Drain Valve on 3029 Engines 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
102. Component Technical Manual for 4045 and 6068 base engines English e CTM125 Component Technical Manual for 3029 engines English e CTM385 Component Technical Manual for 6090 HPCR fuel system engines English e CTM400 Component Technical Manual for 6090 base engines English CTM502 Component Technical Manual for HPCR Fuel System on 4045 and 6068 with 2 Valve Head Engines English RG4624 UN 15DEC88 e CTM67 Component Technical Manual for OEM Engine accessories English only CD03523 00002CC 19 20DEC10 1 1 Do Not Modify Fuel System BolT 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 IMPORTANT Never steam clean or pour cold water on an injection pump while it is still warm To do so may cause seizure of pump parts Modification or alteration of injection pump or high pressure fuel pump A injection timing or fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser In addition tampering with fuel system which alters emission related equipment on engines may result in
103. Connect the electrical circuit of the trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook on the tow vehicle CORRECT CORRECT Tow vehicle Tow vehicle Ei Trailer Trailer INCORRECT INCORRECT Tow vehicle Tow vehicle Trailer Diagram 4 1 Coupling a trailer 4 2 Check before towing Before towing check the following LNNANNNNNRRA RN 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 29 260 EN 4 3 Operation On site trailer These trailers are not fitted with a main brake and so cannot be braked in motion the tyres allow for a maximum speed of 27 km h So it is absolutely prohibited to exceed this speed Nor are these trailers fitted with signalling lights On road use is prohibited On road trailer The driving speed must be suited to the condition of the road and the handling of the trailer Driving at high speed causes heating of the tyres so it is important to stop from time to time and check them Excessive heating may cause a punctu
104. DEC10 earance 6090 Engines Valve Clearance Setting Procedure C Rocker Arm Foot D Feeler Gauge Access has reached top dead center TDC on compression stroke Insert timing pin JDG1571 B into flywheel bore NOTE To assist in adjusting valve clearance push the rocker arm foot C forward for easier feeler gauge access D Continued on next page CD31265 UN 16DEC10 CD03523 00002CA 19 23DEC10 1 3 40 3 170 260 020811 PN 92 Maintenance 2000 Hours 2 Years 3 With engine locked at TDC of No 1 piston s compression stroke use a bent feeler gauge to check valve clearance on Nos 1 3 and 5 exhaust valves and Nos 1 2 and 4 intake valves If out of specification loosen lock nut on rocker arm adjusting screw Turn adjusting screw until feeler gauge slips with a slight drag Hold the adjusting screw from turning with screwdriver and tighten lock nut to es S specifications S ti Specification Intake Valve Clearance 5 Rocker Arm to Valve Q Tip With Engine 8 Cold Clearance oe eececeec cere eeeeeeneeeeeeseneeeeseseseeeeeeeeenea 0 18 mm z 0 007 in Exhaust Valve Clearance Rocker Arm to Valve Tip With Engine Cold Clearance 0 iiccciscccssencccteascostenecteasesstaneceteatenstenectenscaves 0 64 mm 0 025 in Valve Adjusting Screw Lock Nut Torque c cceeeseeeseeeeeeeneeeeeneeeeeeeeeseeeeeeeae 27 Nem 20 Ib ft g o Recheck cleara
105. DEC10 1 1 02 4 88 260 020811 PN 10 Maintenance Records 4000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check or drain and flush if COOL GARD II is not used o Engine speed check and adjust a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Valve clearance adjust Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 000029D 19 03JAN11 1 1 4500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace a Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 000029E 19 22DEC10 1 1 02 5 020811 PN 11 89 260 Maintenance Records 5000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground con
106. Deere equipment include such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source TS1133 UN 26NOV90 Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer DX DRAIN 19 03MAR93 1 1 05 8 020811 PN 29 107 260 Fuels Lubricants and Coolant Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area In general diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed Diesel fuels specified to EN 590 or ASTM D975 are recommended Renewable diesel fuel produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels Required Fuel Properties In all cases the fuel shall meet the following properties Cetane number of 43 minimum
107. Display OURGP11 00000B2 19 O3SEP03 12 14 15 24 020811 PN 57 135 260 Operating the Engine 13 Repeat the parameter selection process until all spaces are as desired 14 Press the Menu key to return to the main menu 425 F 1000 RPM COOL TEMP ENG RPM 443 F 57 PSI OIL TEMP OIL PRES Return To Main Menu RG13154 UN 24SEP03 OURGP11 00000B2 19 03SEP03 13 14 15 Press the Menu key to exit the main menu and return to the engine parameter display GOTO 1 UP DISPLAY SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY fomerancuom RCO Select Remaining Parameters RG13155 UN 070CT03 OURGP11 00000B2 19 03SEP03 14 14 Break in period Within first 100 hours of operation During the first 100 hours of operation avoid overloading excessive idling and no load operation If oil has to be added during this time see ENGINE BREAK IN OIL NOTE During the break in period a higher than usual oil consumption should be considered as normal After first 100 hours of operation After the first 100 hours drain the crankcase and change the oil filter see CHANGING ENGINE OIL AND FILTER Fill crankcase with seasonal viscosity grade oil see DIESEL ENGINE OIL Check tension of alternator belt Check connections of air intake hoses Check for proper tightening of cap screws all around the engine DPSG CD03523 17 19 22JAN07 1 1 Starting th
108. E CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT Press Enter Key RG13194 UN 020CT03 OURGP11 00000B1 19 03SEP03 3 18 4 Three options are available for modification of the 1 Up Display a O Use Defaults This option contains the following 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 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 USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13196 UN 26SEP03 1 Up Display Options OURGP11 00000B1 19 O3SEP03 4 18 15 16 127 260 020811 PN 49 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 Select Defaults RG13195 UN 26SEP03 OURGP11 00000B1 19 03SEP03 5 18 6 Press the Enter key to activate the Use Defaults function USE DE
109. EFAULTS 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 SETUP AUTOMATIC SCAN ON Automatic Scan On RG13222 UN 26SEP03 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 ise i a w a oO i z T fe N N ise 10 ia Automatic Scan Off Continued on next page OURGP11 00000B1 19 03SEP03 16 18 1 5 20 020811 PN 53 131 260 Operating the Engine 18 Once the Use Defaults Custom Setup and Automatic Scan functions have been set press the Menu key to return to the main menu USE DEFAULTS CUSTGM SETUP AUTOMATIC SCAN ON RG13224 UN 26SEP03 OURGP11 00000B1 19 03SEP03 17 18 19 Press the Menu key to exit the main menu and return S a to the engine parameter display 1800 RPM ETELE lt COOL TEMP Tif G0 Q0 Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000B1 19 03SEP03 18 18 Setup 4 Up Display F 1000 RPM phg Pre 1 Turn the key switch to the ON position From the single or four engine parameter
110. FAULTS Defaults Selected RG13197 UN 29SEP03 OURGP11 00000B1 19 03SEP03 6 18 7 The display parameters are reset to the factory defaults then the display will return to the Setup 1 Up Display menu Continued on next page RESTORED TO DEFAULTS Restored To Defaults RG13149 UN 24SEP03 OURGP11 00000B1 19 O3SEP03 7 18 15 17 128 260 020811 PN 50 Operating the Engine 8 Custom Setup To perform a custom setup of the USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF 1 Up Display use the arrow buttons to scroll to and highlight Custom Setup on the display RG13198 UN 26SEP03 Select Custom Setup OURGP11 00000B1 19 03SEP03 8 18 9 Press the Enter key to display a list of engine parameters USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF RG13199 UN 26SEP03 Engine Parameters OURGP11 00000B1 19 03SEP03 9 18 ENGINE SPEED PERCENT LOAD AT CURRENT RPM 3 10 Use the Arrow keys to scroll to and highlight a selected parameter parameter with a number to right of it ENGINE OIL PRESSURE Tras mr 3er ime cates ENGINE COOLANT TEMPERATURE if eer 2 dJisulay lor 2 17e pararelers anc T nal she pa ameler is D se esed tr Onsulay 7 rf 3 arah X ee D D ina Select Parameters Continued on next page OURGP11 00000B1 19 03SEP03 10 18 020811 15 18 PN 51 129 260 Operating the Engine
111. G option N Nbr Description N Nbr Description 1 1 Stator assembly 90 1 Exciter field 4 1 Rotor assembly 91 4 Exciter field fixing screw 15 1 Fan 100 1 Exciter armature 16 6 Fixing screws 44 2 only 107 1 Diode crescent support 28 1 Earth terminal 120 1 Terminal block support AREP 30 1 DE shield 124 1 Terminal block 33 1 Air outlet grille 198 1 Voltage regulator AVR 36 1 Shield on exciter end 207 1 AVR damper seal 37 4 Tie rod 217 1 Terminal block 41 1 Cover front panel 290 1 PMG housing 47 1 Cover rear panel 291 1 Adaptation shaft 48 1 Cover top panel 292 1 Magnetic rotor 49 34 Fixing screws 293 1 Stator 51 1 Air intake grille 294 2 Fixing screws 59 3 Inspection door 295 1 Tie rod 60 1 DE bearing 296 1 Cable gland washer nut 62 2 4 Bearing retainer fixing screw 297 1 End plate 63 1 Cable gland washer 43 2 only 320 1 Hub 44 2 only 67 1 Circlips 343 1 Diode bridge assembly 68 1 Inner bearing retainer 347 1 Surge suppressor 70 1 NDE bearing 349 1 O ring 79 1 Preloading wavy washer 410 1 End shield LEROY 18 SOMER 228 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS LEROY SOMER Electric Power Generation DECLARATION of COMPLIANCE related to CE marking This Declaration applies to the generators designed to be incorporated into machines complying with the Machine Directive Nr 2006 42 CE dated 17 May 2006 MOTEURS LEROY SOMER Boulevard
112. G820 Flywheel Turning Tool A I rotate engine flywheel in running direction clockwise 7 viewed from water pump until No 1 piston front 3 has reached top dead center TDC on compression 2 stroke Insert timing pin JDG1571 B into flywheel 7 bore Lock Engine at Top Dead Center A Flywheel Turning Tool B Timing Pin CD03523 00002C9 19 23DEC10 1 4 3 Check and adjust valve clearance to specifications according to the following procedure Specification Valve Clearance Engine Cold Intake isivc cceevecsdocseesseusts cocsersecsss totnerseasvesoes 0 35 mm 0 014 in EXNaUSti A T Bt dE 0 45 mm 0 018 in 4 If valves need adjusting loosen the locknut on rocker 2 arm adjusting screw Turn adjusting screw until feeler F gauge slips with a slight drag Hold the adjusting screw 5 from turning with screwdriver and tighten locknut A to 1 27 N m 20 Ib ft Recheck clearance after tightening locknut Readjust clearance as necessary n Adjust Valve Clearance 5 Reinstall rocker arm cover and crankcase vent tube A Locknut CD03523 00002C9 19 23DEC10 2 4 4045 Engine NOTE Firing order is 1 3 4 2 i Ba iii We 1 Lock No 1 piston at TDC compression stroke B Lt La IL iT 2 Adjust valve clearance on No 1 and 3 exhaust valves and No 1 and 2 intake valves S QO 3 Rotate flywheel 360 Lock No 4 piston at TDC S compression stroke C 2 4 Adjust valve clearance on No 2 and 4 exhaust valves e and No 3 and 4
113. ISPLAY SELECT UNITS ADJUST BACKLIGHT CoG Enter Key RG13165 UN 020CT03 OURGP11 00000AB 19 03SEP03 3 6 4 Use the Arrow keys to scroll through the engine configuration data ENGINE SPEED PT 4 1000 RPM RG13166 UN 29SEP03 Use Arrow Keys To Scroll OURGP11 00000AB 19 03SEP03 4 6 5 Press the Menu key to return to the main menu ENGINE SPEED PT 1 1000 RPM oO O a w a D il z 5 amp o D 0 ia Return To Main Menu Continued on next page OURGP11 00000AB 19 03SEP03 5 6 1 5 4 020811 PN 37 115 260 Operating the Engine 6 Press the Menu key to exit the main menu and return U Yi to the engine parameter display 1800 RPM ETELE lt COOL TEMP Ti ge OE E ED Exit Main Menu RG13159 UN 26SEP03 OURGP11 00000AB 19 03SEP03 6 6 Accessing Stored 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 ye Oa Gee Si For description of trouble codes see chart in Troubleshooting Section 1800 RPM RG13159 UN 26SEP03 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
114. MER 244 260 EN 9 3 Appendix C List of John Deere Volvo and Perkins fault codes L Slol SPN CID SID PID PPID FMI a Z Description Comment 5 7 l 2 28 Throttle 3 Position 3 Throttle Voltage high short to V Short to V 4 Throttle Voltage low short to V Short to V 29 Throttle 2 Position 3 Throttle Voltage high short to V Short to V 4 Throttle Voltage low short to V Short to V 14 Throttle voltage out of range 84 Vehicle speed Vehicle invalid or missing Not possible with Genset Vehicle speed mismatch application 91 91 91 132 Accelerator pedal position Oo TE toral Throttle Voltage high short to V Throttle Voltage low short to V Throttle calibration invalid Noi passible With Gensel PWM throttle abnormal pulse width application codes declared Throttle invalid CAN value by the CAN J1587 for Throttle voltage out of range low Meee Throttle calibration aborted Throttle voltage out of range 94 94 Fuel rail pressure sensor 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 expected Fuel s
115. Marcellin Leroy 16015 ANGOULEME France Declares hereby that the electric generators of the ranges PARTNER Industrial and Professional as well as their derivatives manufactured by Leroy Somer or on Leroy Somer s behalf comply with the following International Standards and Directives EN et CEI 60034 1 et 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets The Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with the Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the following International Standards and Directives The Machine Directive Nr 2006 42 CE dated 17 May 2006 The EMC Directive Nr 2004 108 CE dated 15 December 2004 as intrinsic levels of emissions and immunity are concerned WARNING The here above mentioned generators should not be commissioned until the corresponding Gen Sets have been declared in compliance with the Directives Nr 2006 42 CE et 2004 108 CE as well as with the other relevant Directives Technical Managers P Betge O Cadel LL Cy 4152 en 12 2009 c LEROY SOMER 19 229 260 230 260 LEROY SOMER 3971 en 2010 11 f T1 T7 T4 T10 oO x
116. OLINE Ii INOIS MAGE IN FRANCE 3029 4045 and 6068 Engine Serial Number Plate C Engine Model Number Engine Model Number C This information is very important for repair parts or warranty information CD31240 UN 24NOV10 CD03523 00002AA 19 23NOV10 1 1 Record Engine Serial Number 6090 Engines JOHN DEERE Q Engine Serial Number a RG6090L123456 77 il 6090HF U84 ___ DEERE amp COMPANY MOLINE ILLINOIS Made In USA CD31241 UN 24NOV10 6090 Engine Serial Number Plate A Engine Serial Number B Engine Model Number The engine serial number plate C is located on the left hand side of engine block between intake manifold and starter motor Record all of the numbers and letters found on your engine serial number plate in the spaces provided below Engine Serial Number A Location of Engine Serial Number Plate C Engine Serial Number Plate Engine Model Number B This information is very important for repair parts or warranty information w RG13813 UN 11JAN05 ama CD03523 00002AB 19 23NOV10 1 1 03 1 96 260 020811 PN 18 Serial Numbers Engine Option Codes JOHN DEERE NUMBER CD6068L123456 6068HFU82 6 8L 171EC 1100 1200 1300 1400 1500 1600 1700 1800 1900 2100 2300 2400 2500 2700 2800 2900 3000 3100 3500 4000 4300 5200 5500 5600 5700 6000 6200 6400 6500 6600 7500 7600 8600 8700 8800 000000 Order 2B00000
117. PAINT 19 24JUL02 1 1 020811 05 7 PN 28 106 260 Safety Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 DX RCAP 19 04JUN90 1 1 Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer Components in products that may contain asbestos fibers are brake pads brake band and lining assemblies clutch plates and some gaskets The asbestos used in these components is usually found in a resin or sealed in some way Normal handling is not hazardous as long as airborne dust containing asbestos is not generated TS220 UN 23AUG88 Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding material containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean Keep bystanders away from the area asbestos If not available apply a mist of oil or water on the material containing asbestos DX DUST 19 15MAR91 1 1 Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with John
118. Primary Filter Element F Primary Filter Packing L Final Filter Packing 8 Screw final fuel filter K into final fuel filter header I and turn clockwise CW Tighten until final fuel filter K snugly mates with final fuel filer header 1 9 Turn filter additional 3 4 turn after seal contact with header NOTE Turn ignition Key to ON for 60 seconds to prime the fuel system before starting engine It may be necessary to turn key off and on again to reprime the system before starting CD03523 00002B9 19 23DEC1 RG14250 UN O6JUN05 0 3 3 Check Crankcase Vent System 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 3 in the rocker arm cover for elbow adapter Tighten z hose clamp securely il A Crankcase Vent Tube eg 8 O Crankcase Vent System CD03523 00002C0 19 23DEC10 1 1 020811 30 12 PN 80 158 260 Maintenance 500 Hours Check Engine Mounts Engine mounting is the responsibility of the vehicle or generator manufacturer Follow manufacturer s guidelines for mounting specifications IMPORTANT Use only Grade SAE 8 or higher grade of hardware for engine mounting g 1 Check the engine mounting brackets A vibration J isolators and mounting bolts on support frame and F engine block for tightness Tight
119. RNING the arrow keys to scroll to the next trouble code see 94 FMI 18 FUEL DF IYFRY PRE EL FITE R ANE a S 3 4 i Use Arrow Keys To Scroll Continued on next page OURGP11 00000AD 19 03SEP03 3 7 15 7 PN 40 118 260 Operating the Engine IMPORTANT Ignoring active trouble codes can result in severe engine damage 4 To acknowledge and hide the code and return to the single or four parameter display press the Enter Key tafx WARNING SPN 94 FMI 18 FAULT FUEL DF IYFRY P CORRECTIVE ACTION 3 L FILTER ANC NEXT gt HIDE RG13242 UN 30SEP03 Hide Trouble Codes OURGP11 00000AD 19 03SEP03 4 7 5 The display will return to the single or four parameter display but the display will contain the warning icon Pressing the Enter key will redisplay the hidden trouble code 1000 RPM Pri y RG13176 UN 26SEP03 Active Trouble Code Icon OURGP11 00000AD 19 03SEP03 5 7 IMPORTANT Ignoring active trouble codes can result in severe engine damage 6 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four parameter display tafx WARNING SPN 94 FMI 18 FAULT FUEL DF IYERY PRESSURE TIVE ACTION 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 corrected 1000 RPM
120. Remove both ball bearings 60 and 70 using a puller with a central screw 4 6 6 2 Reassembly Heat the new bearings by induction or in a drying oven at 80 C do not use an oil bath and fit them to the machine Check that both the preloading wavy washer 79 and the new O ring seal 349 have been fitted on the NDE shield 36 Refit the NDE shield and pass the bundle of wires between the top bars of the shield Refit the DE shield 30 and tighten the 4 fixing screws Check that the machine assembly is correctly mounted and that all screws are tightened LEROY SOMER 13 223 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 4 6 7 Accessing the main field and stator 4 6 7 1 Dismantling Follow the procedure for dismantling the bearings see sections 4 6 5 1 and 4 6 6 1 Remove the coupling disc single bearing alternator or the DE shield two bearing alternator and insert a tube of the corresponding diameter on the shaft end Restthe rotor on one ofits poles then slide it out Use the tube as alever 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 R
121. S Generation set cooling in progress Countdown for Engine Stop delay cooling OR G10 Gradual Stop delay Coolant temperature OR COOLING DOWN 1 min 30 sec 24 08 2005 Overload Gradual Stop delay OR OFF load test delay Date and time depending on settings 59 260 Generating setstop EN Screen Screen Data displayed no G11 OFF Generating set stop in progress IN PROGRESS 24 08 2005 Date and time depending on settings Operating mode changeover switching from Manual Mode to Auto Mode following auto start demand Screen Screen Data displayed no Start Demand AUTO Do you wish to change a to Auto Mode Operating mode operation in Manual Mode WARNING Immediate start OK Esc AUTOMATIC start demand Generating set stop request due to fault or by pressing STOP in Auto Mode ei Screen Data displayed Manual Mode activated Operating mode operation in Auto Mode Do you wish to change generating set in operation G13 Warning message for switching to Manual Mode to AUTO mode OK Esc after the STOP button has been pressed or a fault has appeared 60 260 EN 6 3 2 Starting A Check that the generating set circuit breaker has triggered Danger 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
122. Serial Numbers Option Description Option Description Codes Codes 22 Thermostat 63 Low Pressure Fuel Line 23 Fan Drive 640 Exhaust Elbow 24 Fan Belt 65 Turbocharger 25 Fan 66 Coolant Temperature Switch 26 Engine Coolant Heater 67 Electronic Tachometer Sensor 27 Radiator 68 Damper 28 Exhaust Manifold 69 Engine Serial Number Plate 29 Ventilator System 72 ECU Electronic Software Option 30 Starting Motor T4 Air Conditioner Compressor Mounting 31 Alternator 75 Air Restriction Indicator 32 Instrument Panel 76 Oil Pressure Switch 35 Fuel Filter 81 Primary Fuel Filter 36 Front Plate 83 Electronic Software 37 Fuel Transfer Pump 84 Electrical Wiring Harness 39 Thermostat Housing 8 amp Fan Pulley 40 Oil Dipstick 87 Belt Tensioner 4l Belt Driven Front Auxiliary Drive 88 Oil Filter 4300 Starting Aid 910 Special Equipment Factory Installed 44 Timing Gear Cover with Gears 930 Emission Label 45 Balancer Shaft 98 Shipping 46 Cylinder Block With Liners and Camshaft 47 Crankshaft and Bearings 48 Connecting Rods and Pistons 49 Valve Actuating Mechanisms CD03523 00002AC 19 03JAN11 2 2 Record fuel injection pump model number Record the fuel injection pump model and serial information found on the serial number plate A Model No RPM Manufacturer s No Serial No CD30749 UN 24SEP99 DPSG CD03523 15 19 22JAN07 1 1 020811 03 3 PN 20 98 260 Serial Numbers
123. Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground tae 8 Cooling status of the piston Ei 4 Status of the starting request input wen 6 Stop request on CIU 257 260 EN SAE J1939 73 March 2004 FMI and Description FMI 0 DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition Region e of the signal range 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 FMI 2 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 connect
124. TANDART 8 Maximum altitude of the site above sea level m 17 Sound pressure for the rated power 18 Sound power Figure 2 2 Example of generating set identification plate 15 260 EN 2 4 Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this option to be collected Diagram 2 3 Fluid retention container The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers via the drain port v Note Never allow these fluids to drain onto the ground ensure they are collected in a designated container 2 5 Fuel and consumables All specifications product features are given in the engine maintenance manuals attached to this manual Fuels The specifications refer to European or international standards Fuels complying with the standards indicated in the engine maintenance manuals can be used without any contraindications Only these fuels may be used Consumables In addition to the specifications indicated in the engine maintenance manuals the c
125. Tier 3 and Stage III A Engines 10 3 Lubricant Storage ierre E r 10 3 Mixing of L bricantan se ntan ea 10 4 Diesel Engine Coolant 10 4 Operating in Warm Temperature Climates 10 4 Operating the Engine Using Diagnostic Gauge to Access Engine Information Optional equipment 15 1 Main Menu Navigation 15 1 Engine Configuration Data 0 0 00 cece 15 3 Accessing Stored Trouble Codes 15 5 Accessing Active Trouble Codes 08 15 7 Engine Shutdown Codes 15 9 Adjusting Backlighting cceeeeeseeeeeeees 15 10 Adjusting Contrast 0 ccceeesseeeeeesteeeeeenaes 15 12 Selecting Units Of Measurement 6 15 13 Setup 1 Up Display ccccceeeeeeteeeeteeees 15 15 Setup 4 Up Display cecceceeeeteeeeeteeees 15 21 Break in period ccecceceeeeeeeeeeeeecceeeeeeeees 15 25 Starting the engine eee eeeeeeeeteteeeeeees 15 25 Cold Weather Operation cceeeeeeeees 15 26 Using a booster battery or charger 15 28 Engine operation ccceccccceeesseeeeeeeenteeeeeeeaes 15 29 Standby power units 20 00 eeeeeeeeeeeeeeeeeeeeees 15 29 Stopping the engine 15 29 Changing Generator Frequency ceee 15 29 Maintenance Observe service intervals ccceeeeeeeeees 20 1 Use correct fuels lubricants and coolant 20 1 Maintenance Interval Chart ceeeeeeeee 20 2 Maintenance Dai
126. Tighten bleed screw securely continue operating hand nozzles as explained next primer until pumping action is not felt Continued on next page CD03523 00002D1 19 21DEC10 2 6 45 6 020811 PN 102 180 260 Maintenance As Required 5 At Fuel Injection Pump a Slightly loosen fuel return line connection C at fuel injection pump b Operate fuel pump primer lever until fuel without air bubbles flows from fuel return line connection for D A c Securely tighten return line connection R C Fuel Return Line T Connection lt 8 oO Mechanical Injection Pump Return Line CD03523 00002D1 19 21DEC10 3 6 6 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 S 27 N m 20 Ib ft S TARERE ET c Repeat procedure for remaining injection nozzles if Z necessary until all air has been removed from fuel d system If engine still will not start see your authorized a servicing dealer or engine distributor Bleed Fuel System at Fuel Injection Nozzles Continued on next page CD03523 00002D1 19 21DEC10 4 6 020811 45 7 PN 103 181 260 Maintenance As Required 4045 and 6068 Engines ak A TION High pressure fluid remaining in fuel lines can cause ser
127. User and maintenance manual for generating sets i Eso 4 a E Rental Compact COM mf Rental A477 7772 7 R90C3 33504022801NE_0_1 1 PrelaCe sc civics tien Gl eee eee ates eve ea eee ea eed td Ae sd Se ee et Bee aa 1 1 General recommendations 000 1 2 Pictograms and their meaning6 1 3 Instructions and safety regulations 1 3 1 General advice eeeeeseeeeeseeeeessteeeeseeees 1 3 2 Risks related to exhaust gases and fuels 1 3 3 Risks related to toxic products 1 3 4 Risk of fire burns and explosion 1 3 5 Risks related to electrical networks secere 1 3 6 Dangers presented by electric Currents first aid 00 eee eeeeeeseeee sents eeeeneeetenaeeeesenaeeeeeeaaeeeseaaeeeeeaeeeeeeaaeeeseaaeeeeesaeeeeeenaeeeeenaeeees 9 1 3 7 Risks related to moving the set 1 3 8 Risks related to noise ceeeeeeeeeeeee 2 General description yess ieee aeketg esac ieee We hil e ea eRe atelier tes eset EO A eee 2 1 DOSCHrIPUOM EEA AEE E ET iuns asvens oh ebitee tied oe spying ores atid saan hid E T 2 2 Technical specifications 23 Identifying setss 2 4 8 chara eke AL eae di eee Sve An eon Dei ee 2 4 PUIG FeteNtlOMN E aE AEEA Be eh EEE aden eM E ee de aad a 2 5 Fuel and consumables 2 5 1 Specifications 0 0 eee 2 5 1 1 Oil GradeS ss i2 cisiiceseceasaedisteetee Space 2 5 1 2 Specifications of coolants 3 Installation Connections
128. a battery lamp see section 4 5 2 4 6 4 2 Reassembly Replace the bridges respecting the polarity see section 4 5 1 Replace the surge suppressor 347 Refit the air intake grille 51 Replace the terminal box lid 48 4 6 5 Replacing the NDE bearing on single bearing machines 4 6 5 1 Dismantling Remove the terminal box lid 48 Remove the air intake grille 51 Unscrew the fixing clamps on the power output cables remove the connector from the exciter and the R 791 module Remove the 4 nuts on the tie rods Remove the NDE shield 36 using a puller eg U 32 350 FACOM 4 6 5 2 Reassembly Heat the inner slipring of a new bearing by induction or in a drying oven at 80 C do not use an oil bath and fit it to the machine Place the preloading wavy washer 79 in the shield and fit a new O ring seal 349 Refit the NDE shield and pass the bundle of wires between the top bars of the shield Refit the fixing clamps on the cables the R 791 module and the exciter connector Refit the air intake grille 51 Replace the terminal box lid 48 seep JA NDE shield E Screw rod E lt 4 6 6 Replacing the bearings on two bearing machines 4 6 6 1 Dismantling Uncouple the alternator from the prime mover Remove the 8 assembly screws Remove the DE shield 30 Remove the NDE shield see section 4 6 5 1
129. 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 are equipped with a primary fuel filter F and a final fuel filter B Both fuel filters have to be replaced together at the same time 1 Thoroughly clean fuel filter assembly and surrounding area 2 Disconnect water in fuel sensor wiring 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 4 Firmly grasp the retaining ring A and rotate it clockwise 1 3 turn Remove ring along with filter element B or F CD30930 JOHN DEF F CD30930 UN 07FEB07 Fuel Filters E Water Separator Bowl F Primary Fuel Filter Element IMPORTANT Do not dump the old fuel into 5 the new filter element This could cause fuel injection problems A plug is provided with the new element for plugging the used element Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must 6 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 co
130. accessories such as radiator air filter and other small components If RG7784 UN 11NOV97 larger components such as power take off transmission generator air compressor etc are attached to engine the lifting straps provided with engine or through parts channel are not intended for this purpose Technician is responsible for providing adequate lifting devices under these situations See machine manuals for additional information on removing engine from machine 3 Carefully move engine to desired location DPSG CD03523 95 19 22JANO07 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 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 TS201 UN 23AUG88 If you do not understand any part of this manual and need assistance contact your John Deere
131. ake System CD03523 00002CF 19 20DEC10 1 1 45 3 PN 99 177 260 Maintenance As Required Clean or Replace Air Filter Element Oo O a a 4 T S 3 CD31267 Replace Air Filter Element 6090 Engine Shown A Air Filter Cover B Air Filter Element NOTE The procedure for replacing air filter element can punched dented etc allowing no filtered vary depending on air filter configuration air to enter the engine Clean air filter element when restriction indicator is red Air 5 Clean air filter element with compressed air working filter element can be cleaned up to six times Thereafter from clean to dirty side or at least once a year it must be replaced Proceed as follows 1 2 3 4 IMPORTANT Do not reinstall an air filter element which shows evidence of bad condition Thoroughly clean all dirt around air filter area Unlatch and remove air filter cover A Remove air filter element B from canister Clean all dirt from inside canister NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi 6 Mark air filter to keep track of each cleaning operation Fully depress air restriction indicator reset button and release to reset indicator 8 Check air system entirely for proper condition see Check Air Intake System CD03523 00002CE 19 20DEC10 1 1 020811 45 4 PN 100 178 260 Maintenance As Required Replace Fan Alternato
132. all be of a quality that provides cavitation protection to cast iron and aluminum parts in the cooling system John Deere COOL GARD meets this requirement Freeze protection A 50 mixture of ethylene glycol engine coolant in water provides freeze protection to 37 C 34 F 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 Water quality is important to the performance of the cooling system Distilled deionized or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate IMPORTANT Do not use cooling system sealing additives or antifreeze that contains sealing additives IMPORTANT Do not mix ethylene glycol and propylene glycol base coolants DX COOL8 19 16NOV01 1 1 Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants Always use a recommended glycol base engine coolant even when operating in geographical areas where freeze protection is not required John Deere COOL GARD II Premix is available in a concentration of 50 ethylene glycol 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
133. ance 3P N 3P 2P N 1P N 1 P3 P3 P3 P3 2 P4 P4 P6 P7 3 P5 P8 P8 P9 4 P8 P9 P9 P2 5 P9 P2 P2 P10 6 P2 P10 P10 7 P10 Change screens by using the scrolling and selection wheel When the wheel is rotated clockwise the screens scroll upwards and vice versa The screens scroll in a loop E g On three phase neutral network then screen 7 then screen 1 and vice versa 6 3 1 6 Display of messages in zone 4 The display zone 4 among other things displays messages relating to the operation of the generating set The messages are as follows Initialisation of TELYS Screen no Screen Data displayed Initialisation of TELYS when the power is switched G1 on and or when loading a configuration SERIAL No 08030010000 Generating set serial no SOFTWARE 6 1 0 Software version of TELYS NOMINAL VOLTAGE 400V Alternator Nominal Voltage G2 FREQUENCY 50Hz Alternator Nominal Frequency NOMINAL KW 320kW EARTH SYSTEM TNS E Nominal Active Output Neutral Point Bar graph indicating the display delay of the screen 57 260 Generating set stopped EN Screen no Screen Data displayed OPERATION MANUAL Press START Operating mode generating set in Manual Mode G3 to start ready to start Date and time depending on settings 24 08 2005 OPERATION AUTO WARNING Operating mode generating set in Auto Mode G4 START UP POSSIBLE ready to start
134. and filter at least once a year 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Open oil pan drain valve A Drain crankcase oil from engine while warm 4 Replace oil filter as follows a Remove and discard oil filter element B using a suitable filter wrench b Oil packing C and install new filter element Hand tighten element according to values printed on filter element If values are not provided tighten element Continued on next page CD30760 UN 26AUG99 CD30926 UN 30JAN07 Oil Filter Packing A Oil Pan Drain Valve B Oil Filter Element C Oil Filter Packing approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element CD03523 00002B4 19 23DEC10 1 2 30 1 020811 PN 69 147 260 Maintenance 500 Hours CD31251 UN 06DEC10 FD000047 UN 13MAR96 FDOO0047 Oil Filler Cap Crosshatch Area on Oil Dipstick D Oil Filler Cap 5 Close oil pan drain valve 7 Start engine and run to check for possible leaks 6 Fill engine crankcase with correct John Deere engine oil through opening on rocker arm cover D 8 Stop engine and check oil level after 10 minutes If necessary top up 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 area o
135. are shock absorber to enable instant repairs 31 260 EN PARKING LEVER 1 NUT 5 COMPENSATING TENSIONER6 CROSS BAR7 BRAKE CABLE _ SPRING 5 Hi a i Sp 9 SLIDE 2 ae a eaae A LINKAGE CASING STOP SETTING SCREW 8 AUTOMATIC JET BACKWARD JAW FER simece saw KJO RETRACTOR z Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 32 260 4 7 Faults and repairs N Fault observed Origin Solutions Erratic braking of trailer Faulty shock absorber Replace the shock absorber Braking too weak Jaws worn Replace the jaws Jaws not run in Fault will disappear only after running in Incorrect linkage setting Adjust the setting Significant friction on the slide Grease the sliding parts Slide corrosion Remove the corrosion and grease Coupling height does not match that of the towing vehicle Adjust the height so that the two parts are in the same horizontal plane Drum temperature abnormally high Incorrect linkage setting Adjust the settings Incorrect brake setting Adjust the settings High levels of dust in the drums Remove the dust Jaws springs drums damaged Replace the damaged parts Brake cables or link rod damaged Replace the damaged parts Jerky braking Incorrect linkage setting Adjust the
136. articular 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 when the set is running Proper ventilation is required for your generating set pump unit or lighting column to work properly Without this ventilation the engine would very quickly rise to an excessively high temperature causing accidents or damage to the equipment and to surrounding property Do not remove the radiator cap if the engine is hot and the coolant is pressurised due to risks of burns Depressurise the air oil and cooling circuits before removing or disconnecting all the fittings pipes or connected components Watch out for the possible presence of pressure when disconnecting a device from a pressurised system Do not try to find pressure leaks by hand Oil at high pressure can cause bodily damage Some preservative oils are flammable Also some are dangerous to inhale Ensure proper ventilation Use a protective mask Hot oil causes burns Avoid contact with hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine with the oil filler cap off oil may splash out Never coat the generating set pump unit or lighting column with a
137. as 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 Switch Activated 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 Active High Pressure Fuel Pump Control Valve Signal Out of Range High High Pressure Fuel Pump Solenoid Number 1 Circuit Has High Resistance High Pressure Fuel Pump Not Able to Meet Required Rail Pressure Requested Torque Curve Signal Unreliable Engine in Derate Condition Security Violation Corrective Action Check Wiring Check Wiring 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 Inject
138. ated Dry N m Ib in N m Ib in Nem Ib in N m_ Ib in N m Ib in N m Ib in Nem Ib in N m_ 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 N m Ib ft Nem lb ft 5 16 77 68 9 8 86 12 106 15 5 137 19 5 172 25 221 28 20 5 35 26 N m Ib ft Nem lb ft 3 8 13 5 120 17 5 155 22 194 27 240 35 26 44 32 5 49 36 63 46 N m Ib ft Nem Ib ft Nem lb ft 7 16 22 194 28 20 5 35 26 44 32 5 56 41 70 52 80 59 100 74 N m lb ft 1 2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115 9 16 48 35 5 60 45 76 56 95 70 125 92 155 115 175 130 220 165 5 8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225 3 4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400 7 8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640 1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960 1 1 8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 1 1 4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 Torque values listed are for general use only based on the strength of the bolt Replace fasteners with the same or higher grade If higher or screw DO NOT use these values if a different torque
139. ated as well as the potentiometer terminals wires at the same voltage as the power R731 external module sensing of 3 phase voltage 200 to 500 V compatible with parallel operation Disconnect ST1 to connect the module set the voltage via the module po tentiometer R 734 module detection of 3 phase current and voltage for parallel operation on unba lanced installations imbalance gt 15 R 726 module 3 functions mounted exter nally P F regulation 2F and voltage sensing cir cuit before paralleling 3 F Control through DC voltage used monito ring apply to the terminals for connection of a potentiometer DC voltage e internal impedance 1 5 KQ e 0 5V enable a voltage setting of 10 LEROY SOMER 238 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 3 INSTALLATION COMMISSIONING 3 1 Electrical checks on the AVR Check that all connections have been made properly as shown in the attached wi ring diagram Check that the ST3 frequency selection jumper is on the correct frequency setting Check whether the ST4 jumper or the re mote adjustment potentiometer have been connected Optional operating modes e ST1 jumper open to connect the R 7310r R 734 3 phase sensing module e ST2 jumper open if rapid response time used e ST5 jumper open to suppress the LAM function 3 2 Settings The machine is tested and
140. ating range Continued on next page CD03523 00002B0 19 23DEC10 2 3 25 1 PN 65 143 260 Maintenance Daily or Every 10 Hours 6090 Engines 1A yee Before starting the engine for the first time of the day check engine oil level on oil dipstick filler cap A as follows 1 Remove oil dipstick filler cap A 2 Wipe dipstick blade to remove oil 3 Reinstall dipstick then tighten by hand 4 Again remove dipstick and check oil level CD31244 UN 30NOV10 Add oil as required using seasonal viscosity grade oil IMPORTANT DO NOT fill above the crosshatch area B Oil levels anywhere within crosshatch area are considered in the acceptable operating range A Oil Dipstick Filler Cap B Crosshatch Area on Oil Dipstick Filler Cap CD31245 UN 30NOV10 CDO31245 Crosshatch Area on Oil Dipstick Filler Cap CD03523 00002B0 19 23DEC10 3 3 Check Coolant Level S 2 6 Q 3 a oO z 7 5 Z x 8 Wop31246 z 2 8 Radiator Cap A Radiator Cap CAUTION Explosive release of fluids Remove radiator cap A and check coolant level which from pressurized cooling system can should be at bottom of filler neck Fill radiator with proper cause serious burns coolant solution if level is low Check entire cooling a 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 remov
141. belts for stretching Replace as required CD03523 00002D7 19 22DEC10 3 4 50 11 193 260 020811 PN 115 Troubleshooting Symptom High fuel consumption Problem Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Defective turbocharger Low engine temperature Solution Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace if necessary Use correct grade of fuel Use proper type of fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Check thermostat CD03523 00002D7 19 22DEC10 4 4 50 12 194 260 020811 PN 116 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 en
142. cceeeseeeeeeneeeeeeeaeeesenaeeeeeeeaeeeeeeaaeeeeeaaeeeseeeeeeeaaeeteneeeeneneeeeeee 207 9 3 Appendix C List of John Deere Volvo and Perkins fault codes ecceeeeeeeeeeeeeeeeneeeeeeeeeeeeeeaeesaaeeseaeeeaeeseaeesnaeeteeeesaeenes 245 2 260 EN 1 Preface 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to help you operate and maintain your electrical generating set correctly The information contained in this manual is taken from technical data available at the time of print In line with our policy of continually improving the quality of our products this information may be amended without warning Read the safety instructions attentively in order to prevent any accidents faults or damage These instructions must always be followed You are likely to encounter several warning symbols in this manual A This symbol indicates an immediate danger to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure Danger A This symbol draws attention to the potential risks to human health and life in case of exposure Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure Warning This symbol indicates a dangerous situation if the warning is not heeded Failure to fo
143. coupling disc screws to the recommended torque and check that there is lateral play on the crankshaft 3 1 2 2 Two bearing alternator Semi flexible coupling Careful alignment of the alternator and the heat engine is recommended checking that the differences in concentricity and parallelism of the two parts of the coupling do not exceed 0 1mm CAUTION This alternator has been balanced with a half key 3 1 3 Location Ensure that the ambient temperature in the room where the alternator is placed cannot exceed 40 C for standard power ratings for temperatures gt 40 C apply a derating coefficient Fresh air free from damp and dust must be able to circulate freely around the air intake grilles on the opposite side from the coupling 3 2 Inspection prior to first use 3 2 1 Electrical checks Under no circumstances should an alternator new or otherwise be operated if the insulation is less than 1 megohm for the stator and 100 000 ohms for the other windings There are three possible methods for restoring the above minimum values a Dry out the machine for 24 hours in a drying oven at a temperature of approximately 110 C without the AVR b Blow hot air into the air inlet having made sure that the machine is rotating with the exciter field disconnected c Run in short circuit mode disconnect the AVR Short circuit the three output terminals power using connections capable of supporting the rate
144. ctual consumption active status codes status codes recorded coming from the engine MDDM20 parameter configuration for display display of the engine configuration parameters etc depending on the type of engine B Use The Murphy module MDDM offers simple menu navigation 1 To browse the list of parameters press the Up and Down buttons AP 2 To enter or exit a sub menu press both arrows simultaneously Pal 44 260 EN The Parameter menu to navigate in this menu simply use the arrow buttons separately The sub menus The sub menus are available at the end of the parameter menu To go to these sub menus scroll through the parameters using the A and Y buttons until you reach the required sub menu C The Sub menus The sub menus enable certain aspects of the fault finding module display to be modified Changing the unit of measurement There are two display modes available for units English or metric To change your units of measurement use the A and Y scroll buttons until you get to the sub menu Press the A and Y arrows simultaneously if you want to retain the current designation KAN Press one of the scroll buttons to show the second mode for displaying units If you want to retain the second display mode confirm this by pressing the A and YW buttons simultaneously 46 260 EN D Displaying the active service codes The fault finding module enables the machine faults and alarms to b
145. d Replace the cable and adjust the setting 33 260 EN 4 8 Electrical connection diagram 2 white side lights on flexible support depending on model 2 two coloured side marker lights depending on model 2 x 6 function rear lights depending on model fo 7 metal pin male plug Jf 2 x 2 conductor cables 2 plate lights 2 Metal socket J connector 7 conductor cable 2 x 2 conductor cables depending on model 2 x 2 conductor cables depending on model Figure 4 6 Electrical connection diagram 4 9 Complete wheels technical information TYRES COMPLETE WHEELS Dimensions Indices Diameter mm Cross section Radius under Load Pressure mm load Kg bar mm 135 R13 550 134 265 335 2 4 145 R13 75T 566 145 272 387 2 4 155 R 13 79T 578 150 277 437 2 4 145 70 R 13 71T 534 150 259 345 2 5 155 70 R 13 75T 548 147 263 387 2 5 185 70 R 13 86 T 594 185 285 530 2 5 165R 14C 98 N 622 172 284 650 3 8 155 70 R12 100 N 525 155 244 650 6 25 800 185R 14C 102 P 650 188 316 675 7 4 5 850 195R14C 106 P 666 198 32 950 4 5 195 50 x 10 98 N 450 190 750 6 0 Wheel with 4 holes Wheel with 5 holes 34 260 5 Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate Specific skills are required to carry out these operations They
146. d Numnser Detection Note conductors TT 4 poles Measurement of residual current Triggering of 1 fault by RCD TN C 3 poles No measurement oi residual current Triggered by overcurrent protection S 4 poles upon 1 fault Triggered upon 2 fault by IT SN 3 poles Insulation resistance measurement overcurrent protection 25 260 3 5 3 TT system Ground connected to earth T Neutral earth Figure 3 2 TT neutral system The alternator neutral is earthed and the grounds of the user equipment have their own earth connection In the TT system automatic power cut off via a Residual Current Device RCD is obligatory at the upstream part of the facility to ensure protection of personnel with a maximum 30 mA device on outlet circuits 3 5 4 Differential protection In order to ensure that people are protected from electric shocks from the TT system the generating set is equipped with a residual current device this can be fixed or adjustable depending on the option chosen e Ifthe generating set s residual current device is not adjustable and the activation threshold has been set at 30 mA all terminal circuits in use are protected e Ifthe generating set s residual current device is not adjustable and the activation threshold has been set at 300 mA a 30mA residual current device must be added to each of the circuit outlets in use I
147. d current try not to exceed 6 A mm Inserta clamp ammeter to monitor the current passing through the short circuit connections Connect a 48 Volt battery in series with a rheostat of approximately 10 ohms 50 W to the exciter field terminals respecting the polarity Open all the alternator openings fully Run the alternator at its rated speed and adjust the exciter field current using the rheostat to obtain the rated output current in the short circuit connections Note Prolonged standstill In order to avoid these problems we recommend the use of space heaters as well as turning over the machine from time to time Space heaters are only really effective if they are working continuously while the machine is stopped CAUTION Ensure that the alternator has the degree of protection matching the defined environmental conditions LEROY SOMER 216 260 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3434 en 2010 10 i 3 2 2 Mechanical checks 3 3 Terminal connection diagrams Before starting the machine for the first time check that the fixing bolts on the feet are tight the cooling air is drawn in freely the protective grilles and housing are correctly in place the standard direction of rotation is clockwise as seen from the shaft end phase rotation in order 1 2 3 For anti clockwise rotation swap 2 and 3 the winding connection correspo
148. e Below normal engine temperature Improper valve clearance Dirty or faulty injection nozzles Injection pump out of time Turbocharger not functioning Leaking exhaust manifold gasket Defective aneroid control line Restricted fuel hose Low fast idle speed Low oil level Continued on next page Solution See Engine Overheats Remove and check thermostat Replace fuel filter element Drain flush fill and bleed system Have authorized servicing dealer or engine distributor check injectors Remove and check thermostat Check gauge sender and connections Reduce load Service air cleaner Replace filter elements Use proper fuel See Engine Overheats Remove and check thermostat See your authorized servicing dealer or engine distributor Have authorized servicing dealer or engine distributor check injectors See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Clean or replace fuel hose See your authorized servicing dealer or engine distributor Add oil CD03523 00002D7 19 22DEC10 2 4 50 10 192 260 020811 PN 114 Troubleshooting Symptom High oil consumption Engine emits white smoke Engine emits black or gray exhaust smoke Engine o
149. e and at the other end leaving a 2 mm gap J2 max between the spring and nuts 5 00 6 Tighten all the lock nuts Checking the setting trailer on axle stands Pulthe 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 Pullthe parking lever fully The wheels will not turn either in FORWARD or REVERSE and the cross bar s must remain parallel with the axle body gt Check the transmission setting after 180 miles 300 km running in period and if necessary adjust the gap J1 using the tensioner Parking gt The lever must be fully pulled up so that the compensating spring is fully compressed gt Every 900 miles 1500 km check the braking settings and distribution on all the wheels Important gt The brake controls are designed to draw trailers behind flexible suspension touring vehicles If used behind an HGV be sure to provide the fitted ball joint with a shock absorber to prevent premature wear gt During any manoeuvres with the trailer coupled do not turn more than 90 or force reverse gt The specifications of our brake controls are indicated on a manufacturer s plate and the items on this should be supplied to us when requesting replacement parts in particular for the shock absorber of a special type approved by the Service des Mines to correspond to European standards it is advisable to have a sp
150. e alternator Connect the mains power supply using a transformer 200 240V as_ indicated X1 X2 48V Install a 10A D C ammeter in series with the exciter field Turn P5 fully anti clockwise and activate the power supply If there is no output current from the AVR turn potentiometer P2 voltage clockwise until the ammeter indicates a stable current Switch the power supply off then on again turn P5 clockwise until the required max current is obtained no more than 8 A 10 LEROY SOMER 240 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R Checking the internal protection Open switch D the excitation current should increase to its preset ceiling remain at that level for 10 seconds and then drop to lt 1A To reset switch off the power supply by ope ning switch A Note After setting the excitation ceiling as described adjust the voltage again see section 2 1 1 In some countries itis a legal requirement to have a short circuit current of 3 IN so as to offer selective protection 3 2 3 Special type of use Excitation circuit E E must not be left open when the machine is running AVR damage will occur 3 2 3 1 R438 field weakening SHUNT E The exciter is switched off by disconnecting the AVR power supply 1 wire X1 or X2 Contact rating 16 A 250V A C 3 2 3 2 R438 field weakening AREP PMG EE T
151. e at the time of publication The right is reserved to make changes at any time without notice If an engine is ordered without a particular component the last two digits of that functional group option code will be 99 00 or XX The list on the next page shows only the first two digits of the code numbers For future reference such as ordering repair parts it is important to have these code numbers available To ensure this availability enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page NOTE NOTE Your engine option code label may not contain all option codes if an option has been added after the engine left the producing factory If option code label is lost or destroyed consult your servicing dealer or engine distributor selling the engine for a replacement Option Description Option Description Codes Codes Engine Base Code WW Rocker Arm Cover 50 Oil Pump 12 Oil Filler Neck 51 Cylinder Head With Valves 1300 Crankshaft Pulley 62 Auxiliary Gear Drive 14 0 Flywheel Housing 63 Fuel Heater 150 Flywheel 5400 Oil Heater 16 Fuel Injection Pump 55 Shipping Stand 17 Air Inlet 56 Paint Option 18 Air Cleaner 57 Coolant Inlet 19 Oil Pan 59 Oil Cooler 20 Coolant Pump 60 Add on Auxiliary Drive Pulley 21 Thermostat Cover 62 0 Alternator Mounting Continued on next page CD03523 00002AC 19 03JAN11 1 2 03 2 97 260 020811 PN 19
152. e displayed in real time When a fault appears the display shows the message SrvcCode every five seconds between displaying the current parameters The orange LED will light up when an alarm code is displayed engine does not stop the red LED will light up when a fault code is displayed SPN and FMI codes are used in standard J1939 to identify faulty equipment SPN Suspect Parameter Number FMI Failure Mode Indicator Enter Srvcecode First SPN FMI combination FMI combination In the event that there are no active fault codes the following screen will appear Depending on the SPN FMI code refer to the attached List of engine fault codes and Engine user and maintenance manual for help on fault finding and maintenance Note that the manufacturer documents do not always stipulate the SPN used for example Volvo uses a set of codes called PID Parameter Identifier or SID System Identifier these two names relate to standards J1587 or J1979 but in the case of VOLVO engines they relate to standard J1587 These two codes find their equivalent in standard J1939 SPN The attached List of engine fault codes indicates the SPN equivalent to Volvo s SID and PID John DEERE complies with standard J1939 and uses SPN codes 47 260 EN E display of machine codes programmed The MDDM can display the codes of services programmed in the ECU memory These programmed service codes are usefu
153. e engine P did beat Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aids See COLD WEATHER OPERATION 1 Perform all prestarting checks outlined in Maintenance Daily Section Open the fuel supply shut off valve if equipped 3 Activate the starter motor switch to crank the engine and release it as soon as engine starts NOTE Do not operate the starter motor more than 20 seconds at a time DPSG CD03523 18 19 22JAN07 1 1 15 25 020811 PN 58 136 260 Operating the Engine Cold Weather Operation Depending on equipment various cold weather starting aids are available to assist in starting the engine at temperature below 0 C 32 F Air intake heater P ecard DO NOT use starting fluid on engines equipped with grid type air intake heater or glow plug s Ether starting fluid is highly flammable and may explode causing serious injury NOTE On engines with electronically controlled fuel system 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 heate
154. e 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 Danger If electrolyte comes into contact with your eyes rinse immediately with plenty of water and seek medical attention as soon as possible If electrolyte is accidentally swallowed gargle with plenty of water and drink large quantities of water Consult a doctor immediately Large quantities of electrolyte should be rinsed off using a neutralising agent A common method is to use a solution of
155. e signal which is emitted Broadcast of data value is substituted with the error indicator value FMI 9 ABNORMAL UPDATE RATE Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not at the update rate expected or required by the ECM outside Region c of the signal range definition Also any error that causes the ECM not to send information at the rate required by the system This type of fault may or may be directly associated with the value of general broadcast information 258 260 EN FMI 10 ABNORMAL RATE OF CHANGE Any data exclusive of the abnormalities covered by FMI 2 that is considered valid but whose data is changing at a rate that is outside the predefined limits that bound the rate of change for a properly functioning system outside Region c of the signal range definition Broadcast of data values is continued as normal FMI 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 FMl 12 BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU used here to mean the packaged unit that includes some microprocessor and its associated components and circuits It can be assumed that the communicatio
156. e temperature extremely high Short to V 16 Turbine temperature moderately high Short to V 1184 173 Exhaust gas temperature sensor 1239 96 a cia pressure system of the 1347 Pump control valve status cone ag Vas 1 3 Pump control valve current high 5 Pump control valve error mismatch 7 Fuel rail pressure control error 10 Pump control valve fuel flow not detected 1348 Pump control valve 2 status Only for 6081HF070 5 Pump control valve 2 error mismatch 10 Pump control valve 2 fuel flow not detected 1485 1485 5 Pump power relay status E EON relay of VOLVO 2 Pump power relay fault 3 ECU main relay short circuit high 1568 Torque curve selection Torque curve selection invalid 4 Torque curve input voltage high 9 Torque curve selection missing 1569 Fuel supply status 31 Fuel de rate 1639 Fan speed sensor 1 Fan speed signal missing 2 Fan speed signal erratic Not possible with Genset 16 Fan speed higher than expected application 18 Fan speed lower than expected 2000 ECU status 6 Vehicle ID missing 13 Security violation 2630 Air temperature at the air cooler outlet 0 Air temperature extremely high 3 Sensor input voltage high Short to V 4 Sensor input voltage low Short to V 15 Air temperature high 16 Air temperature moderately high 256 260 EN
157. e volatile degreasing agents can be used such as Normal petrol without additives inflammable Toluene slightly toxic inflammable Benzene or benzine toxic inflammable Ciclohexare non toxic inflammable The insulating components and the impregnation system are not at risk of damage from solvents see the list of authorized products Avoid letting the cleaning product run into the slots Apply the productwith a brush sponging frequently to avoid accumulation in the housing Dry the winding with a dry cloth Let any traces evaporate before reassembling the alternator These operations must be performed ata cleaning station equipped with a vacuum system that collects and flushes out the products used 4 2 5 Mechanical servicing CAUTION Cleaning the machine using a water spray or a high pressure washer is strictly prohibited Any problems arising from such treatment are not covered by our warranty The machine should be cleaned with a degreasing agent applied using a brush Check that the degreasing agent will not affect the paint Compressed air should used to remove any dust If filters have been added to the machine after manufacture and do not have thermal protection the service personnel should clean the air filters periodically and systematically as often as necessary every day in very dusty atmospheres Cleaning can be performed using water for dry dust or in a bath containing soap or detergent
158. eassembling the main field Follow the dismantling procedure in reverse order Take care not to knock the windings when refitting the rotor in the stator If the fan is being replaced on the 43 2 assemble the parts as shown in the following diagram Fit a tube and a threaded screw On the 44 2 the fan is fixed by screws on the hub i P Follow the procedure for reassembling the bearings see sections 4 6 5 2 and 4 6 6 2 After operational testing replace all access panels or covers Installation and maintenance of the PMG For the LSA 43 2 and LSA 44 2 the PMG reference is PMG 1 See the PMG maintenance manual ref 4211 CAUTION and operation at rated load with separate field excitation All values are given at 10 for exact values consult the test report and are subject to change without prior warning For 60 Hz machines the resistance values are the same and the excitation current i exc is approximately 5 to 10 weaker 4 8 1 3 phase LSA 43 2 4 P SHUNT excitation Resistances at 20 C Q LSA 43 2 Stator L N Rotor Field Armature S1 0 155 1 35 18 4 0 23 S15 0 155 1 35 18 4 0 23 S25 0 155 1 35 18 4 0 23 S35 0 128 1 41 18 4 0 23 M45 0 105 1 57 18 4 0 23 L65 0 083 1 76 18 4 0 23 L8 0 063 1 96 18 4 0 23 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 43 2 no
159. em This excitation system consists of a PMG permanent magnet generator This is fitted at the rear of the machine and connected to the R438 AVR The PMG supplies the AVR with constant voltage which is independent of the main MAIN FIELD PMG SYSTEM e e _e _ alternator winding As a result the machine has a short circuit current capacity and good immunity to distortions generated by the load The AVR monitors and corrects the alterna tor output voltage by adjusting the excitation current 50 60 Hz selection via the ST3 jumper STATOR 6 wires marked T1 to T6 STATOR 12 wires marked T1 to T12 a 9 gt a 3 a Armature i M T T4 T10 TS Tial Te T12 lel 14 15 16 ST5 u ST3 wm of Frequency sb Booz ST10 a amp LAM 13 25 Excitation 61 P5 ceiling ST1 1 F Topen knee point 65 Hz F1 Slow fuse TEE O E 250V 8 A according voltage 140 mm 4 x holes 5 8 x 175 x 115 mm Quad P1 droop M AREP ST9 r T PMG ST4 Option External potentiometer for adjusting the voltage Response fM normal ST2 time ra fast ST1 m Single Stabili n amp P3 3 stability detection Option R731 3 ph ie Adi in 3 ph detection ST1 open Pae 1 3 SHUNT or separate excitat
160. em G 5 i A or press the Menu Button to exit the main menu and aa return to the engine parameter display SELECT UNITS ADIVST BACKLIGHT RG13163 UN 020CT03 Use Arrow Buttons To Scroll Quadrant Display OURGP11 00000A9 19 03SEP03 5 5 Engine Configuration Data NOTE The engine configuration data is a read 1800 RPM only function ENG REM lt COOL TEMP NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine ne DIEA Om start up is desired See Starting The Engine All 1 oy COG y of the engine values illustrated on the diagnostic gauge indicate the engine is running Menu Key RG13159 UN 26SEP03 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key OURGP11 00000AB 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow GO TO 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 z ADJUST BACKLIGHT lo oO 2 7 3 D t Select Engine Configuration Continued on next page OURGP11 00000AB 19 03SEP03 2 6 020811 15 3 PN 36 114 260 Operating the Engine 3 Once Engine Config menu item has been highlighted GOTO UP DISPLAY j press the Enter key to view the engine configuration data ENGINE CONFIG SETUP 4 UP DISPLAY SETUP 4 UP D
161. en as necessary 3 2 Inspect overall condition of vibration isolators if 2 z equipped Replace isolators as necessary if rubber Engine Mounting has deteriorated or is crushed due to a loss of elasticity A Mounting Bracket CD03523 00002C3 19 23DEC10 1 1 Check Engine Electrical Ground Connections Keep all engine ground connections clean and tight to prevent electrical arcing which can damage engine or electronic components CD03523 00002C4 19 23DEC10 1 1 30 13 PN 81 159 260 Maintenance 1000 Hours 1 Year Check Belt 3029 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 Belt tension New belt 578 622 N 130 140 Ib force Used beltiecicnscciistenrticaiicenrecittneet 378 423 N 85 94 Ib force NOTE Belt is considered used after 10 minutes of operation b Use of tension tester B and straight edge C A 89 N 20 Ib force applied halfway between pulleys should deflect belt by 19 mm 0 75 in 3 If adjustment is necessary loosen alternator nuts D and E Pull alternator frame outward until belt is correctly tensioned IMPORTANT Do not pry against the alternator rear frame Do not tighten or loosen belts while they are hot 4 Tighten alternator bracket nuts firmly 5 Run engine for 10 minutes then recheck belt tension A JDG529 Tens
162. ent filter optional 35 7 Serial number 2000 Hours Engine Control Unit ECU 03 4 Check and adjust engine valve High pressure fuel PUMDP ceeeeeeeeeeeesteeeeeeeees 03 4 clearance 3029 engines 40 1 Serial numbers Check and adjust engine valve 3029 4045 and 6068 engines eeeees 03 1 clearance 4045 and 6068 engines 40 2 6090 CNGINGS ensi aia itani aiai 03 1 Check and adjust engine valve Engine Control Unit ECU serial number 03 4 clearance 6090 engines 40 3 Engine option codes ssesssssesserreserrresessrrnserrneerees 03 2 Drain and flush cooling system 0 eeeee 40 5 Fuel pump model numbet ccsccceceeeeeeeeeees 03 4 500 Hours Record fuel injection pump model number 03 3 Change engine oil and filter 3029 Engines 30 1 Specifications Change engine oil and filter 4045 and Bare engincar o a a ia 60 2 6068 Engines reen e EEE A 30 3 ENGING patko naana rer EA 60 1 Change engine oil and filter 6090 Engines 30 5 Speed droop governor Change fuel filter element 3029 Engine 30 7 Adjust 3029 engines 0 eceeeeeeeeeeeeeeeneeeeeeeeees 35 8 Change fuel filter element 4045 and Storage 6068 Engines cceeeceeeeeeeeeeeeeenteeeeeeeeaees 30 9 GUIDCIINGS oie E A 55 1 Change fuel filter element 6090 Engines 30 10 Preparation for long term storage period 55 1 Check cran
163. entiometer P3 to around 1 3 of the anti clockwise limit f Start the engine and set its speed to a fre quency of 48 Hz for 50 Hz or 58 for 60 Hz g Set the output voltage to the desired va lue using P2 Rated voltage UN for solo operation eg 400 V Or UN 2 to 4 for parallel operation with C T eg 410 V If the voltage oscillates use P3 to make ad justments try both directions observing the voltage between E and E approx 10V D C LEROY SOMER 9 239 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R The best response times are obtained at the limit of the instability If no stable position can be obtained try disconnecting or repla cing the ST2 jumper normal fast h Check LAM operation ST5 closed i Vary the frequency speed around 48 or 58 Hz according to the operating frequency and check the change in voltage from that observed previously 15 j Readjust the speed of the unit to its rated no load value Adjustments in parallel operation Before any intervention on the alterna tor make sure that the speed droop is identical for all engines k Preset for parallel operation with C T connected to S1 S2 Potentiometer P1 quadrature droop in centre position Apply the rated load cos 0 8 inductive The voltage should drop by 2 to 3 If it in creases check that V and W and also S1 and S2 have not been rev
164. equipment can operate at top efficiency only when clean lubricants are used Use clean containers to handle all lubricants Whenever possible store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain DX LUBST 19 18MAR9Q6 1 1 020811 10 3 PN 32 110 260 Fuels Lubricants and Coolant Mixing of Lubricants In general avoid mixing different brands or types of oil Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance Consult your John Deere dealer to obtain specific information and recommendations DX LUBMIX 19 18MAR9Q6 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 The coolant concentrate sh
165. er Engine speed Battery voltage Fuel Level Air Preheating TELYS Standard specifications Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage 14 260 EN 2 3 Identifying sets Generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documentation contained in the appendices of this manual 6 12 10 21 7 3 A 16 17 GROWPE ELGCTROGENE GENERATING SET PLAQUE CONSTRUCTEUR MANUFACTURER PLATE Pai PRESSION ACOUSTIQUE SOUND PRESSURE aaan an n Type 3 i Execution Iv Masse Kg 80 lt Version 333070080 1 13 8 15 18 1 Generating set 9 Maximum ambient temperature for the rated power 2 Manufacturer name C 3 Model 10 Rated frequency Hz 4 Serial number 11 Generating set rotation speed RPM 5 Year of manufacture 12 Rated voltage V 6 Rated output kVA and kW according to the ISO 13 Rated current A 8528 1 standard 14 Weight kg PRP main power 15 CE marking ESP emergency power 16 Non CE standard marking 7 Rated power factor e g GOSS
166. ersed 1 The no load voltages should be identical for all the alternators intended to run in pa rallel Couple the machines in parallel By adjusting the speed try to obtain 0 KW power exchange By altering the voltage setting P2 on one of the machines try to cancel or minimise the current circulating between the machines From now on do not touch the voltage set tings m Apply the available load the setting is only correct if a reactive load is available By altering the speed match the kW or di vide the rated power of the units proportionally By altering the quadrature droop potentiome ter P1 match or divide the currents 3 2 2 Max excitation setting excitation ceiling Depending on Main the mains frequency Max excitation 50 60 Hz supply 50Hz 60Hz Field a Spy CEE 4110 220 380 V 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 Isc to the actual operating power derated machine which is safer for the alternator and the installation Disconnect power supply wires X1 X2 and Z1 Z2 and the voltage reference 0 110V 220V 380V on th
167. excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field LSA 43 2 Stator L N Rotor Field Armature vous ae S1 0 058 1 35 13 9 0 23 57 1 38 25 0 058 1 35 13 9 0 23 S75 1 42 35 0 046 1 41 13 9 0 23 M95 12 4 M45 0 037 1 57 13 9 0 23 L12 1 38 L65 0 027 1 76 13 9 0 23 L8 0 019 1 96 13 9 0 23 Fiel aor 4 8 6 Dedicated single phase LSA 44 2 ield excitation current i exc A 240 V 60 Hz 4 pole SHUNT excitation 60 Hz only i exc excitation current of the exciter field Resistances at 20 C Q LSA 43 2 no load on load S1 0 59 1 44 LSA 44 2 Stator L N Rotor Field Armature S25 0 59 1 68 VS3 0 0194 2 51 18 4 0 5 S35 0 66 1 65 VS45 0 0194 2 51 18 4 0 5 M45 0 61 1 48 S7 0 0140 2 91 18 4 0 5 L65 0 62 1 48 M95 0 0088 3 32 18 4 0 5 ES 0 4 146 Field excitation current i exc A 240 V 60 Hz i exc excitation current of the exciter field 4 8 4 3 phase LSA 44 2 4 pole SHUNT LSA 44 2 no load on load excitation VS3 0 44 1 18 Resistances at 20 C 9 VS45 0 44 1 25 S7 0 43 1 2 LSA 44 2 StatorL N Rotor Field Armature M95 0 55 1 28 VS3 0 046 2 51 18 4 0 5 VS45
168. ey switch to the ON position Starting at 3 the single or four engine parameter display press the 1800 RPM D Menu key 7 5 l Qoe Q0 2 Menu Key Continued on next page OURGP11 00000B0 19 03SEP03 1 7 15 1 3 PN 46 124 260 Operating the Engine 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Select Units is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 4 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 5 2 i Select Units 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 RG13189 UN 020CT03 Press Enter Key OURGP11 00000B0 19 03SEP03 3 7 4 There are three choices for units of measurement English Metric kPa or Metric Bar English is for Imperial units with pressures displayed in PSI and temperatures in F oO Metric kPa and Metric bar are for IS units with a pressures displayed in kPa and bar respectively and temperatures in C H x Use the Arrow keys to highlight the desired units of 2 measurement 5 rd Select Desired Units Continued on next page OURGP11 00000B0 19 03SEP03 4 7 020811 15 14 PN 47 125 260 Operating the En
169. f the generating set s residual current device is adjustable located upstream this must be above those devices located downstream terminal circuits this means that continuity on clean circuits will be maintained in the event of a fault on one of the terminal circuits Example Generating set 300mA Generating set s residual eee current device Residual current device Residual current device Residual current device 30MA Terminal circuit 1 30MA Terminal circuit 2 30MA Terminal circuit 3 Any change to the setting on the generating set s residual current device could pose a risk to personal safety The user will be held liable any changes must only be made by trained qualified engineers When the generating set is disconnected from an installation after use the general residual current device must be restored to factory settings by a qualified engineer who can then check this Important 26 260 EN 3 5 5 Adjusting the genset differential protection Before adjusting the settings on the generating set s residual current device the following two parameters must be taken into account the sensitivity of the current threshold and the activation time The generating set s residual current device must have in relation to the downstream device terminal circuit a sensitivity three times greater a longer cut off time oz 1234 Seecece ALI ecee Type A AC
170. g 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 Thoroughly clean fuel filter assembly and surrounding area Loosen drain plug A and air bleed plug B Drain fuel into a suitable container NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators Firmly grasp the retaining ring C and rotate it clockwise 1 4 turn Remove ring with filter element D Save retaining ring and if equipped water separator bowl for reuse IMPORTANT Do not dump the old fuel into the new filter element This could cause fuel injection problems A plug is provided with the new element for plugging the used element X9811 UN 23AUG88 CD31258 UN 07DEC10 A Drain Plug C Retaining Ring B Air Bleed Plug D Fuel Filter Element 5 Inspect filter mounting base for cleanliness Clean as required Continued on next page CD03523 00002B7 19 23DEC10 1 2 30 7 020811 PN 75 153 260 Maintenance 500 Hours 6 Inspect condit
171. g moderately out of synchronisation 11 ECU Pump timing speed out of synchronisation 31 ECU Pump timing extremely out of synchronisation 1079 232 Sensor supply voltage 5 Volt Analog throttle reference Sensor supply voltage high gt 5 5 Volt Sensor supply voltage low lt 4 44 Volt 1080 211 Sensor supply voltage Oil pressure Coolant temp pressure 5V sensor supply 2 fuel Sensor supply voltage high gt 5 5 Volt Sensor supply voltage low lt 4 40 Volt 1109 Engine ECU status 31 Engine shutdown warning 1110 Engine status 31 Engine shutdown 1111 268 Check parameters 1136 55 Programmed parameter fault ECU Temperature ECU temperature extremely high ECU temperature moderately high 1172 Input temperature of the TGV compressor Input voltage of the temperature sensor high Short to V Input voltage of the temperature sensor low Short to V 255 260 EN 2 Slol SPN CID SID PID PPID FMI z 2 x Description Comment g 7 gQ 1180 Input temperature of the TGV turbine 0 Turbin
172. g the set 5 1 Installation checks 5 2 Checks after starting the generating Set eeceeeeeeeseeeeseeteaeeeeaeeteaeeeaeeceaeeesaeeseaeeseaeessaaeceaeeseaeenaeeseseeeeaeeseseeseaeeseeeeneeeteaes 1 260 6 Using the generator Sete neat ath Sp eee ees ee eed Re A ae en ve i ee ee 36 6 1 Pre StartINSPeCtionys 5 2 5 5schess Sh cea eaa a aaa e a a hated a tefl ede Sa dll veces eel seat honed ea e Aa a eaS 36 6 2 Generator set with NEXYS Control panel ecceeeseeeesceeeneeeeseeceaeeseaeeeeaeeseaeeesaeeseaeeseaeeseaeesaeeseacessaeseaeeseaeeseseeseaeeseeeeeeesenes 38 6 21 Controlipanel presentation s inon soc cases ences aks ea ea saved snanseacncnsSeassnecbagindececstechaucnens o a E AA Ea ERO ae aia r EREE aE 38 6 2 1 1 Introduction to piIctogr MS iieri saian eiae aa aaae ae aapea e tp cdvebenje diaaa aah Aae ETE Aaa EERE 39 6 2 2 Manual starting ine Se Se A Sei Antes A is eee fee ele a ea SE Pe A eae eee ete 40 CRAS SWITCHING EON AREE A E MEO eee PSE ee eee ae art ee aa ois dad ted ee det 41 624 Alame ANG aU E a E ys dat av sae tenes a a a a a rr a a EE AEE Na 41 6 2 5 Faults alo alarms DEA r E E E piles seeedbes sucess 42 6 2 6 MURPHY diagnostic module aiies rea peika aaea iea E Sa E a pahe EARE E aio E E apare SAES aa AEA Aea EERE p 44 6 3 Generator set with TELYS Control Panel ccecceeseeeesceceneeeeseeeeaeeseaeeceaeeseaeeeaeeseaeesaeeseaeesaeeseaeaseeseseeseaeeseseeseaeeseeeenaeetenees 50 6 3 1 Control
173. geometry is used If the tensioner stop A on swing arm is hitting the fixed stop B check mounting brackets alternator belt belt as needed see Replace Fan and Alternator Belt tensioner idler pulley etc and the belt length Replace Maintenance As Required Section Continued on next page CD03523 00002BD 19 10DEC10 1 2 020811 35 3 PN 84 162 260 Maintenance 1000 Hours 1 Year e Check tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below a Release tension on belt using a long handled 1 2 inch drive tool in tensioner arm Remove belt from pulleys b Release tension on tensioner arm and remove dri tool ve c Put a mark A on swing arm of tensioner as shown d Measure 21 mm 0 83 in from mark A and put mark B on tensioner mounting base e Install torque wrench in square hole so that it is a aligned with center of roller and tensioner as shown Rotate the swing arm using a torque wrench until marks A and B are aligned f Record torque wrench measurement and compar e with specification below Replace tensioner assembly as required Specification SPriNG FOPCE 0 eee eee eeeeeeeeeeteeeseeteeeeeneees 18 22 N m 13 16 lb ft A Mark on Swing Arm B Mark on Tensioner Mounting Base
174. gine 5 Press the Enter key to select the highlighted units ENGLISH METRIC KPA METRIC BAR RG13191 UN 30SEP03 Press Enter Key to Select OURGP11 00000B0 19 03SEP03 5 7 6 Press the Menu key to return to the main menu ENGLISH METRIC KPA METRIC BAR RG13192 UN 26SEP03 Return To Main Menu OURGP11 00000B0 19 03SEP03 6 7 7 Press the Menu key to return to the engine parameter Yi display 1800 RPM ETELE lt COOL TEMP Goe COG Press Menu Key 1000 RPM phg ere RG13159 UN 26SEP03 OURGP11 00000B0 19 03SEP03 7 7 Setup 1 Up Display T Ti 1 Turn the key switch to the ON position Starting at the 3 single engine parameter display press the Menu key 1800 RPM D ETELE lt COOL TEMP T G OR O F CO g Menu Key Continued on next page OURGP11 00000B1 19 03SEP03 1 18 15 15 PN 48 126 260 Operating the Engine 2 Use the Arrow keys to scroll through the menu until Setup 1 Up Display is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT g Setup 1 Up Display RG13193 UN 020CT03 OURGP11 00000B1 19 03SEP03 2 18 3 Once Setup 1 Up Display menu item has been highlighted press the Enter key to access the Setup 1 Up Display function GO TO t UP DISPLAY STORED CODES ENGIN
175. gine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Stretched poly V belt or defective belt tensioner Engine under load Loose or corroded connections Low battery output voltage Faulty start circuit relay Blown fuse Low battery output Crankcase oil too heavy Loose or corroded connections Faulty battery connection Continued on next page Solution Remove accessories or install higher output alternator Increase engine rpm when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your authorized servicing dealer or engine distributor Adjust belt tension or replace belts Remove load Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Replace fuse See your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections Clean and tighten connections CD03523 00002D8 19 22DEC10 1 2 50 13 195 260 020811 PN 117 Troublesho
176. gnation Qty LSA 43 2 44 2 AREP 4 P Code 198 AVR 1 R 438 AEM 110 RE 017 343 Diode bridge assembly 1 LSA 432 9 100 ALT 432 KD 001 347 Surge suppressor 1 LSA 432 1 13 AEM 000 RE 126 AVR fuse 2 250 V 8 A fast blow 5 2 Bearing designations Ref Designation Qty LSA 43 2 Code LSA 44 2 Code 60 Bearing on shaft extension end 1 6312 2RS C3 RLTO60ET007 63152RS C3 RLTO75ET004 70 Bearing on exciter end 1 6307 2RS C3 RLTO35ET030 63092RS C3 RLT045ET030 5 3 Technical support service Our technical support service will be pleased to provide any additional information you may require When ordering spare parts you should indicate the complete machine type its serial number and the information given on the genset nameplate Address your enquiry to your usual contact CAUTION Part numbers should be identified from the exploded views and their description from the parts list Our extensive network of service centres can dispatch the necessary parts without delay Toensurecorrectoperationandthesafety ofour machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage LEROY 16 SOMER 226 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 5 4 Exploded views parts list 5 4 1 Single bearing LSA
177. harts to solve engine problems Solution Verify correct starting procedure Check fuel in tank and manual shut off valve Check and correct exhaust restriction Replace fuel filter or drain water from filter Check fuel flow at supply pump or bleed fuel system Consult authorized diesel repair station for repair or replacement Remove load Review starting procedure Check fuel tank Bleed fuel line Use cold weather starting aids See Starter Cranks Slowly Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Have authorized servicing dealer or engine distributor check injectors Turn key switch to OFF then to ON Add oil to engine crankcase See your authorized servicing dealer or engine distributor Remove and check thermostat CD03523 00002D7 19 22DEC10 1 4 50 9 191 260 020811 PN 113 Troubleshooting Symptom Engine runs irregularly or stalls frequently Below normal engine temperature Lack of power Low oil pressure Problem Engine overheating 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 engin
178. he 1800 RPM D Menu key i i if D 2 QCG QOO z Menu Key OURGP11 00000AF 19 03SEP03 1 6 2 The main menu will be displayed Use the Arrow GO TO tr DISPLAY keys to scroll through the menu until Adjust Contrast STORED CODES is 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 Sane STORED CODES highlighted press the Enter key to activate the ENGINE CONFIG Adjust Contrast function SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 8 ADJUST CONTRAST S ji 5 Press Enter Key Continued on next page OURGP11 00000AF 19 03SEP03 3 6 15 12 PN 45 123 260 Operating the Engine 4 Use the Arrow keys to select the desired contrast intensity ADJUST CONTRAST 3 5 l Adjust Contrast Intensity OURGP11 00000AF 19 03SEP03 4 6 5 Press the Menu key to return to the main menu ADJUST CONTRAST 2 i 5 e Return To Main Menu OURGP11 00000AF 19 03SEP03 5 6 6 Press the Menu key to exit the main menu and return U F to the engine parameter display a 1800 RPM g ETELE lt COOL TEMP ai z l if el o QE O E CO 2 Exit Main Menu OURGP11 00000AF 19 03SEP03 6 6 Selecting Units Of Measurement 1 Turn the k
179. he best performance economy and service life from your engine ensure service is carried out according John Deere oils and coolants have been formulated to this present manual and recorded in the following to give maximum protection and performance to your pages Itis 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 ill gi lue to th hi h engine is covered by extended warranty it is important to aa N eee CR AN A SS A AEE N maintain this record for the duration of the warranty DPSG CD03523 6 19 22JAN07 1 1 100 Hours of operation a Engine oil drain a Engine oil filter replace o Hose connections check Number of hours Observation Dealer or distributor stamp Date Job done by DPSG CD03523 7 19 22JAN07 1 1 500 Hours of operation a Engine oil drain o Crankcase vent system clean a Engine oil filter replace a Engine mounts check o Fuel filter elements replace a Engine ground connection check Number of hours Observation Dealer or distributor stamp Date Job done by CD03523 0000295 19 22DEC10 1 1 02 1 020811 PN 7 85 260
180. his section is a list of possible engine problems and diagnostic trouble codes that may be encountered accompanied by possible causes and corrections This troubleshooting information is of a general nature 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 e Know the engine and all related systems e Study the problem thoroughly e Relate the symptoms to your knowledge of engine and systems e Diagnose the problem starting with the easiest things first e Double check before beginning the disassembly e Determine cause and make a thorough repair e After making repairs operate the engine under normal conditions to verify that the problem and cause was corrected NOTE 4045 6068 and 6090 engines have electronic control systems which may generate diagnostic trouble codes to signal problems see Displaying of Diagnostic Trouble Codes 1 If diagnostic trouble codes are present perform the suggested corrective actions 2 If this does not correct the engine problem contact your servicing dealer 3 If engine has problems but no diagnostic trouble codes are displayed refer to Engine Troubleshooting for problems and solutions CD03523 00002D2 19 22DEC10 1 1 Using Diagnostic Gauge for Retrieving Diagn NOTE The method below applies on application
181. hout prior authorization All brands and models have been registered and patents applied for LEROY 2 LS SOMER 212 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 1 RECEIPT 4 SERVICING MAINTENANCE 1 1 Standards and safety measures 4 4 1 Safety Measures eee eee eetteeeeentteeeeeeenaees 10 T2 INSPOCHON nasaan e e 4 4 2 Regular maintenance 10 1 3 Identification 2 0 00 cece aaiae 4 4 3 Fault detection 0 0 0 ccccceeeeeeeeeeeeseeeeeeeeees 10 1 45 Stra Jeonan a a eh oh 4 4 4 Mechanical defects ec ceseeeeesseeeeeeeenaes 11 TD ADpliGations neinir beget te lea tee cept iveeivereesaes 4 4 5 Electrical faultS 0 cccccccecceeesesescteeeeeeeeees 11 1 6 Contra indications to use 4 4 6 Dismantling reassembly 12 4 7 Installation and maintenance of the PMG 14 2 TECHNICAL CHARACTERISTICS 4 8 Table of characteristics eeeeees 14 2 1 Electrical characteristics 0 ceceeee 4 9 Table of Weights cc ceeeeeeeeeeeetteeeeeeenaees 15 2 2 Mechanical characteristics eee 5 SPARE PARTS 3 INSTALLATION COMMISSIONING 5 1 First maintenance parts eeceeeeeeeeees 16 3 1 Assembly ic cccccevdencteeeseanienev eesceeneeeeacceteeeveseen 5 2 Bearing designations eeceeeeeeeeeeeees 16 3 2 Inspection pr
182. i LSA 43 2 44 2 4 POLE ALTERNATORS 4 6 1 Tools required To fully dismantle the machine we recommend using the tools listed below 1 ratchet spanner extension 1 torque wrench 1 set of flat spanners 7 mm 8 mm 10 mm 12 mm 1 socket set 8 mm 10 mm 13 mm 16 mm 18 mm 21 mm 22 mm 24 mm 1 size 5 Allen key eg Facom ET5 1 size 6 Allen key eg Facom ET6 1 size 10 Allen key eg Facom ET10 1 size 14 Allen key eg Facom ET14 1 T20 and T30 TORX bit 1 puller eg Facom U35 1 puller eg Facom U32 350 4 6 2 Screw tightening torque IDENTIFICATION screw Torque N m Field terminal block screw M4 4N m Field screw M6 10N m Diode bridge RP M6 5N m Diode nut M5 4N m 43 2 tie rod M12 57 N m 44 2 tie rod M14 90 N m Earth screw M8 26 N m 43 2 disc shaft screw M12 110 N m 44 2 disc shaft screw M16 250 N m 44 2 turbine screw M6 5N m Grille screws M6 5N m Cover screws M6 5N m Terminal block nut M10 20 N m 4 6 3 Access to connections and the regulation system The terminals are accessed directly by removing the terminal box lid 48 To access the AVR adjustment potentiometers the side plate 367 should be removed 4 6 4 Accessing checking and replacing diodes 4 6 4 1 Dismantling Remove the air intake grille 51 Remove the surge suppressor 347 Disconnect the 6 diodes using an ohmmeter or
183. ield windings short circuited Rotating diodes burnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the AVR voltage pot P2 before running at the correct speed Voltage too high Adjust AVR voltage Adjustment ineffective Faulty AVR potentiometer Voltage Adjust AVR stability If no effect try normal rapid recovery Check the speed possibility of cyclic irregularity oscillations potentiometer modes ST2 Loose connections Faulty AVR Speed too low when on load or LAM set too high Voltage correct at no load and too low when on load Run at no load and check Voltage between E and E SHUNT lt 20 V AREP PMG lt 10 V Check the speed or LAM set too high the voltage between E and E on the AVR Voltage between E and E SHUNT gt 30 V Faulty rotating diodes Short circuit in the main field Check the resistance Faulty exciter armature AREP PMG gt 15 V Caution For single phase operation chec k that the sensing wires coming from the AVR are correctly connected to the operating terminals Voltage disappears during operation e Check the AVR the surge suppressor the rotating diodes and replace any defective components value The voltage does not return to the rated Exciter winding open circuit Faulty exciter armature Faulty AVR Main field open circu
184. igit codes read from a fault lamp which gives blink codes SPN FMI CODES Stored and active diagnostic trouble codes are output on the diagnostic gauge on the Deere electronic instrument panel according to the J1939 standard as a two part code as shown on the tables on the following pages The first part is a six digit Suspect Parameter Number SPN followed by a two digit Failure Mode Identifier FMI code In order to determine the exact failure both parts SPN and FMI of the code are needed The SPN identifies the system or the component that has the failure for example SPN 000110 indicates a failure in the engine coolant temperature circuit The FMI identifies the type of failure that has occurred for example FMI 03 indicates value above normal Combining SPN 000110 with FMI 03 yields engine coolant temperature input voltage too high or the equivalent of 2 digit fault code 18 If diagnosing an application that shows DTCs as SPNs and FMs using the following list determine the equivalent 2 digit code and have your dealer use the diagnostic procedure in the component technical manual for that 2 digit code Always contact your servicing dealer for help in correcting diagnostic trouble codes which are displayed for your engine CD03523 0000190 19 02FEBO7 1 1 Using Blink Code Method for Retrieving Diagnostic Trouble Codes DTC s NOTE The method below applies to applications having a fault lamp on instrument pa
185. in the case of greasy dust Petrol or chloroethylene can also be used After cleaning the alternator it is essential to check the winding insulation see sections 3 2 and 4 8 4 3 Fault detection If when commissioned the alternator does not work normally the source of the malfunction must be identified To do this check that the protective devices are fitted correctly the connections comply with the diagrams in the manuals supplied with the machine the speed of the unit is correct see section 1 3 Repeat the operations defined in section 3 10 LEROY SOMER 220 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 4 Mechanical defects Fault Action Excessive overheating of one or both If the bearing has turned blue or if the grease has turned black change the Bearing bearings temperature gt 80 C on the bearing bearing retainers with or without abnormal Bearing not properly seated noise End shields misaligned flanges not properly fitted Air flow intake outlet partially clogged or hot air is being recycled from Excessive overheating of alternator frame the alternator or engine Temperature more than 40 C above the ambient Alternator operating at too high a voltage gt 105 of Un on load abnormal temperature Alternator overloaded Misalignment coupling Excessive vibration Defective
186. inder 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 18 260 N PACKAGING STORAGE e GenCOOL PC 26 is supplied in 210 metallic barrels with smooth interior linings e Itcan be stored for 2 years in its original container and packaging e Avoid zinc coated containers RECOMMENDATIONS FOR USE e Compatible with the original fluid e It is recommended that the cooling system is completely drained when replacing the fluid SPECIFICATIONS UNITS SPECIFIED VALUES TRIAL METHODS po tos nET Freezing point Glassware corrosion test with antifreeze mg tes
187. ing completely CD03523 00002B1 19 03JAN11 1 1 25 2 020811 PN 66 144 260 Maintenance Daily or Every 10 Hours Check Air Filter CD31247 Check Dust Unloader Valve A Dust Unloader Valve B Air Restriction Indicator 1 If air filter has a dust unloader valve A squeeze valve tip to release any trapped dirt particles 2 Check air intake restriction indicator B When indicator is red air filter needs to be cleaned IMPORTANT Maximum air intake restriction is 6 25 kPa 0 06 bar 1 0 psi 25 in H20 A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to the engine CD31247 UN 30NOV10 CD31248 Check Air Restriction Indicator 3 Make a thorough inspection of the engine compartment NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination CD31248 UN 30NOV10 CD03523 00002B2 19 23DEC10 1 1 Check Fuel Filter 3029 Engines Check the fuel filter daily for water or debris and drain as necessary IMPORTANT Drain water into a suitable container and dispose of properly 1 Loosen drain plug A at bottom of fuel filter two or three turns 2 Loosen air bleed plug B two full turns on fuel filter base and drain water from bottom until fuel starts to drain out 3 When fuel starts to drain out hand tighten drain plug After draining water from the fuel fi
188. ing 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 v Engine with turbocharger never start the engine without fitting the air filter The compressor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage y Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube causing bodily injury v Do not touch the lighting column lights when they are switched on Maintenance y Follow the maintenance table and its instructions v Always use tools in good condition which are suited to the work to be done Ensure you have understood the instructions before beginning any operation v Goggles should be worn when carrying out maintenance operations and watches bracelets etc should be removed v Fit only original parts v Disconnect the battery and the pneumatic starter if fitted before undertaking any repairs to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt to start Only use the correct crankshaft turning techniques for turning the crankshaft manually Do not try to turn the crankshaft by pulling
189. ion Gauge D Upper Nut B Tension Tester E Lower Nut C Straight Edge CD30644 UN 04MAY98 CD30645 UN 04MAY98 CD30646 UN 04MAY98 Alternator Fastening CD03523 00002BA 19 15DEC10 1 1 35 1 160 260 020811 PN 82 Maintenance 1000 Hours 1 Year Check Belt 4045 and 6068 Engines with Man F TE Ve ma Manual Belt Tensioner on 4045 and 6068 Engines A Belt Gauge B Cap Screw C Cap Screw D Reference Mark 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 slack in belt Scribe a reference mark D on line with notch E on upper alternator bracket RG9132 UN 040CT99 ual Tensioner y CD30843 CD30843 UN 10JANO03 Reference Marks E Alternator Upper Bracket Notch 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 Tighten cap screws B and C CD03523 00002BB 19 10DEC10 1 1 Check Belt 4045 and 6068 Engines with Automatic Tensioner NOTE With the belt loosened inspect pulleys and bearings Rotate and feel for hard t
190. ion equipment of diesel engines DX FUEL1 19 0O3AUG09 1 1 Handling and Storing Diesel Fuel P carbs he Handle fuel carefully Do not fill the fuel tank when engine is running DO NOT smoke while you fill the fuel tank or service the fuel system Fill the fuel tank at the end of each day s operation to prevent water condensation and freezing during cold weather Keep all storage tanks as full as practicable to minimize condensation Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering Monitor water content of the fuel regularly When using bio diesel fuel the fuel filter may require more frequent replacement due to premature plugging Check engine oil level daily prior to starting engine A rising oil level may indicate fuel dilution of the engine oil IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an original vented cap When fuel is stored for an extended period or if there is a slow turnover of fuel add a fuel conditioner to stabilize the fuel and prevent water condensation Contact your fuel supplier for recommendations DX FUEL4 19 19DEC03 1 1 10 1 108 260 020811 PN 30 Fuels Lubricants and Coolant Diesel Engine Break In Oil New engines are filled at the factory with either John Deere Break In or Break In Plus Engine Oil During the break in period
191. ion of dust seal C Replace if necessary Install dust seal as shown NOTE Proper installation is indicated when a click is heard and a release of pressure on the ring is felt 7 Align keys on filter element with slots in filter base then tighten retaining ring counterclockwise 1 4 turn until it snaps into the detent DO NOT overtighten 8 If equipped with water separator remove water separator bowl from removed filter element Drain and clean separator bowl Dry with compressed air Install water separator bowl onto new element Tighten 8 securely a 9 Bleed the fuel system 5 S A Correct Installation C Dust Seal 5 f B Incorrect Installation ir Fuel Filter Dust Seal Installation CD03523 00002B7 19 23DEC10 2 2 020811 30 8 PN 76 154 260 Maintenance 500 Hours Change Fuel Filter Elements 4045 and 6068 Engines A Retaining Ring B Final Fuel Filter Element C Drain Plug D Bleed Plug Acorn Escaping fluid under pressure can X9811 UN 23AUG88 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
192. ion system A V R can be operated with SHUNT supply with a transformer secondary 50V or a 48V battery S5 EROY SOMER 5 235 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 2 R438 A V R 2 1 2 Setting potentiometers 2 1 Characteristics Storage 55 C 85 C Operation 40 C 70 C Standard power supply AREP or PMG Rated overload current 8 A 10s Electronic protection overload short cir cuit on opening of voltage sensing circuit excitation overload current for 10 seconds then return to approximately 1A The alter nator must be stopped or the power switched off in order to reset the protection Fuse F1 on X1 X2 8A slow 250V Voltage sensing 5 VA isolated via trans former e 0 110 V terminals 95 to 140 V e 0 220 V terminals 170 to 260 V e 0 380 V terminals 340 to 520 V Voltage regulation 1 Normal or rapid response time via ST2 jumper see below Voltage adjustment via potentiometer P2 other voltages via adapter transformer Current sensing parallel operation C T 2 5 VA cl1 secondary 1 A optional Quadrature droop adjustment via potentio meter P1 Max excitation current adjustment via P5 see below 2 1 1 Configuration jumpers function Delivrery config Open Closed 3 ph Open for module pit installation tri detection Response time 50 ou 60 Hz Frequency selection
193. ion 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 FMI 3 VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE a A voltage signal data or otherwise is above the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose voltage remains at a high level when the ECM commands it to low Broadcast of data value is substituted with the error indicator value FMI 4 VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE 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 FMI 5 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
194. ions in sequence The displays can be selected as either customary English or metric units The following menu of engine parameters can be displayed on the diagnostic gauge window e Engine hours e Engine rpm e System voltage e Percent engine load at the current rom E Red STOP ENGINE Indicator Light F Amber WARNING Indicator Light e Coolant temperature e Oil pressure e Throttle position e Intake manifold temperature e Current fuel consumption e Active service diagnostic codes e Stored service diagnostic codes from the engine e Set the units for display e View the engine configuration parameters NOTE Engine parameters which can be accessed will vary with the engine application Six languages for readouts are available and can be selected during setup of gauge The diagnostic gauge includes a graphical backlit Liquid Crystal Display LCD screen The display can show either a single parameter or a quadrant display showing four parameters simultaneously The diagnostic gauge uses two arrow keys C for scrolling through the engine parameter list and viewing the menu list and an enter key D for selecting highlighted items The red E and amber F lights are used to signal active trouble code received by the diagnostic gauge CD03523 000018B 19 22JANO7 1 1 Main Menu Navigation NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine start up
195. ior to first use 00 0 2 5 3 Technical support ServiCe eeeeeeeees 16 3 3 Terminal connection diagrams ceeee 5 4 Exploded view parts list eeeeee 17 3 4 COMMISSIONING ceeeeeeeeeeeteeeeeetetteeeeeeeeee 3 5 gt S tliNS iis a nil aaia ieee EC DECLARATION OF INCORPORATION 19 AVRO SOMER 3 213 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 1 RECEIPT 1 1 Standards and safety measures Our alternators comply with most international standards See the EC Declaration of Incorporation on the last page 1 2 Inspection On receipt of your alternator check that it has not suffered any damage in transit If there are obvious signs of knocks contact the transporter you may able to claim on their insurance and after a visual check turn the machine by hand to detect any malfunction 1 3 Identification The alternator is identified by means of a nameplate glued to the frame Make sure that the nameplate on the alternator conforms to your order The alternator name is defined according to various criteria see below Example of description LSA 43 2 M45 J6 4 e LSA Name used in the PARTNER range eM Marine C Cogeneration eT Telecommunications 43 2 Machine type e M45 Model oJ Excitation system C AREP J SHUNT or PMG E COMPOUND 6 4 Winding number number of
196. ious injury Do not disconnect fuel lines between the high pressure fuel pump and nozzles Only bleed the fuel system at the fuel filter bleed screw A 1 Loosen the air bleed screw A two full turns on final filter base only 2 Operate fuel supply pump primer lever B until fuel flow is free from air bubbles 3 Tighten bleed screw securely Continue operating primer until pumping action is not felt 4 Start engine and check for leaks If engine will not start repeat steps 1 4 A Air Bleed Screw B Fuel Pump Primer Lever TS1343 UN 18MAR92 RG12220 UN 24MAY02 RG12221 UN 24MAY02 6090 Engines NOTE The fuel system is self priming and self bleeding and does not require a bleeding procedure by the operator If engine will not start after filter change turn ignition key ON for 60 seconds to prime the fuel system It may be necessary to turn the key OFF and ON again to reprime the system before starting CD31269 UN 21DEC10 CD03523 00002D1 19 21DEC10 6 6 45 8 020811 PN 104 182 260 Trouble shooting 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 An engine wiring layout is provided in this section to identify electrical components engine controller sensors connectors etc Later in t
197. is U S A by calling 1 800 822 8262 or 1 309 748 5636 DX FLUID 19 20AUG09 1 1 Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can accidentally burst when heat goes beyond the immediate flame area TS953 UN 15MAY90 DX TORCH 19 10DEC04 1 1 Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Remove paint before heating e 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 If you sand or grind paint avoid breathing the dust Wear an approved respirator e If 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 TS220 UN 23AUG88 Do all work in an area that is well ventilated to carry toxic fumes and dust away Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly will take place DX
198. is at the edge of a diagnostic region and 2 for the older SPN 611 to 615 where the problem is in determining which of two or more circuits which may interact is the one that needs repair SPNs 611 through 615 are defined as System Diagnostic Codes and are used to identify failures that cannot be tied to a specific field replaceable component Specific subsystem fault isolation is the goal of any diagnostic system but for various reasons this cannot always be accomplished These SPNs allow the manufacturer some flexibility to communicate non specific component diagnostic information Since SPNs 611 615 use the standard SPN FMI format it allows the use of standard diagnostic tools electronic dashboards satellite systems and other advanced devices that scan Parameter Groups containing the SPN FMI formats Because manufacturer defined codes are not desirable in terms of standardization the use of these codes should only occur when diagnostic information cannot be communicated as a specific component and failure mode Possible reasons for using a System Diagnostic Code include 1 Cost of specific component fault isolation is not justified or 2 New concepts in Total Vehicle Diagnostics are being developed or 3 New diagnostic strategies that are not component specific are being developed Due to the fact that SPNs 611 615 are manufacturer defined and are not component specific FMIs 0 13 and 15 31 have little meaning Therefore FMI 14 S
199. is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine is running 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key Continued on next page 1000 RPM phg ore 1800 RPM ETELE lt COOL TEMP ge d Menu Key Ti CO Si RG13159 UN 26SEP03 OURGP11 00000A9 19 03SEP03 1 5 15 1 020811 PN 34 112 260 Operating the Engine 2 The first seven items of the Main Menu will be displayed GO TO 14 UP DISPLAY STOREO CODES ENGINE CONFIG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT RG13160 UN 020CT03 Menu Display OURGP11 00000A9 19 03SEP03 2 5 3 Pressing the Arrow keys will scroll through the menu selections GO TO 1 UP DISPLAY STORED CODES ENGINE CONFIG SETUP 1 UP DISPLAY RG13161 UN 020CT03 Main Menu Items OURGP11 00000A9 19 03SEP03 3 5 4 Pressing the right arrow key will scroll down to reveal the last items of Main Menu screen highlighting the next item down ADJUST CONTRAST UTILITIES oO O a w a Oo i Zz 5 N o D O ia Last Items On Main Menu Continued on next page OURGP11 00000A9 19 03SEP03 4 5 1 5 2 020811 PN 35 113 260 Operating the Engine 5 Use the arrow keys to scroll to the desired menu it
200. 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 bubble 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 ANNAN lt AN Consumables v Observe regulations in force concerning use of fuel before using your generating set pump unit or lighting tower vy Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit Environment v The operator must take the necessary measures to comply with the aesthetics of the site of use The whole site must be maintained in a good state of cleanliness v The premises must be kept clean and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust which could ignite or cause an explosion The cleaning equipment must be suited to the risks posed by the
201. it or short circuited Caution Internal protection may be activated overload open circuit short circuit LEROY SOMER 221 260 11 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 5 1 Checking the winding You can check the winding insulation by performing a high voltage test In this case you must disconnect all AVR wires CAUTION Damage caused to the AVR in such conditions is not covered by our warranty 4 5 2 Checking the diode bridge Anode oA y 4 Cathode LSA 43 2 44 2 diode bridge Oooo ee C C AAA oe TI C CC A diode in good working condition allows the current to flow in only one direction from anode to cathode 4 5 3 Checking the windings and rotating diodes using separate excitation During this procedure make sure that the alternator is disconnected from any external load and inspect the terminal box to check that the connections are fully tightened 1 Stop the unit disconnect and isolate the AVR wires 2 There are two ways of creating an assembly with separate excitation Assembly A Connect a 12 V battery in series with a rheostat of approximately 50 ohms 300 W and a diode on both exciter field wires 5 and 6 Assembly A 6 Exciterfield 5 Rh 50 9 300 W Diode 1A 12 V battery Assembly B Connect a Variac variable power supply and a
202. jury 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 of 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 system has been opened up for service lines knowledgeable medical source disconnected or filters removed it will be necessary to bleed air from the system On dual fuel filter NOTE 3029 engines have a single fuel filter while system bleed air only from final filter 4045 6068 and 6090 engines have two fuel filters primary and final Whenever the fuel X9811 UN 23AUG88 CD03523 00002D1 19 21DEC10 1 6 3029 Engines 3 6 A ie S T Z Zz lt 3 S R g o 4 c4 Fuel Filter Bleed Screw Fuel Pump Primer Lever A Air Bleed Screw B Fuel Pump Primer Lever 1 Loosen the air bleed screw A two full turns 4 Start engine and check for leaks 2 Operate fuel pump primer lever B until fuel flow is free rom ir bubbles If engine does not start it will be necessary to bleed air from fuel system at fuel injection pump or injection 3
203. kcase vent system 30 12 Remove engine from long term storag 55 1 Check engine electrical ground connections 30 13 Storing fuel 0 eee ee eeeeee eee eeeeeeeeeteeeaeeeeeeeaaeees 10 1 Check engine mount ce eeeeeeeeeeneeeeeeeneaes 30 13 Storing lubricants eee eee eeteee eee eeteeeeeeeeeeeeeeee 10 3 As required Additional service information 00000 45 1 T Bleed the fuel system cc eeceeeeeeeeeeeeeeneeeees 45 6 Clean or replace air filter one piece 45 3 Torque charts Clean or replace air filter element 1 45 4 Meteren shot cn ata tent ats mie enc eee 60 4 Do not modify fuel system eee eee 45 1 U ified inchisi cies nil alms uel ohne 60 3 Replace fan alternator belt 4045 6068 Trouble CONS Sic 35 vs coosassegnncsiidieste sai selaiSbeanniherdsoad 50 4 and 6090 engines eeseeeeeeeeeeeeeeeeeeeteees 45 5 Troubleshooting Daily or every 10 hours Electrical System 50 13 Check air filter 0 R 25 Continued on next page Index 2 Nae 204 260 4045 or 6068 engine 2 eeeeeeeeeeeeeeeetteeeeeees 4045 and 6068 Engines 0 ccceeeeeeeeeeeeeeeeees Page Ege erini cee diated weedy 50 9 General information 0 cceccceceeeesteeeeeetteeeeeees 50 1 6090 engines U Unified inch bolt and screw torque values 60 3 Wiring harness Units of measure ChANGING ceeeeeeteeeeetteeeeeeee
204. l filters have to be replaced together at the same time Replace fuel filter elements anytime audible alarm sounds and trouble codes indicate plugged fuel filters low fuel pressure If no alarm sounds during the 12 month service interval replace elements at that time or after 500 hours operation whichever comes first 1 Thoroughly clean final filter header 1 and surrounding area to prevent dirt and debris from getting into fuel system 2 Connect a fuel drain line to final filter drain valve J on bottom of filter and drain all fuel from the filter 3 Turn final filter K counterclockwise CCW to remove 4 Inspect final filter header I sealing surface Clean as required 5 Install new final filter fuel drain valve J tighten to specification Specification Final Fuel Filter Drain ValVO TOrque cccceeecceeceeeeeeeteeeeeeeeeeeeeetes 3 4 4 Nm 30 35 lb in 6 Place new final filter packing L on filter 7 Place thin film of fuel on packing L IMPORTANT Do NOT pre fill filter with fuel This may introduce debris into the fuel system NOTE Final filter replacement instructions are printed on the new filter A Primary Filter Header B Primary Filter Canister G Primary Filter Canister Lip H Primary Filter Header Lip Drain Valve I Final Fuel Filter Header C Water In Fuel Sensor J Final Filter Drain Valve Connector K Final Fuel Filter D Primary Filter Canister E
205. l for generating set fault finding and maintenance To display the programmed codes scroll through the parameters until you reach the following sub menus In the event that there are no programmed codes to display the following screen will appear The purpose of programmed codes is to create a fault log which is used to determine recurrent faults and thereby carry out effective corrective and preventive maintenance on the engine also it not desirable to delete these when the generating set is in operation onsite Note that at the test bench outlets the EEPROM memory in which the programmed codes are stored is reset to zero The following diagram shows the structure of the STORCODE programmed code menu and how to go to each parameter Enter Storcode Codes available First code Last code line Display if no codes available 48 260 EN F Fault finding module internal errors Like any equipment using internal memory and a program the fault finding module generates fault codes Two types of code can be recognised Address Claim Procedure Errors Run Time Bus Errors Address Claim Procedure Errors ACP Err The following fault codes relate to the switching on of the fault finding module Error Code 1 When switched on the fault finding module must issue a request to the ECU for the network addresses used in order to exploit them this screen appears when an addre
206. l mode MANU SE Flashing For 5 seconds when switching from MANU Mode AUTO mode to MANU mode Fixed TELYS in automatic mode AUTO AUTO Flashing For 5 seconds when switching from AUTO Mode MANU mode to AUTO mode Flashing Generating set in start up phase Fixed Generating set started Fixed Generating set stabilised voltage and frequency Flashing appearance of movement from left to right constant The generating set is powering the installation nel Fixed The installation is supplied of Not used WwW Not used 53 260 EN 6 3 1 4 Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised Data displayed Fuel level indicator Alarm Fault Alarm Fault lt low fuel level lt high fuel level Coolant level temperature indicator Alarm High 4 ae 4 No preheating Low level level fault g fault lt alarm temperature fault fault alarm s Battery E Min battery a Max battery Battery charge voltage A l l flashing l l INN j indicator voltage flashing INN l ilashing bars Oil pressure temperature indicator Oil pressure pari I lt Pgh on low ol l temperature P Alarm Fault j q pout le Alarm Fault A Emergency stop Emergency stop fault Overload or short circuit Tripping of circuit breaker follo
207. lant Temperature Sensor T ECU Connector D VGT Turbocharger Connector Connector U Auxiliary Power Connector E Exhaust Gas Recirculation L Alternator Excitation EGR Exhaust Temperature Connector Sensor Connector M Fuel Temperature Sensor F Exhaust Gas Recirculation Connector EGR Valve Sensor N Fuel Pump Control Valve Connector Connector G Exhaust Pressure Sensor Connector CD03523 00002D6 19 22DEC10 2 2 50 8 020811 190 260 PN 112 Troubleshooting Engine Troubleshooting NOTE Before troubleshooting 4045 6068 or 6090 engine first retrieve any diagnostic trouble codes Symptom Engine cranks but will not start Engine hard to start or will not start Engine knocks on the diagnostic gauge display and perform the 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 Continued on next page corrective actions If any problems remain use the following c
208. lant temperature sensor input voltage high Coolant temperature sensor input voltage low Coolant temperature sensor open circuit Coolant temperature high least severe Coolant temperature moderately high Water temperature very low Coolant temperature high 111 111 Coolant level sensor Engine coolant level low Engine coolant level low Coolant level sensor input voltage high Coolant level sensor input voltage low 153 153 Crankcase pressure sensor Value above normal Crankcase pressure sensor input voltage high Crankcase pressure sensor open circuit 157 Fuel pressure sensor in the common rail Fuel pressure too low Input voltage of the pressure sensor high Short to V Input voltage of the pressure sensor low Short to V Loss of fuel pressure detected Fuel pressure moderately high Fuel ramp pressure not reached Oil pressure moderately low 247 260 EN 15 2 a2 o SPN CID SID PID PPID FMI 2 5x Description Comment E gt g 9 158 158 Battery voltage sensor 1 Voltage above normal 7 ECU power down error 160 Wheel speed sensor 2 Oo Wheel speed input noise 164 164 Injection pressure control 168 168 Electrical system voltage 2 Electrical system voltage low
209. ld 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 1 1 Standby power units To assure that your engine will deliver efficient standby operation when needed start engine and run at rated speed with 50 70 load for 30 minutes every 2 weeks DO NOT allow engine to run extended period of time with no load DPSG CD03523 22 19 22JANO07 1 1 Stopping the engine 1 Before stopping run engine for at least 2 minutes at fast idle and no load 2 Stop the engine DPSG CD03523 23 19 22JAN07 1 1 Changing Generator Frequency All generator sets are dual frequency 50 Hz 1500 rpm or 60 Hz 1800 rpm Refer to the generator set documentation for more information CD03523 00002AE
210. lectrical connection 2 Ifa connector is not in use put on the proper dust cap or an appropriate seal to protect it from foreign debris and moisture 3 Control units are not repairable 4 Since control units are the components LEAST likely to fail isolate failure before replacing by completing a diagnostic procedure See your John Deere dealer 5 The wiring harness terminals and connectors for electronic control units are repairable RG16946 UN 31MARO9 DX WW ECU04 19 11JUN09 1 1 45 2 176 260 020811 PN 98 Maintenance As Required Clean or Replace Air Filter One Piece Clean air filter when restriction indicator A is red Air filter can be cleaned up to six times Thereafter or at least once a year it must be replaced Proceed as follows 1 Thoroughly clean all dirt around air filter area f 2 Loosen clamp B then remove air filter if IMPORTANT Never reinstall an air filter which shows evidence of bad condition punched dented S etc allowing no filtered air to enter the engine 8 3 Clean air filter with compressed air working from clean to dirty side NOTE Compressed air pressure must not exceed 600 kPa 6 bar 88 psi 4 Mark air filter to keep track of each cleaning operation g Fully depress air restriction indicator reset button and release to reset indicator 2 6 Check air system entirely for proper condition see S Check Air Int
211. ledged if the cause of the fault has been removed reset not performed if the cause of the fault is still present 64 260 EN 6 3 4 4 Engine fault codes display Certain alarms and engine faults generate specific fault codes These codes are standardised according to the J1939 and or J1587 standards 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 o o This represents the type of fault that has occurred This may be an electrical FMI Failure Mode identifier mechanical or equipment fault Terminology used by VOLVO 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 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
212. level is not below the low level marker Do not exceed the hatched area The oil level is correct if it is within the hatched area Check the oil level using the dipstick A 2 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 gcb3124 e Checking the coolant level A Warning Fluid may abruptly exit the cooling circuit and cause serious burns Only remove the filler cap once the engine and cap have cooled sufficiently to enable them to be handled with bare hands Firstly loosen the cap slightly by one notch to eliminate any pressure then remove it Remove the cap from the radiator E and check the coolant level The level should reach the lower section of the filler neck Fill the radiator with the appropriate coolant if the level is too low Check for leaks in the cooling circuit 36 260 EN e Checking the air filter A A clogged filter element limits the engine s air intake and a reduced air supply to the engine Important If the air filter is fitted with a dust control valve A press the tip of the valve to evacuate any accumulated dust particles Check the air filter clogging indicator B If the indicator is red clean the air filter e Checking the fuel filters A Drain water into a suitable container and dispose of properly
213. linder 1 unknown error mechanical failure Cylinder 2 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required 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 2 circuit open Cylinder 2 circuit shorted Cylinder 2 balancing error mechanical failure Cylinder 2 unknown error mechanical failure 653 653 Cylinder 3 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors required 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 3 circuit open Cylinder 3 circuit shorted Cylinder 3 balancing error mechanical failure Cylinder 3 unknown error mechanical failure 252 260 N SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 654 654 Cylinder 4 injector status Injector outside the specifications Recalibration of the injectors required Injector outside the specifications Recalibration of the injectors
214. llow the corresponding advice risks resulting in minor injury of personnel or damage to any other object in case of exposure Important In order to obtain optimum efficiency and the longest possible life for the electrical generating sets maintenance operations must be carried out according to the periods indicated in the attached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training Dealers have this qualification and can answer all of your questions They can also supply you with spare parts and other services The left and right sides can be seen from the back of the electrical generating set the radiator is at the front Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum For any replacement of parts contact your nearest dealer for our company who will have the necessary equipment and can offer properly trained and informed 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 sh
215. load on load S1 0 5 1 3 S15 0 5 1 5 S25 0 5 1 6 S35 0 5 1 8 M45 0 4 1 6 L65 0 4 1 6 L8 0 4 1 6 4 8 2 3 phase LSA 43 2 4 P AREP excitation Resistances at 20 C Q Stator Wind Widing LSA 43 2 L N Rotor X1 X2 21 22 Field Armat S1 0 155 1 35 0 32 0 52 4 6 0 23 S15 0 155 1 35 0 32 0 52 4 6 0 23 S25 0 155 1 35 0 32 0 52 4 6 0 23 S35 0 128 1 41 0 29 0 5 4 6 0 23 M45 0 105 1 57 0 26 0 51 4 6 0 23 L65 0 083 1 76 0 26 0 44 4 6 0 23 L8 0 063 1 96 0 21 0 4 4 6 0 23 Field excitation current i exc A 400 V 50 Hz i exc excitation current of the exciter field Mounting is impossible with the regreasable bearings LSA 43 2 no load on load option with the LSA 44 2 s1 1 26 4 8 Electrical ch isti SIs 8 Electrical characteristics S25 1 32 Table of average values S35 1 3 6 Alternator 2 and 4 poles 50 Hz 60 Hz Winding n 6 and M M45 08 32 or M1 connected in dedicated single phase 400 V for the excitation values L65 0 8 3 2 The voltage and current values are given for no load operation L8 0 8 3 0 LEROY 14 SOMER 224 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 8 3 Dedicated single phase LSA 43 2 4 pole SHUNT excitation 60 Hz only Field
216. low 1000 rpm Emergency stop or external emergency stop fault Associated message Cc C iLi STOP fault activated if the STOP button is pressed whilst the AUT LED is flashing to indicate that the generating set is operating in automatic mode Associated message D List of alarms associated with a pictogram Low fuel level alarm Indicates the need to fill up with fuel Associated pictogram o Sah Alternator charging fault alarm indicates a problem affecting the alternator charging rate Associated pictogram PA n IL 43 260 EN 6 2 6 MURPHY diagnostic module The fault finding module MDDM is an indicator for analysis and fault finding designed and manufactured for reading information available on the J1939 CAN Bus The fault finding module is easy to use and will enable you to view the values of the various engine parameters and engine operating status codes It shows two lines each of 8 characters on a backlit LCD display Two scroll buttons enable you to navigate in the menus and parameters Two LEDs one red and one orange indicate the fault or alarm status of the engine or ECU DISPLAY SCROLL BUTTONS A Machine Parameters The following parameters are available on the Murphy fault finding module working hours counter engine speed battery voltage engine speed coolant temperature oil pressure fuel economy air manifold temperature a
217. ls 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 LNNANKA 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 2 Adjust the brake setting using screw 8 with the cables not connected to the cross bar s The shoes should rub the drum slightly Connect the brake cables to the cross bars s and tighten the nuts and lock nuts leaving the end of the threaded end protruding by around 10 mm Fig 4 4 IMPORTANT Wherever possible cables must cross over to achieve the highest possible gain curve Fig 4 5 Check that the parking lever 1 is in the REST position and that the compensating spring 4 is completely free on its rod unscrew the nuts 5 fully Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position Fit the transmission and adjust the assembly using the tensioner 6 until a gap J1 of 1 mm max is obtained between the linkage 9 and slide 2 Adjust the compensating spring 4 at one end pressing it against the anchorage plat
218. lter the filter must be primed by bleeding all air from the fuel system 4 Operate primer lever C of the fuel supply pump until fuel flow is free from air bubbles 5 Tighten bleed plug securely by hand Continue operating hand primer until pumping action is not felt When finished pull hand primer outward away from engine as far as it will go Continued on next page Drain Water from Fuel Filter A Drain Plug C Primer Lever B Air Bleed Plug CD31249 UN 30NOV10 CD03523 00002B3 19 23DEC10 1 3 25 3 145 260 020811 PN 67 Maintenance Daily or Every 10 Hours 4045 and 6068 Engines NOTE Engines have two fuel filters primary and final equipped with a water in fuel sensor Depending on application an indicator light on the instrument panel will signal the operator that water should be drained from filter bowls Check fuel filters C and D daily for water or debris and drain as necessary 1 Loosen drain plugs A at bottom of both fuel filters two or three turns 2 Loosen air bleed plugs B two full turns and drain water into a suitable container 3 When fuel starts to drain out tighten drain plugs securely 4 Bleed fuel system ii m a lt N f sii o all J CD30929 UN 07FEB07 CD30929 Drain Water from Fuel Filters A Drain Plugs B Air Bleed Plugs C Primary Fuel Filter D Final Fuel Filter
219. ly or Every 10 Hours Check Engine Oil Level n 25 Check Coolant Level aseeseen 25 Check Air Fite Tns aaa aia 25 Check Fuel Fiter ont nornnseisiin ennn 25 Maintenance 500 Hours Change Engine Oil and Filter 3029 Engines 30 Change Engine Oil and Filter 4045 and 6068 Engines 30 Change Engine Oil and Filter 6090 Engines 30 Change Fuel Filter Element 3029 Engines 30 WWN 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 2010 DEERE amp COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION Manual 81 260 020811 PN 1 Contents Page Change Fuel Filter Elements 4045 and 6068 Engines 30 9 Change Fuel Filter Elements 6090 Engines 30 10 Check Crankcase Vent System 30 12 Check Engine Mount 00 ceeeceeeeeeeeeteeeeeees 30 13 Check Engine Electrical Ground Connections 30 13 Maintenance 1000 Hours 1 Year Check Belt 3029 Engines 35 1 Check Belt 4045 and 6068 Engines with Manual Tensioner cccceeeereeeees 35 2 Check Belt 4045 and 6068 Engines with Automatic Tensioner 35 2 Check Belt 6090 Engines with Automatic Tensioner cccecceceeeseereeees 35 3 Check Cooling System 3
220. mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combination Terminology used by JOHN DEERE SPN Suspect Parameter This represents the system or component at fault for example SPN 100 Number indicates an oil pressure problem or a problem with the oil pressure sensor Rs e This represents the type of fault that has occurred This may be an electrical FMI Failure Mode identifier mechanical or equipment fault 65 260 EN In the event of a fault the screen will display the following message Engine fault code ALARM Pressing OK will display fault finding information ENGINE GENERAL 110 18 In addition appendix D indicate the meaning of the 25 12 2005 15 30 code The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation OK HELP For JOHN DEERE JD and VOLVO VO engines the 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 7 Maintenance schedule 7 1 Reminder of use The maintenance interval frequency and the ope
221. mounting or play in coupling Vibration Rotor balancing fault Excessive vibration and humming noise coming from the machine Alternator operating in single phase mode single phase load or faulty contactor or installation fault Stator short circuit Abnormal noise Alternator damaged by a significant impact followed by humming and vibration System short circuit Mis paralleling Possible consequences Broken or damaged coupling Broken or bent shaft end Shifting and short circuit of main field Fan fractured or coming loose on shaft Irreparable damage to rotating diodes or AVR 4 5 Electrical faults disappears when the battery is removed Fault Action Effect Check Cause The alternator builds up and its voltage is Lack of residual magnetism still correct when the battery is removed The alternator builds up but its voltage Check the connection of the voltage reference to the No Connect between E and does not reach the rated value when AVR voltage E anew battery of 4to the battery is removed Faulty diodes at no load 12 volts respecting Armature short circuit on start up the AVR polarities for 5 2 to 3 seconds The alternator builds up but its voltage Faulty AVR Field windings disconnected Main field winding open circuit Check the resistance Voltage too low Correct speed Check the drive speed Check the AVR connections AVR may be faulty F
222. n dipstick whichever is present DO NOT overfill CD03523 00002B4 19 23DEC10 2 2 30 2 020811 PN 70 148 260 Maintenance 500 Hours Change Engine Oil and Filter 4045 and 6068 Engines CD31252 Oil Pan Drain Valve on 4045 6068 Engines 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 least once a year 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Open oil pan drain valve A Drain crankcase oil from engine while warm 4 Replace oil filter as follows a Remove and discard oil filter element B using a suitable filter wrench b Apply clean engine oil to inner C and outer D seals and to filter threads c Wipe both sealing surfaces E of the filter header with a clean rag Ensure notches in dust seal F are properly installed in the slots in the housing Replace dust seal if damaged d Install and tighten oil filter by hand until it is tight against dust seal F DO NOT overtighten 5 Close oil pan drain valve CD31254 A Oil Drain Valve B Oil Filter Element C lInner Seal Continued on next page O Ww a Zz 2D a 16 nN 2 Q O CD31254 UN 06DEC10
223. nce again after tightening lock nut I Readjust clearance as necessary 7 g A Front of Engine 3 O Valve Adjusting Sequence No 1 Cylinder at TDC CD03523 00002CA 19 23DEC10 2 3 4 Remove timing pin and rotate flywheel 360 then reinstall timing pin No 6 piston is now at TDC of its compression stroke Rocker arms for No 6 piston should be loose 5 Check and adjust valve clearance to the same 8 specifications on Nos 2 4 and 6 exhaust and Nos z 3 5 and 6 intake valves 7 5 A Front of Engine gt k t Valve Adjusting Sequence No 6 Cylinder at TDC CD03523 00002CA 19 23DEC10 3 3 020811 40 4 PN 93 171 260 Maintenance 2000 Hours 2 Years Drain and Flush Cooling System NOTE Drain and flush cooling system every 3000 hours 3 years when John Deere COOL GARD coolant is used Otherwise every 2000 hours 2 years CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 23AUG88 1 Slowly open the radiator cap 2 Drain engine coolant according to following procedures CD03523 00002CB 19 23DEC10 1 6 a 3029 Engines Remove engine block drain plug A A Engine Block Drain Plug RG4894 UN 14DEC88 Engine Block Drain Plug CD03523 00002CB 19 23DEC10 2 6
224. ndicator reading If runout exceeds specifications given below replace vibration damper Specification Damper Maximum radial PUNOU r aa aa a aden deg tivediedoat 1 50 mm 0 060 in RG8018 UN 15JAN99 RG7508 UN 23NOV97 CD03523 00002C2 19 23DEC10 1 1 35 7 020811 PN 88 166 260 Maintenance 1000 Hours 1 Year Check Engine Speed 3029 Engines NOTE Most engines for generator set application 1500 rpm for 50 Hz or 1800 rpm for 60 Hz run only at fast idle and therefore they do not have slow idle Specification Fast Idle 50 Hz Generator Sets Arrera sesini 1550 1580 rpm 60 Hz Generator Set 1865 1890 rpm NOTE Fast idle is settled by the factory and 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 CD31260 UN 10DEC10 Fast Idle Adjusting Screw A Fast Idle Adjusting Screw CD03523 00002C5 19 23DEC10 1 1 Adjust Speed Droop Governor 3029 Engines 1 Warm engine to normal operating temperature 2 Run engine at fast idle 3 Apply full load 4 If specified power cannot be obtained turn screw B to adjust droop until the requested power is reached NOTE If surging exits upon removing the load turn screw B clockwise to eliminate B Speed Droop Governor Adjusting Screw CD31261 wks Speed Droop Governor Adjusting Screw CD31261 UN 10DEC10 CD035
225. nds to the site operating voltage see section 3 3 To modify the connection change the position of the terminal cables The winding code is specified on the nameplate A Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped Connections codes L1 U os 3 phases L L voltage 50 Hz 190 208 Factory connection 60 Hz T1 T5 my 16 T12 gt N T10 T4 0p T3 CL p T2 T1 AR Winding 190 240 220 230 g 190 208 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 220 V gt T2 50 Hz 380 415 60 Hz 380 480 Winding N 440 460 gt L3 W 380 416 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensing 0 gt T3 380 V gt T2 50 Hz __ 1 9 v M L1 U Winding 60 Hz 6 220 240 220 240 250 260 200 220 240 R 250 voltage sensing 0 gt T1 110 V gt T4 R 438 voltage sensing 0 gt T10 220 V gt T1 1 phase r o 3 phases L3 W LM voltage 1 2 LL voltage Winding 50 Hz 60 Hz 6 220 240 220 240 7 250 260 200 220 240 R 250 voltage sensing 0 gt T8 110 V gt T11 R 438 voltage sensi
226. ne by Dealer or distributor stamp CD03523 00002A2 19 22DEC10 1 1 020811 02 7 PN 13 91 260 Maintenance Records 7000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Engine speed check and adjust Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 00002A3 19 03JAN11 1 1 7500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 00002A4 19 22DEC10 1 1 02 8 020811 PN 14 92 260 Maintenance Records 8000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check or drain and flush if COOL GARD II is not used o Engine speed check and adjust a Crankcase vent system clean or replace filter optional o Air intake system check a C
227. nection check a Engine speed check and adjust Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 000029F 19 03JAN11 1 1 5500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 00002A0 19 22DEC10 1 1 02 6 020811 PN 12 90 260 Maintenance Records 6000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system drain and flush a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Engine speed check and adjust o Valve clearance adjust Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 00002A1 19 03JAN11 1 1 6500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace a Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job do
228. nel refer to the generator documentation for more information The Electronic Control Unit ECU has the ability to display DTCs using blinking sequence of the fault lamp NOTE The ECU blinks the codes in 2 digit codes only See Listing of Diagnostic Trouble Codes DTCs 1 Press Override Shutdown Switch while turning the ignition switch ON 2 The Fault Lamp will begin to flash a code number For example flash three times short pause flash two times long pause This example is code 32 3 The ECU begins the flashing sequence by flashing a code 32 this indicates the start of blinking active codes If there are any active DTCs the ECU will flash its 2 digit number If there is more than one active DTC the ECU will flash each code in numerical order If there are no active DTCs the Fault Lamp will flash a code 88 4 Following the active codes the Fault Lamp will flash a code 33 This indicates the start of blinking stored codes If there are any stored DTCs the Fault Lamp will flash its 2 digit number If there is more than one stored DTC the ECU will flash each code in numerical order If there are no stored DTCs the Fault Lamp will flash a code 88 5 Once completed this sequence will be repeated 6 When completed turn ignition OFF As an example if an engine had an active DTC 18 and stored DTC 53 the flashing sequence would be flash three times short pause flash two times long pause
229. nementers 12 A Wie DOSIQMAUOM 2s zzces vues szada cass E p a a eE S 12 4 2 Technical SUPPOrt SEMVICE 0 cce cece scveeccuessaneneen ceca ee cee eesteeeeebocdescenes a aai aaia 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 3 233 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 1 SUPPLY to that of the alternator characteristic 1 1 AREP excitation system For both AREP amp PMG excitation systems the alternator voltage regulator is the R438 With AREP excitation the R438 electronic AVR is powered by two auxiliary windings which are independent of the voltage match circuit The first winding has a voltage in proportion MAIN FIELD AREPSYSTEM Sh
230. ng 0 gt T3 220 V gt T2 L3 W ee gt L1 U AR LEROY SOMER 217 260 LEROY SOMER INSTALLATION AND MAINTENANCE LSA 43 2 44 2 4 POLE ALTERNATORS 3434 en 2010 10 i Connection codes L L voltage Factory connection L1 V Winding 50 Hz T5 1 phase or ee 110 120 T12 a 120 130 8 110 120 L m gt L2 V R 250 voltage sensing 0 gt T8 110 V gt T11 gt L1 U L R 438 voltage sensing 0 gt T3 110 V gt T2 A FOR LSA 44 2 THE COUPLING B IS NOT POSSIBLE AR Connection not Winding 50 Hz 60 Hz recommended 6 220 240 220 240 7 250 260 T9 70 3 8 200 220 240 R 250 voltage sensing T2 0 gt T8 110 V gt T11 T7 to R 438 voltage sensing J AR LM voltage 1 2 LL voltage 0 gt T3 220 V gt T2 T1 SINGLE PHASE 4 WIRE type M or M1 DEDICATED WINDING SERIAL CONNECTION T6 M PARALLEL CONNECTION Not possible with LSA 44 2 T3 T1 T2 L LJ L Voltage 50 60Hz Voltage 50 60Hz Output L L L M Link M L L L M Link L L 220 110 110 230 115 T2 T3 T1 T3 T2 T3 115 T1 T3 T2 T4 240 120 120 i 12 74 T4 R 251 voltage sensing 0 gt T1 110 V gt T2 R 251 voltage sensing 0 gt T1 110 V gt T2 3 3 1 Connexion de l e
231. ning 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 is drained flushed and refilled Refill with appropriate coolant See Diesel Engine Coolant Fill the fuel tank Remove fan alternator belt if desired Remove and clean batteries Store them in a cool dry place and keep them fully charged Clean the exterior of the engine with salt free water and touchup any scratched or chipped painted surfaces with a good quality paint Coat all exposed machined metal surfaces with grease or corrosion inhibitor if not feasible to paint Seal all openings on engine with plastic bags and tape Store the engine in a dry protected place If engine must be stored outside cover it with a waterproof canvas or other suitable protective material and use a strong waterproof tape CD03523 00002DC 19 22DEC10 1 1 Remove Engine from Long Term Storage Refer to the appropriate section for detailed services listed below or have your authorized servicing dealer or engine distributor perform services that you may not be familiar with 1 Remove all protective coverings from engine Unseal all openings in engine and remove covering from electrical systems 2 Remove the batteries from storage Install batteries fully charged and connect the terminals Install fan alternator belt if
232. nly 628 240 Battery voltage below the operating voltage For John DEERE Tiers III Memory fault in EMS2 629 254 ECU status controller error CIU module status RAM cell test failure CPU watchdog reset test failure 11 12 13 19 630 253 Main and fuelling ASIC test fail RAM address test failure Watchdog trip failure ECU to injection pump communication error Possible only with 6068HF475 VP44 Data set memory EEPROM 250 260 EN SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 632 Injection status Fuel shutoff error Fuel shutoff non functional 636 21 Pump position sensor Cam position sensor Speed sensor CAM Pump position sensor cam position sensor input noise Pump position or CAM position in function of the type of injection Permanent loss of signal High impedance of the position sensor or circuit open Sensor short to ground Pump position sensor cam position sensor input missing Not informed by VOLVO Pump position sensor cam position sensor input pattern error 637 22 Crank position sensor Speed sensor flywheel Crank position input noise Permanent loss of signal High impedance of the position sensor or open circuit
233. nnections general information As with low voltage electrical installations use and maintenance is governed by standard NFC 15 100 France or by the standards in the relevant country based on international standard IEC 60364 6 61 They must also adhere to the regulations in the NFC 15 401 application guide France or to the regulations and standards in the relevant country 3 4 2 Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose The cable cross section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation The choice of conductors must comply with international standard IEC 30364 5 52 Three phase Calculation hypothesis Fitting method wiring in cable runs or non perforated trays Permissible voltage drop 5 Multiconductors or single conductor joined when precision 4X 1 Cable type PVC 70 C e g HO7RNF Ambient temperature 30 C Circuit breaker Cable sizes calibre 0 50m 51 100m 101 150m A mm2 AWG mm2 AWG mm2 AWG 10 1 5 14 25 12 4 10 16 25 12 4 10 6 9 20 25 12 4 10 6 9 25 4 10 6 9 10 7 32 6 9 6 9 10 7 40 10 7 10 7 16 5 50 10 7 10 7 16 5 63 16 5 16 5 25 3 80 25 3 25 3 35 2 100 35 2 35 2 4X 1X50 0 125 1 4X 1X50 0 4X 1X
234. 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 259 260 EN FMI 18 DATA VALID BUT BELOW NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is below what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region j of the signal range definition Broadcast of data values is continued as normal FMI 19 RECEIVED NETWORK DATA IN ERROR Any failure that is detected when the data received via the network is found substituted with the error indicator value i e FE16 see J1939 71 This type of failure is associated with received network data The component used to measure the real world signal is wired directly to the module sourcing the data to the network and not to the module receiving the data via the network The FMI is applicable to Region f and g of the signal range definition This type of fault may or may be directly associated with the value of general broadcast information FMIl 20 30 RESERVED FOR SAE ASSIGNMENT FMI 31 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
235. ns 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 FMl 13 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 case that the mechanical subsystem is determined to be out of calibration This failure mode does not relate to the signal range definition as do many of the FMls FMI 14 SPECIAL INSTRUCTIONS Special Instructions is the FMI to be used when the on board system can isolate the failure to a small number of choices but not to a single point of failure When the FMI is used there is clear necessity for the service technician to take some action to complete the specific diagnosis and the manufacturer has provided instructions for the completion of that diagnosis There are two cases where this will be used 1 for emission related diagnostics where the particular failure cannot be separated between a sensor out of range and the case where the actual value
236. ntities 38 260 Fig 6 2 Description of the LEDs A lit LED indicates Module being supplied green lights up and remains lit Emergency stop activated control panel or external emergency stop red lights up and remains lit generate green lights up and remains lit General alarm orange flashing General fault red flashing OO OO 6 2 1 1 Introduction to pictograms The pictograms are as follows Operating temperature Symbols for electric and mechanical sizes Overspeed a en Non starting fault Battery Starting on external command Preheating __ _ __ _ __ Air intake v0 KBAR Oil pressure Fig 6 3 View of pictograms The fuel level pictogram is used to display the fault the alarm and the fuel level The operating temperature and oil pressure pictograms are used to display the fault and analog value The overspeed and non starting fault pictograms are used to display the fault The battery pictogram is used to display the alternator charge fault and to indicate the battery voltage VVVV 39 260 Visualisation of starting phase and speed voltage stabilisation flashing and generating set operating OK or set ready to EN 6 2 2 Manual starting A Check that the generating set circuit breaker has triggered Danger o connect the generating set battery turn the key switch to the ON position without forcing it All of the LEDs
237. of operation check that all fixing screws on the alternator are still tight plus the general state of the alternator and the various electrical connections in the installation 4 2 2 Cooling circuit It is advisable to check that circulation of air is not reduced by partial blocking of the air intake and outlet grilles mud fibre grease etc and to check whether the ventilation guards are corroded or scratched 4 2 3 Bearings The bearings are permanently greased approximate life of the grease 20 000 hours or 3 years As an option they are regreasable for the LSA 44 2 Itis advisable to lubricate the alternator during operation Time intervals and quantity of grease are given in the table below NDE DE bearing 6315 C3 6309 C3 Quantity of grease 30g 15g Regreasing interval 6000 hrs 10 000 hrs Lubrication intervals are given for grease type LITHIUM standard NLGI 3 In the factory the grease used for lubrication is ESSO UNIREX N3 Before using another grease check for compatibility with the original one Monitor the temperature rise in the bearings which must not exceed 50 C above the ambient temperature Should this value be exceeded the alternator must be stopped and checks carried out 4 2 4 Electrical servicing Cleaning product for the windings CAUTION Do not use trichlorethylene perchlorethylene trichloroethane or any alkaline products Certain strictly defined pur
238. 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 List of emission related components Fuel injection pump Intake manifold Turbocharger Charge air cooling system Piston 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 CD03523 0000293 19 23DEC10 1 1 020811 PN 2 80 260 Contents Page Identification Views Identification Views ccccceceeeseceeeeeeeeeeteees 01 1 Maintenance Records Using maintenance records 0 eeeeeeeeee 02 1 100 Hours of operation ceeeeeeeteeeees 02 1 500 Hours of operation ccceceeseeeeeeeees 02 1 1000 Hours of operation ecceeeeeetteees 02 2 1500 Hours of operation ccceeeeeetteees 02 2 2000 Hours of operation cceceeceeeeees 02 3 2500 Hours of operation ccceeceeeeees 02 3 3000 Hours of operation ceecceeeees 02 4 3500 Hours of operation 0 cceceeeeeeeees 02 4 4000 Hours of operation eeeeeeeeeeeees 02 5 4500 Hours of operation
239. ogram Ol on m wll 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 CoC wa Lu Lt Low fuel level fault Indicates the need to top up the fuel Associated pictogram Sah 42 260 EN List of faults which will cause the generating set to stop and generate a fault code Low coolant level fault indicates that the level of coolant is low in the radiator linked to a two second time delay Or Overload or short circuit fault optional with the circuit breaker SD contact closing overload or short circuit the generating set switches off immediately also causing the main circuit breaker to be triggered Associated message Additional fault linked to message opposite is displayed in the following two cases gt Differential fault 1 gt insulation fault 2 1 Differential fault optional with a differential fault causing the activation of the differential relay the generating set stops immediately also causing the main circuit breaker to be tripped 2 Insulation fault optional with an insulation fault causing the activation of the control unit performing insulation the generating set stops immediately Associated message mi wlll Underspeed fault indicates an incorrect rotation speed be
240. olant 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 CD03523 00002AF 19 21DEC10 1 1 20 2 142 260 020811 PN 64 Maintenance Daily or Every 10 Hours Check Engine Oil Level 3029 Engines CD30754 UN 26AUG99 CD30755 UN 24SEP99 Oil Dipstick on 3029 Engines Die Gap Before starting the engine for the first time of the day check engine oil level on dipstick A Add oil as required using seasonal viscosity grade oil at rocker arm cover filler cap B IMPORTANT DO NOT fill above the crosshatch area Oil levels anywhere within crosshatch area are considered in the acceptable operating range A Oil Dipstick B Oil Filler Cap FDOo0047 FD000047 UN 13MAR96 Crosshatch Area on Oil Dipstick CD03523 00002B0 19 23DEC10 1 3 4045 and 6068 Engines S 3 1 J Z Iz l l 5 g S C S Fboo0047 S CD31243 8 A Oil Dipstick and Oil Filler Neck on 4045 6068 Engines Crosshatch Area on Oil Dipstick Before starting the engine for the first time of the day IMPORTANT DO NOT fill above the crosshatch area check engine oil level 9n dipstick A Add oil as required Oil levels anywhere within crosshatch area are using seasonal viscosity grade oil at oil filler neck B considered in the acceptable oper
241. on check Number of hours Observation Dealer or distributor stamp Date Job done by CD03523 00002A8 19 22DEC10 1 1 02 10 94 260 020811 PN 16 Maintenance Records 10000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check or drain and flush if COOL GARD II is not used a Crankcase vent system clean or replace filter optional a Thermostats replace o Air intake system check a Crankshaft vibration damper check a Engine mounts check a Engine ground connection check a Engine speed check and adjust o Valve clearance adjust o Fuel injectors replace Number of hours Date Job done by Observation Dealer or distributor stamp CD03523 00002A9 19 03JAN11 1 1 02 11 95 260 020811 PN 17 Serial Numbers Record Engine Serial Number 3029 4045 and 6068 Engines RG8007 UN 15JAN99 Engine Serial Number Plate A Engine Serial Number Plate B Engine Serial Number The engine serial number plate A is located on the right hand side of engine block behind the fuel filter Record all of the numbers and letters found on your engine serial number plate in the spaces provided below Engine Serial Number B JOHN DEERE Engine Serial Number CD6068L123456 z DrERF amp COMPANY M
242. onsumables mentioned in the section entitled Specifications are recommended 16 260 2 5 1 Specifications 2 5 1 1 Oil grades EN Engine Oil Make Type Make Type Johni Deere All John Deere John Deere PLUS 50 GenPARTS GENLUB TDX 15W40 MITSUBISHI All GenPARTS GENLUB TDX 15W40 Volvo All GenPARTS GENLUB TDX 15W40 GENLUB TDX 15W 40 Top of the range lubricant recommended for diesel engines for generating sets used under severe conditions USES v Particularly suited to more modern engines with or without turbochargers intercoolers or sophisticated injection systems e g HEUI injector pumps v All types of use can cope with the most demanding applications v Depolluted engines complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel especially ecological diesel with low sulphur content PERFORMANCE ACEA E3 API CH 4 v Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition ADVANTAGES v 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 C 0 883 Cinematic vi
243. ontact with the eyes In the event of contact with the eyes rinse immediately with plenty of water for at least 15 minutes Avoid prolonged or repeated contact with the skin In the event of contact with the skin wash thoroughly with water and soap CONSULT A DOCTOR IMMEDIATELY KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN Warning The anti rust product is toxic and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging SSS Caution fuels and oils are dangerous to inhale Ensure proper ventilation and use a protective mask Never expose the equipment to liquid splashes or rainfall and do not place it on wet ground The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 7 260 EN 1 3 4 Risk of fire burns and explosion The engine should not be operated in environments containing explosive products As not all of the electrical and mechanical components are shielded there is a risk of sparks forming Danger AN AN ANN SSS 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 p
244. or 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 Check Wiring Check Wiring Check Wiring Check Wiring Shut Down Engine Check Diagnostic Trouble Codes Shut Down Engine Check Diagnostic Trouble Codes Contact Servicing Dealer Check Pump Wiring Check Fuel Filter and Lines Contact Servicing Dealer Check Diagnostic Trouble Codes Contact Servicing Dealer DTC s Listing in Ascending SPN FMI Codes CD03523 00002D4 19 22DEC10 2 2 50 5 187 260 020811 PN 109 Troubleshooting Engine Wiring Harness Layout 4045 and 6068 Engines RG12224 UN 19JUN02 6068HFU82 Engine Shown A Engine Coolant Temperature E Optional Instrument Panel or I Fuel Rail Pressure Sensor M Fuel Temperature Sensor ECT Sen
245. ore 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 03MARQ3 1 1 Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death Keep master shield and driveline shields in place at all times Make sure rotating shields turn freely Wear close fitting clothing Stop the engine and be sure the PTO driveline is stopped before making adjustments or i aa performing any type service on the engine or PTO driven equipment TS1644 UN 22AUG95 CD PTO 19 22JANO7 1 1 05 5 020811 PN 26 104 260 Safety Practice Safe Maintenance Understand service procedure before doing work Keep area clean and dry Never lubricate service or adjust machine while it is moving Keep hands feet and clothing from 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
246. osition it Release the sling then detach it O00000 Forklift truck Position the arms of the forklift truck in the forklift pockets no 2 Lift the equipment handling it gently 000 Set down the generating set in its unloading position 20 260 EN 3 2 Choice of location This shall be determined according to the application There are no strict rules governing the choice of location other than the proximity of the electrical supply panel and the disturoance caused by the noise However it is important to take into account the fuel supply the evacuation of burnt gases the direction of these gases and evacuation noises The choice of location will therefore be the result of a carefully considered compromise Examples of problems that may be encountered Incorrect ventilation and exhaust Building or terrain too rough Reduced access Generating set incorrectly seated Impossible to fill with fuel Impossible to open enclosure doors Figure 3 1 Examples of problems that may be encountered Ensure that the generating set is placed on a flat surface Warning 3 3 Moving the genset Whenever the generating set is moved the appropriate equipment must be used sling forklift etc and you must know the parts of the generating set which enable it to be moved see below mo r asa Central lifting ring Forklift pockets Drawbars 21 260 EN 3 4 Connections 3 4 1 Co
247. oting Symptom Problem Solution Sulfated or worn out batteries See your authorized servicing dealer or engine distributor Blown fuse Replace fuse CD03523 00002D8 19 22DEC10 2 2 ous PN 118 196 260 Storage Engine Storage Guidelines 1 John Deere engines can be stored outside for up to three 3 months with no long term preparation IF COVERED BY WATERPROOF COVERING 2 John Deere engines can be stored in a standard overseas shipping container for up to three 3 months with no long term preparation 3 John Deere engines can be stored inside warehoused for up to six 6 months with no long term preparation John Deere engines expected to be stored more than six 6 months MUST have long term storage preparation See Prepare Engine for Long Term Storage CD03523 00002DB 19 22DEC10 1 1 Prepare Engine for Long Term Storage The following storage preparations are used for long term engine storage up to one year After that the engine should be started warmed up and retreated for an extended storage period IMPORTANT Any time your engine will not be used for over six 6 months the following recommendations for storing it and removing it from storage will help to minimize corrosion and deterioration 1 Change engine oil and replace filter Used oil will not give adequate protection See Change Oil and Filter 2 Service air cleaner See Clean or Replace Air Filter Drai
248. ou should also refer to any local and national regulations that apply in accordance with your own jurisdiction KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries 1 3 1 General advice Use v The operating and safety instructions must be made known to operating personnel They will be regularly updated v Read and understand the manuals provided with the generating set pump unit or lighting column properly The manufacturer s instructions must remain at the disposal of technicians if 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 v Do not wear loose clothing or get close to machines in operation Note that the fans are not clearly visible when the engine is running v Warn personnel present to keep their distance during operation Do not run the generating set pump unit or lighting column without refitting the protective covers and closing all the access doors v Never let a child touch the generating set pump unit or lighting column even when shut down v Avoid operating the generating set pump unit or lighting tower in the presence of animals disturbance scares etc v Engage the parking brake when the generat
249. ounting arrangements IM 1201 MD 35 foot and flange mounted single bearing with SAE coupling disc IM 1001 B 34 double bearing with SAE flange and standard cylindrical shaft extension Drip proof machine self cooled Degree of protection IP 23 2 2 1 Options Air inlet filter Regreasable bearings only for LSA 44 2 and SHUNT or AREP version IP 44 protection MAIN FIELD STATOR 12 wires marked T1 to T12 Exit mney x x lt O T1 T7 T2 T8 T3 T9 Armature E 0 5 bak 5 Field ba a a K KR XK C T4 T10 T5 T11 T6 T12 connection Power supply and voltage reference 2 1 3 AREP system with R 438 AVR MAIN FIELD STATOR 12 wires marked T1 to T12 Exiter Auxiliary windings N T r7 r2 T8 T3 T9 Armature ES peo 5 N l e Field 5 6 K K lt T4 T10 r5 T11 T6 T12 PARALLEL ee connection Voltage reference 2 1 4 PMG system with R 438 AVR MAIN FIELD Exiter 9 2 Armature nee 5 s e m amp H E qe 54 Field 6 Q fe E C PARALLEL e amp connection STATOR 12 wires marked T1 to T12 T1 T7 T2 T8 T3 T9 T4 T10 T5 T11 T6 T12 R 438 Voltage reference LEROY SOMER 215 260 LEROY SOMER INSTALLATION AND MAINTENANCE
250. panel presentat OT lt i si2 cesciace r rE aaa aa a aaa a Aaa aaa a E ae aaa pace Dads nal lec deta dg ee dedi a 50 6 3 1 1 Viewof the front panel sisareen a a a aa a A 50 6 3 1 2 Description ot the Scree nMi san norni cane ta iage pt cua eens shea peste teva ce vide ce ose cv aaO EATA a Seea oe ahd Peeters Ants 52 6 3 1 3 Description of the pictograms i Zone 1 ccccesesceeeeseneeeesensenenseeeeenseneeeesenseneeeseeseenseseseasensaneeseseeeeeseneaeensenseneesees 53 6 3 1 4 Description of the pictograms IN ZONE 2 0 eeeeeeseeeeseneeeeeeeaeeeeeeaeeeeteaaeeeeeaaeeeeesaaeeeseaeeeeseaeeeeeeaaeseeaeeseseneeeeeseeeeeenaes 54 6 3 1 5 Description of the pictograms iN ZONE 3 0 00 ecseceseseeeeeseneeeeeenteneneeceeeeteeeeeesensensenteeeeseneeseseaseeensneesseceeeenseeeeseseneeeeesces 55 6 3 1 6 Display of MeSSageS IN ZOME 4 osrin ree voiries ndata nanpi oaeee aana arie en aa aa airaa ea aTa Eara KAK a ATE due eeeetseeneeicee 57 6 322 SEAMING PEE E E sate E E das E A ease ears E A E 61 6 353 SWING O roria atc alan a a a a a a a aa a a a Sie crete hy ta A eee dee 62 R Alarms and H KEIU CEET T E E 62 6 3 4 1 Viewing alarms andstaults snssoronern e ied e a Gees eter A E T a a Ea 62 6 3 4 2 Activation ofan alarmi or faults Diesenin a a leans a Adee aa ana E OA ies ENRE eng 63 6 3 4 3 Activation ot amal arm and amp fault seodra eree oaeen aonaran areneda ur alibi oa E aea TO SAAN Saario ea a kites 64 6 3 4 4 Engine fault codes displa
251. pecial 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 FMl 15 DATA VALID BUT ABOVE NORMAL OPERATING RANGE LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition Region i of the signal range definition Broadcast of data values is continued as normal FMl 16 DATA VALID BUT ABOVE NORMAL OPERATING RANGE MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range but the real world condition is above what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition Region k of the signal range definition Broadcast of data values is continued as normal 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
252. r i 4 t 3 Y U23 Alternator composite Voltage Indicator P4 a 43 aue Hz U31 Alternator composite Voltage Indicator Alternator Frequency Indicator 55 260 EN Screen Pictograms Data displayed no e 3 3 V1 Alternator single Voltage Indicator 2 p 3 3 y V2 Alternator single Voltage Indicator P5 J p 3 3 V3 Alternator single Voltage Indicator 0 Ge Hy Alternator Frequency Indicator ce 4 t U12 Alternator composite Voltage Indicator be J i i c H V2 Alternator single Voltage Indicator P6 af i i c V1 Alternator single Voltage Indicator S Ha Hz Alternator Frequency Indicator P7 c J t y V1 Alternator single Voltage Indicator A Single phase Alternator current indicator S Ha Hz Alternator Frequency Indicator P8 Single phase Alternator current indicator i 2 Al Two phase Alternator current indicator J n Three phase Alternator current indicator H n Neutral Alternator current indicator k Lf Total Active Power Indicator k Total Reactive Power Indicator FE P9 Ode Total Effective Power Indicator Total Power Factor Indicator lagging or leading 56 260 EN Screen Pictograms Data displayed no a g0 7 Fuel Level Indicator P10 AX Me V cA Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on Type of network Order of appear
253. r Poly V Belt 4045 6068 and 6090 Engines 4 CD30769 UN 01SEP99 CD30770 UN 01SEP99 Fan Alternator Belt Installation on 4045 Engines Fan Alternator Belt Installation on 6068 Engines NOTE With the belt removed inspect pulleys and bearings Rotate and feel for hard turning or ALT any unusual sounds If pulleys or bearings need replacement see your John Deere Dealer or Distributor Refer to Check Belt in Section 35 to determine if belt T needs to be replaced 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary CD31268 UN 21DEC10 2 On engines with automatic belt tensioner release D31268 tension on belt using a breaker bar and socket on tension arm Fan Alternator Belt Installation on 6090 Engines On engines with manual tensioner loosen cap screws ALT Alternator I Idler Pulley holding the alternator CP Crank Pulley T Tensioner FD Fan Dri WP Water P Remove poly V belt from pulleys and discard belt eras age aera 4 Install new belt making sure belt is correctly seated in all pulley grooves Refer to belt routing shown for 6 Start engine and check belt alignment your application 5 Apply tension to belt See Check Belt in Section 35 CD03523 00002D0 19 20DEC10 1 1 020811 45 5 PN 101 179 260 Maintenance As Required Bleed the Fuel System non Escaping fluid under pressure can penetrate the skin causing serious in
254. r or glow plug s Operating time depends on temperature Do not crank engine until light goes OFF e 3029 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 e 4045 6068 and 6090 engines are optionally equipped with the grid type air heater A Turn key switch ON but DO NOT crank engine until engine preheater indicator light turns OFF A Grid Type Air Heater 4045 B Single Glow Plug 3029 6068 and 6090 Engines Engines TS1356 UN 18MAR92 Handle Starting Fluid with Care CD30750 UN O3SEP99 Glow Plug or Grid Type Air Heater CD03523 00002AD 19 25NOV10 1 3 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 approximately 2 hours Extend heating period if ambient temperature is lower Continued on next page Coolant Heater LX1017768 UN 240CT97 CD03523 00002AD 19 25NOV10 2 3 15 26 137 260 020811 PN 59 Operating the Engine Fuel preheater Fuel preheater A switches ON and OFF automatically in relation with the ambient temperature r a nos SHN DEERE OAL ALTER LX1017708 UN O90CT97 LX1017708 Fuel Preheater CD03523 00002AD 19 25NOV10 3 3 1 5 27 020811 PN 60 138
255. rankshaft vibration damper check a Engine mounts check a Engine ground connection check a Valve clearance adjust Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 00002A5 19 03JAN11 1 1 8500 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace a Crankcase vent system clean a Engine mounts check a Engine ground connection check Number of hours Observation Date Job done by Dealer or distributor stamp CD03523 00002A6 19 22DEC10 1 1 02 9 020811 PN 15 93 260 Maintenance Records 9000 Hours of operation a Engine oil drain a Engine oil filter replace o Fuel filter elements replace o Belt check tension and wear a Cooling system check or drain and flush if COOL GARD II is used a Crankcase vent system clean or replace filter optional o Air intake system check a Crankshaft vibration damper replace a Engine mounts check a Engine ground connection check a Engine speed check and adjust Number of hours Observation Dealer or distributor stamp Date Job done by CD03523 00002A7 19 03JAN11 1 1 9500 Hours of operation a Engine oil drain o Crankcase vent system clean a Engine oil filter replace a Engine mounts check o Fuel filter elements replace a Engine ground connecti
256. rate switch status 31 External engine de rate switch active Not used 1069 Tire size status Tire size error Not possible with Genset Tire size invalid application 31 Tire size error 1075 Feed pump of the fuel circuit High impedance at the terminals of the pump or open circuit 6 Pump coil short to ground 12 Pump defective 254 260 EN SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 1076 Fuel Injection pump status Pump control valve closure too long Injection DE10 Pump control valve closure too short Injection DE10 Pump detected defect Injection VP44 Pump solenoid current high Injection DE10 Pump solenoid circuit open Injection DE10 Pump solenoid circuit severely shorted Injection DE10 NISJA N o Pump control valve closure not detected Injection DE10 Pump solenoid circuit moderately shorted Injection DE10 a o4 ujo Pump current decay time invalid Injection DE10 1077 Fuel injection pump controller status Attempting to fuel without command 11 Pump supply voltage out of range 12 Pump self test error 19 Pump detected communication error 31 Pump initiated engine protection 1078 ECU Pump timing status ECU Pump timin
257. rations to be carried out are outlined in the maintenance schedule given as a guideline N B the environment in which the generating set is operating determines this schedule If the generating set is used in extreme conditions shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel oil and coolant which conform to the specifications given in this manual 7 2 Maintenance safety instructions Before each operation please observe the following maintenance safety instructions read the safety instructions carefully chapter 1 refer systematically to the maintenance instructions the battery isolating switch must be in the open position no operations must be carried out while the motor is running wear protective equipment gloves goggles safety shoes etc before operating on a pressurised circuit ensure that the circuit pressure has been reduced atmospheric pressure after the operations ensure that the equipment is clean or clean it if necessary KNNNNNRSN 66 260 EN 7 3 Table of maintenance operations 10h 1000 h 2000 h 20 000 h Every 2 sooh 4500h 5000h 10 000 h OPERATIONS Daily Weeks 1 years 2 years 3 years Generator set e Check the general condition e Check the tightening torques e Check the absence of leaks e Check the condition of battery charge e Clean the battery terminals e Check condi
258. re 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 A Particular attention must be paid to the tightness of the wheels on new vehicles Nonetheless the tightness must be checked whenever you are about to tow the trailer Warning Lights signalling only for on road trailers Warning lights are obligatory for on road driving Signalling must comply with regulations in force in the country of use Front reflective devices white Red rear lights direction indicators stop lights Rear reflective devices red triangle Side reflective devices orange Figure 4 2 Example of French signalling 4 4 Unhitching the trailer This operation should be carried out on horizontal flat stable ground Lock the wheels Lower the front wheel Disconnect the road signals wire Refit the hitch using the wheel to release the hook ring from the tow vehicle Release the tow vehicle Engage the handbrake 000000 30 260 EN 4 5 Implementation for installation Operations to be carried out Ensure that the ground is strong enough for the assembly not to sink into it Unhitch the trailer Immobilise the trailer by placing chocks under the whee
259. rect contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire may be cut with an axe Take great care to avoid the electric arc that will be generated by this Begin emergency procedures Resuscitation If breathing has stopped begin artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 1 3 7 Risks related to moving the set To unload the generating sets pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions you must ensure that the following points are observed v v The lifting machinery or equipment is suited to the work required in good condition and with sufficient lifting capacity The slings are positioned in the rings provided for this operation the forklift arms are resting fully underneath all of the base frame cross beams or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set according to models For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set pump unit or lighting column the generating set pump unit or lighting column must be lifted up with an adjustable boom All the chains and
260. removed 4 Check for filled fuel tank 5 Perform all appropriate prestarting checks Refer to Maintenance Daily or Every 10 Hours IMPORTANT DO NOT operate starter more than 30 seconds at a time Wait at least 2 minutes for starter to cool before trying again Crank engine for 20 seconds with starter do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to assure bearing surfaces are adequately lubricated Start engine and run at no load for several minutes Warm up carefully and check all gauges before placing engine under load On the first day of operation after storage check overall engine for leaks and check all gauges for correct operation CD03523 00002DD 19 22DEC10 1 1 55 1 197 260 020811 PN 119 Specifications General Engine Pack Specifications ITEM UNIT OF 3029TFU80 4045HFU82 4045HFU82 4045HFU82 MEASURE 80 kVA 100 kVA 120 kVA Number of 3 4 4 4 Cylinders Fuel Diesel Diesel Diesel Diesel Bore mm 106 5 106 5 106 5 106 5 Stroke mm 110 127 127 127 Displacement L 2 9 4 5 4 5 4 5 Compression Ratio 17 2 1 19 0 1 19 0 1 19 0 1 POWER at 1500 kW hp 28 38 76 103 94 127 112 152 rpm Prime POWER at 1500 kW hp 31 42 83 113 103 140 123 167 rpm Standby POWER at 1800 kW hp 33 45 78 106 96 131 115 156 rpm Prime POWER at 1800 kW hp 36 49 86 117 106 144 126 171 rpm Standby Width overall mm 590 755
261. rize cooling system to specification listed for radiator cap 4 With pressure applied check all cooling system hose connections radiator and overall engine for leaks If leakage is detected correct as necessary and test system pressure again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket Have your engine distributor or servicing dealer correct this problem immediately CD03523 00002BE 19 23DEC10 1 1 020811 PN 86 35 5 164 260 Maintenance 1 000 Hours 1 Year Check Air Intake System 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 Inspect all intake hoses piping for cracks Replace as necessary Check clamps on air pipes 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 Replace indicator as necessary If engine has a rubber dust unloader valve C inspect the valve on bottom of air filter for cracks or plugging Replace as necessary Service air filter as necessary A Air Pipes B Air Restriction Indicator CD30762 UN 27AUG99 RG4687 UN 20DEC88 C Dust Unloader Valve CD03523 00002BF 19 15DEC10
262. rrect alignment If equipped with water separator bowl E remove filter element from separator bowl Drain and clean separator bowl Dry with compressed air Install bowl onto new filter element Tighten securely Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click 8 is heard and a release of the retaining ring is felt Bleed the fuel system CD03523 00002B8 19 23DEC10 1 1 30 9 155 260 020811 PN 77 Maintenance 500 Hours Change Fuel Filter Elements 6090 Engines A CAUTION 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 of 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 High Pressure Fluids X9811 UN 23AUG88
263. s by 50 when using biodiesel blends greater than B20 Oil analysis may allow longer service intervals e Use only approved oil types Plus 50 is a trademark of Deere amp Company Torq Gard is a trademark of Deere amp Company Approved Oil Types e Plus 50 Oils include John Deere Plus 50 II and John Deere Plus 50 e Other Oils include John Deere Torq Gard API CJ 4 API Cl 4 PLUS API Cl 4 ACEA E9 ACEA E7 ACEA E6 ACEA E5 and ACEA E4 NOTE The 500 hour extended oil and filter change interval is only allowed if all of the following conditions are met e Use of diesel fuel with sulfur content less than 5000 mg kg 5000 ppm e Use of John Deere Plus 50 II or Plus 50 Oil e Use of an approved John Deere oil filter Engine Oil and Filter Service Intervals Fuel Sulfur Less than 1000 mg kg 1000 ppm Plus 50 Oils 500 hours Other Oils 250 hours Fuel Sulfur 1000 2000 mg kg 1000 2000 ppm Plus 50 Oils 500 hours Other Oils 250 hours Fuel Sulfur 2000 5000 mg kg 2000 5000 ppm Plus 50 Oils 500 hours Other Oils 250 hours Fuel Sulfur 5000 10 000 mg kg 5000 10 000 ppm Plus 50 Oils Contact John Deere dealer Other Oils Contact John Deere dealer Oil analysis may extend the service interval of Other Oils to a maximum not to exceed the interval of Plus 50 Oils DX ENOIL13 T3 PTP 220toMAX 19 21JUN10 1 1 Lubricant Storage Your
264. s 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 NOTE Diagnostic gauge A has a 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 to select 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 DTC to interpret the DTC s present 4 Contact your nearest engine distributor or servicing dealer with a list of DTC s so that necessary repairs can be made ostic Trouble Codes DTC s RG13740 UN 11NOV04 Diagnostic Trouble Code Display on Instrument Panel A Diagnostic Gauge C Arrow Keys B Menu Key D Enter Key CD03523 00002D3 19 22DEC10 1 1 50 1 183 260 020811 PN 105 Troubleshooting Displaying Of Diagnostic Trouble Codes DTCs There are several different methods for displaying both stored and active DTCs from the ECU via a fault lamp or a diagnostic gauge on the electronic instrument panel 2 DIGIT CODES Some engines display Service Codes or DTCs as 2 d
265. s section of 13 3 mm or AWG 6 at most connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically This earthing rod embedded fully in the ground must have a minimum length of 2 5 m 3 5 2 Earthing system principle The Earthing system or SLT formerly Neutral system of the electrical facility defines the situation of the generating set neutral in relation to earth and the grounds of the electrical facility at the user end The purpose of the earthing systems is to protect personnel and equipment by managing risks posed by insulation defects For safety reasons any live conducting part of a facility must be insulated from the earth This insulation may be achieved by distance or by using insulating materials But with time insulation may deteriorate due to vibrations mechanical impacts dust etc and therefore generate an earth with dangerous potential This defect poses risks for personnel and property but also continuity of service Earthing systems are codified by two letters that define the connections y The first letter defines the neutral connection Insulated or earthed via an impedance device T Connected to earth v The second letter defines the grounding situation of the electrical facility Connected to earth N Connected to neutral E g IT Isolated Neutral Ground earthed Spee
266. scosity at 40 C 105 mm2 s cSt 7 Cinematic viscosity at 100 C 14 1 mm2 s cSt Viscosity index 140 F Dynamic viscosity at 15 C 3000 mPa s cP o Pour point 30 C i J Flash point 220 C a 2g Sulphated ash content 1 4 weight lt Values given as examples only m o 17 260 p SAE OW 40 EN 2 5 1 2 Specifications of coolants Engine Coolants Make Type Make Type John Deere All GenPARTS GENCOOL PC 26 C Mitsubishi LLC MITSUBISHI Al GenPARTS GENCOOL PC 26 C Volvo All GenPARTS GENCOOL PC 26 C GenCOOL PC 26 High protection coolant approved by manufacturers GenCOOL PC 26 is a ready to use highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers e Itis made from antifreeze and G 48 inhibitors e It protects up to 26 C e Itis free from nitrates amines and phosphates e Itis aclear fluorescent orange liquid REFERENCES APPROVALS for the antifreeze HEAVY GOODS VEHICLE LIGHTER VEHICLES Approved by MTU MERCEDES BENZ MAN KHD Approved by BMW VOLKSWAGEN MERCEDES PORSCHE GENERAL MOTORS Conforms with VOLVO OPEL SEAT and SKODA Conforms with VOLVO IVECO VAN HOOL and STAYR specifications TRUCK specifications Conforms with the NF R 15 601 standard REINFORCED ANTI CORROSION FEATURES e Protects against high temperature corrosion by oxidisation of ethylene cyl
267. settings Interfering parts on the slide Remove clean and grease Corroded slide Remove the corrosion and grease Damage to slide guide rings Replace the rings and possibly the slide and grease Faulty shock absorber Replace the shock absorber Trailer tending to swerve upon braking Cross bar s not balanced Adjust the cross bar s Different brake setting on the two sides Adjust the brake settings Cables damaged or incorrectly fitted Replace the damaged parts Refit the cables Poor load distribution Check the load distribution When starting the trailer holds back the towing vehicle Damage to slide or to guide rings Replace the faulty parts and grease Slide corrosion Remove the corrosion and grease Tie rod damaged Replace the tie rod and adjust the settings Linkage damaged or incorrectly set Replace the damaged parts and adjust the settings Brake on Loosen the brake Play in the coupling head Head worn see wear indicator Replace the head Ball joint worn Replace the ball joint Parking braking too weak Compensating spring incorrectly set Adjust the setting Braking system incorrectly set Adjust the setting Notched sector damaged Replace the sector setting and adjust the Lever ratchet worn Replace the lever and adjust the setting Cable rupture
268. sor 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 00002D5 19 22DEC10 1 1 50 6 020811 PN 110 188 260 Troubleshooting Engine Wiring Harness Layout 6090 Engines N S D NN R5 lt 3 SRE AN m Cee aN a sA Aa i wa ack Y A S Le oe wq o H Sp E es ee ae y A er x N irs 2 R i S DY s U i N a z V wo Y i g ro x Electrical Wiring Harness Layout Continued on next page CD03523 00002D6 19 22DEC10 1 2 020811 50 7 PN 111 189 260 Troubleshooting A Manifold Air Pressure MAP H Exhaust Gas Recirculation O Fuel Rail Pressure Sensor V Fuel Pressure Sensor Sensor Connector EGR Fresh Air Sensor Connector W Water in Fuel Sensor B Exhaust Gas Recirculation Connector P Camshaft Sensor Connector X Crankshaft Speed Position EGR Mixed Air Temperature I Air Heater Jumper Q Fuel Injector Connector Sensor Sensor Connector Connection R ECU Connector Y Oil Pressure Sensor C Turbocharger Sensor Jumper J VGT Turbocharger Connector S ECU Z Fuel Transfer Pump Sensor Connector K Coo
269. ss cannot be used the fault finding module cannot find the default addresses an address cannot be found in the correct register Error Code 2 Passive Bus Error this code appears when the fault finding module cannot detect the ECU in this case the CAN Bus is open the CAN_hi and CAN_lo run time bus connection is reversed between the source ECU and the fault finding module Error Code 3 This code is the result of the following problems the CAN_Hi or CAN_lo bus or both are connected to an electrical ground or an external source of current data is being not transmitted at a standard baud rate This type of fault generally requires repairs to be carried out on the CAN BUS connection and therefore involves work on the engine wiring harness i e on the fault finding module extension Run Time Bus Errors Fault codes can only be active if the fault finding module has been able to obtain the network addresses when it was switched on see Address Claim Procedure Errors ACP err Error Code 1 EP Passive Error this screen appears when the fault finding module loses contact with the ECU there may be two causes of this one connector on the bus connection is disconnected the CAN Bus is open Error Code 2 BO Bus Off in this case the case is identical to Error code 3 of the ACP Error Code 3 BR Bus Reset this error code is similar to Error code 3 of the ACP as are its causes In this case the
270. ss the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24 08 2005 Switch TELYS off by turning the key to OFF without forcing it to the OFF position 6 3 4 Alarms and faults 6 3 4 1 Viewing alarms and faults Alarms and faults are displayed as follows Alarms All alarms will cause gt the yellow LED to flash General alarm i In conjunction with this LED gt a flashing pictogram appears on the LCD screen gt message on graphic display example representing the circuit affected by the alarm and the associated indicator if present FAULT example ALARM Low Fuel Level 25 12 05 15 30 OK HELP 62 260 Faults All faults will cause gt the generating set to stop immediate or gradual stop coolant temperature and overload or short circuit gt the red LED to flash General fault In conjunction with this LED gt a flashing pictogram appears on the LCD screen gt message on graphic display example FAULT representing the circuit affected by the fault and the associated indicator if present example FAULT Oil Pressure J a 25 12 05 15 30 OK HELP Faults have priority over alarms Faults are displayed in the descending order of their appearance from the most recent to the oldest 6 3 4 2 Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed
271. status Glow plug relay voltage high Glow plug relay voltage low 253 260 EN SPN CID SID PID PPID FMI Description Comment Perkins John Deere Volvo 677 39 3 Start relay status 3 Start relay control short circuit to high Start relay control short circuit low Start relay control open circuit 678 41 8 Volt power supply 3 ACM 8 Volt DC supply open short to B ACM 8 Volt DC supply open short to ground Regulation sensor of the injection i ci pressure control 723 342 Secondary speed sensor Secondary engine speed sensor data intermittent Secondary engine speed sensor loss of 11 3 signal 12 Loss of signal sensor failure Inlet air heater signal Preheat 729 i detection Inlet air heater signal high 810 Vehicle speed Not possible with Genset Calculated vehicle speed input noise application 3 5 E Inlet air heater signal low 861 861 Diagnostic output status 3 Diagnostic output open short to B 4 Diagnostic output short to ground 898 CAN throttle status 9 Speed value invalid or missing Auxiliary engine shutdown switch 970 6 status EMS Auxiliary engine shutdown switch signal invalid Not used 31 Auxiliary engine shutdown switch active 971 External engine de
272. ste ited be dete eeu aes 15 12 Blink code method sx csccxestassccraenhstearxisaceansigerss 50 2 Changing units of MEASUTE sees eens 15 13 Diagnostic gauge inci dtenetatdctat shun hiaih mntany 50 1 Main menu navigation cece 15 1 Stored service codes viewing are eer ee a 15 5 Setup 1 up display ety rete tier tere tery teeter 15 15 Dies lfuehiraniinram ia i 10 1 Setup 4 up display sssssstsssessitesersrrereessreeesnrnree 15 21 DTCs Diagnostic Trouble Codes Shutdown Codes esses teeeeeeeee esses eeeeeneneenens 15 9 View active service COd S cccscscscseseseeeseeeseseees 15 7 Using diagnostic gauge ee 15 1 View stored service codes ssieisiiseeieeeeeeeee 15 5 Viewing active service COdeS ee 15 7 Continued on next page Index 1 Shed 203 260 Page Page Viewing configuration data cesses 15 3 Check coolant level n 25 2 Viewing stored Service codes cceeeeetteeeteees 15 5 Check engine oil level eee eeeeeeeeeeeenaees 25 1 Check fuel filter cccccccceceeceeedeceeteeseeeeeeeseeaaes 25 3 L Observe service intervals 20 1 Use correct fuel lubricant and coolant 20 1 Lubricant Maintenance interval chart ceeeteeteeeeee 20 2 Mixing x nese enea A sas dl anes 10 4 Maintenance records cccseeeeeeeeeeniee 02 1 Strage neran a ee at a uel aana OA 10 3 Metric bolt and screw torque values
273. t 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 Connections 3 1 Unloading 3 1 1 Safety during unloading To unload electrical generating sets from their transport supports with optimum safety and efficiency you must ensure that the following points are observed The lifting machinery or equipment is suitable for the work required The sling is correctly positioned in the central lifting eye or the lifting arms are correctly positioned in the fork lift pockets intended for this purpose The ground is able to bear the load of the generating set and its lifting machinery without stress otherwise lay down stabilising beams of sufficient strength The generating set is put down as close as possible to its place of use or transport in a clear space with free access Example of equipment to be used v crane slings lifting beam safety hook shackles v Forklift truck 19 260 3 1 2 Instructions for unloading Hoisting Attach the sling on the lifting equipment to the ring on the generating set no 1 provided for this purpose Tension the slings slightly Check that the sling is correctly attached and the equipment is steady Lift the generating set carefully Direct the generating set towards the chosen location and stabilise it Carefully set down the equipment while continuing to p
274. tabilisation the LED light comes on continuously 40 260 EN 6 2 3 Switching off O trigger the circuit breaker located at the base of the centre console Let the motor run under no load for 1 to 2 minutes to allow it to cool press the STOP button to stop the generating set switch off the MICS Nexys module by switching the key to OFF without forcing it 6 2 4 Alarms and faults CH The appearance of a fault or an alarm causes the following Q a La pa screen to be displayed one or more pictograms or a fault maim code along with the SOS message are displayed e5f A ny ILI AUT mmr MILILI The user can access the following screens by pressing the key The fault or alarm screen will disappear once the fault or alarm has been removed Only one fault is displayed on this screen the fault which caused the generating set to stop If one or more faults have appeared after the first fault they can only be displayed after the first fault has been reset press Reset as many times as the number of faults present Note an alarm can appear at the same time as a fault 41 260 6 2 5 Faults and alarms Details EN List of faults which will cause the generating set to stop and generate a pictogram Oil pressure fault Indicates that the oil pressure is incorrect Associated pictogram nS wll ot Xe Engine temperature fault temperature is too high Indicates that the engine Associated pict
275. ter at least once a year Have your authorized dealer or engine distributor replace the vibration damper every 4500 hours 5 years Drain and flush cooling system every 3000 hours 3 years when John Deere COOL GARD II coolant isused Otherwise every 2000 hours 2 years 67 260 7 4 Common Spare Parts GENCOOL N Rocker cover gasket 330362994 Fuel injector 330362947 Belt 330364761 Thermostat 330364770 Thermostat Gasket 330361286 Flywheel turning tool 330360151 Timing pin 330361548 Feeler gauge 330030850 330910115 330910095 330910098 330910099 330910100 68 260 EN 330570115 330570116 330362912 330362934 330560661 330411113 330410336 For any need of spare parts please contact Spare Parts department 33 0 02 98 41 13 07 e mail genparts sdmo com To find your nearest center service please consult our website www sdmo com 69 260 EN 7 5 Fault finding Refer to the user manual and engine and alternator maintenance manuals appended Additionally in the event of an abnormal rise in engine temperature check that the radiator is clean 7 6 No load and under load tests Notes on operation at no load and under load When operating at no load or low load lt 30 of nominal po
276. time in order to incorporate the latest tech nological developments The information contained in this document may therefore be changed without notice LEROY SOMER 232 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R CONTENTS 1 SUPPLY E eri cnndsnnervindeedsstedeeuaneediueceevaendcstieesvasweds E T 4 1 T AREP excitation SyStemM ossining ern epei ieai eaS nre Eni E paai 4 1 2 PMG excitation Syste M i aariaa EE aN E EE EEEE 5 1 3 SHUNT or separate excitation SyStemM siissiicnneesiiiiiieeicieuirninineesinssecesuineesi reari stinaa 5 2 R438 ALV R A E O E E E E 6 2 1 GMAPACISMSUCS siistiin serioso roaa earan A o k r ae NLET Naal 6 2 2 Frequency compared with voltage without LAM eeeesessresresrisesiisrrreerireerisrnns 6 2 3 LAM Load Acceptance Module characteristics renren 6 2 4 Typical effects of the LAM with a diesel engine with or without a LAM U F only 7 2 9 RAJS AV R ODtONS sieo ap send venet extat rs deeshsietecaed AE e Taaa iTe i 7 3 INSTALLATION COMMISSIONING cecccceeeteeeeene ee eeeeeeeeeeeeeceeeeeseeeeneeeeeeseeneneseenensneeenes 8 3 1 Electrical checks On the AVR cccccssecciveeccedeses eecen enana a a eani 8 9 2e OEMS reee a E E E sey Scaivexsbenes saneevs 8 3 3 Ele tical TAUNTS sisii a a a e a abe NiE 11 4 SPARE PARTS siccccisscecesseeisueniecinevencscedenendvcscurieaecvanudaeveviedesnsueedenicuscdenevsauedeuineweddan
277. tion and connections of electrical equipment e Clean with compressed air the relays and contactors Engine e Check engine oil and coolant level e e Check air filter restriction indicator e Check fuel filter Water bowl e Operate engine at rated speed and 50 70 load a minimum of e 30 minutes e Change engine oil and filter e Replace fuel filter element s e Check crankcase vent system e Check engine mounts e Check engine ground connection e Check belt tension and automatic tensioner e Check cooling system e Check air intake system e Replace crankcase vent filter Optional e Check crankshaft vibration damper 6cyl e Check and adjust engine speed e Drain and flush cooling system e Adjust valve clearance e Replace crankshaft vibration damper 6cyl e Replace injection nozzles e e Replace thermostat Alternator e Check the tightening torques e Check the general condition e Check the various electrical connections of the installation e Grease the bearings After the first 20 hours Clean air filter element when restriction indicator is red Replace filter element after 6 cleanings or once a year For standby generator set only Change oil and filter after the first 100 hours of operation then every 500 hours maximum thereafter Change oil and fil
278. tle 2 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 Engine 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 Temperat
279. turn to the single or four parameter display but the display will contain the Shutdown 8 icon Pressing the Enter key will redisplay the hidden w trouble code i Sela COOL TEMP Z IMPORTANT Ignoring the shutdown message can ara a result in severe engine damage DQG D k4 Flashing Shutdown Icon Continued on next page OURGP11 00000AE 19 03SEP03 4 6 15 9 PN 42 120 260 Operating the Engine 5 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four vox SHUTDOWN parameter display SPN 100 FMI 4 FAULT ENGINE Olu PRESSURE LOW CORRECTIVE ACTION CHECK IL LEVEL NEXT gt HIDE Redisplay Trouble Code RG13239 UN 29SEP03 OURGP11 00000AE 19 03SEP03 5 6 6 The single or four parameter screen will display the fl shutdown icon until the trouble code condition is i corrected IMPORTANT Ignoring the shutdown message can ENG RPM COOL TEMP result in severe engine damage OCG OCs Shutdown Icon RG13180 UN 26SEP03 OURGP11 00000AE 19 03SEP03 6 6 Adjusting Backlighting T Ti 1 Turn the key switch to the ON position Starting at S the single or four engine parameter display press the 1800 RPM z Menu key ETELE lt COOL TEMP sed z l if el o G ON D E oo 2 Menu Key OURGP11 0000237 19 210CT03 1 6 2 The main menu will be displayed Use the Arrow
280. ty of the battery The power of the charger must be suitable for the battery to be charged and the charging time available You need to use an automatic charger able to provide a sufficient voltage and charging current as well as a compensation voltage to handle spontaneous battery discharge 73 260 8 5 Faults and remedies EN Fault observed Probable origin Measures or observations The acid heats up when a new battery is filled Incorrect composition Incorrect storage Prolonged storage in a damp place Cool Load Check the acid density The acid escapes through the filler holes Overfilled battery Reduce the battery fluid level Acid level too low Battery tray not leaktight Excessive charge voltage leading to a significant accumulation of gas Replace the battery Check the charger and repair if necessary Acid level too low Incorrect operation from start up Insufficient charge Short circuit in the power circuit Consumption fault Recharge Check the electrical installation Acid density too high The battery has been filled with acid instead of battery fluid Reduce the acid level by filling with distilled water Repeat the operation if necessary Starting problems Starting test incorrect Battery empty Battery exhausted or faulty Capacity too low Battery sulphated Recharge the battery Fit a new battery Battery terminals melted Incorrect electrical connection
281. unt the second has a voltage in propor tion to the stator current compound charac teristic Booster effect The power supply voltage is rectified and filtered before being used by the AVR moni toring transistor This principle ensures that regulation is not affected by distortions ge nerated by the load STATOR 6 wires marked T1 to T6 a STATOR 12 wires marked T1 to T12 Aux windings TANTZ T2 TS T3 T9 m o ps 5 2 N EE Armature ome 2 QD C T4 T10 T5 T11 T6 712 Field e e o 10 Yellow 11 Red 12 Black 9 Green Sa according voltage i 140 mm ans aA MARERE 4 x holes 5 8 x F1 250V 8A 175 x 115 mm ST5 L with LAM without LAM L P1 need ST3 ima CO M AREP Frequency 50Hz 60Hz ra PMG ST10 7 og LAM 13 25 Excitation P5 a Option ST4 External potentiometer for adjusting the voltage ceiling F 1 open ST1 1 knee point 65 Hz Response 1 normal ST2 time rn fast ST1 mM Option P2 Single Voltage R731 3 ph detection L P3 gt Stability phase 6 Brat ee detection A in 3 ph detection ST1 open LEROY SOMER 234 260 LEROY SOMER Installation and maintenance 3971 en 2010 11 f R438 A V R 1 2 PMG excitation syst
282. upply pressure moderately high Fuel rail pressure not developed Fuel supply pressure moderately low 97 97 Water in fuel sensor Water in fuel continuously detected Water in fuel input voltage high Short to V Water in fuel input voltage low Short to V Water in fuel detected Water in fuel detected 98 98 Oil level sensor Oil level value below normal Oil level sensor input voltage high Short to V Oil level sensor input voltage low Short to V Oil level sensor open circuit 245 260 EN 2 Pr SPN CID SID PID PPID FMI Description Comment S 100 100 100 Oil pressure sensor 1 Engine oil pressure extremely low 3 Oil pressure sensor input voltage high Short to V 4 Oil pressure sensor input voltage low Short to V 5 Oil pressure sensor open circuit 17 Engine oil pressure low 18 Engine oil pressure moderately low 31 Oil pressure detected motor stopped 102 273 102 Manifold air pressure sensor 0 Manifold air pressure above normal 1 Manifold air pressure below normal 2 Incoherent measurement of the oil pressure 3 arke pressure sensor input Short to V 4 Sea a pressure sensor input Short to V 15 Manifold air pressure moderately low 16 Manifold air pressure low 103 Turbo speed sensor 0 Turbo speed too high 5 Turbo
283. ure 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 Continued on next page Corrective Action Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Check Switch and Wiring Check Switch and Wiring Check Sensor and Wiring Check Sensor and Wiring Check Sensor and Wiring Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Contact Servicing Dealer Check Sensor and Wiring Check Sensor and Wiring Stop and Drain Water Separator Check Oil Level Check Sensor and Wiring Check Sensor and Wiring Check Oil Level Check Air Cleaner Aftercooler or Room Temperature Check Sensor and Wiring Check Sensor and Wiring Check Air Cleaner Aftercooler or Room Temperature Check for plugged air filter Check Cooling System Reduce Power Check Sensor and Wiring Check Sensor and Wiring Check Cooling System Reduce Power Check Cooling System Reduce Power Check Operator s Manual Adding Coolant Contact Servicing Dealer Contact Servicing Dealer Add Fuel or Switch Fuel Tanks Check Sensor and Wiring Check Sensor and Wiring Add Fuel or Switch Fuel Tanks Check Diagnostic Trouble Codes or Contact Servicing Dealer Reduce Engine Speed Reduce Engine Speed Check Wiring Check Wiring
284. urning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer 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 e Check 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 brackets alternator belt tensioner idler pulley etc and the belt length Replace belt as needed see Replace Fan and Alternator Belt Maintenance As Required Section Continued on next page RG13744 UN 11NOV04 A Tensioner Stop B Fixed Stop CD03523 00002BC 19 10DEC10 1 2 35 2 020811 PN 83 161 260 Maintenance 1000 Hours 1 Year e Check tensioner spring tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used Measure tensioner spring tension using a torque wrench and procedure outlined below a Release tension on belt using a long handled 1 2 inch drive tool in tensioner arm Remove belt from pulleys b Release tension on tensioner arm and remove drive tool c Put a mark A on swing arm
285. use death if the concentration levels in the air breathed are too high Always use generating sets pump units or lighting towers in a well ventilated place where gases cannot accumulate In case of indoor use v Be sure to evacuate exhaust gases outdoors Danger v Provide appropriate ventilation so that personnel present are not affected ay Observe the local regulations in force for generating sets pump units or lighting towers as well as local regulations for use of fuel petrol diesel fuel and gas before using your generating set pump unit or lighting tower Fuel filling should be carried out when the engine is off except for generating sets with an automatic filling system Engine exhaust gases are toxic do not run the generating set pump unit or lighting column in unventilated premises If installed in a ventilated room additional requirements for fire and explosion protection must be observed A leaking burnt gas exhaust may increase the sound level of the generating set pump unit or lighting column To check on its efficiency regularly examine the burnt gas exhaust Pipes must be replaced as soon as their condition demands it 1 3 3 Risks related to toxic products Glycol is a toxic product and dangerous if absorbed Avoid all contact with the skin and eyes Read the instructions on the packaging The corrosion inhibitor contains alkali Do not swallow it This substance should not come into c
286. utdown procedures for the engines As the generating sets are fitted with control units that are specific to the generating sets only the information that appears in the documentation for the generating sets control units should be taken into consideration 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 engine documentation Some user and maintenance manuals for the engines fitted to generating sets cover control units and 3 260 EN 1 2 Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator s or maintenance technician s attention to the potential dangers and explain the action to be taken in the interest of safety These notices are reproduced in this publication for ease of identification by the operator Replace any notice that is missing or illegible Warning danger Publications delivered with the generating set must be referred to Warning risk of explosion A A Warning risk of electric shock Protective must be worn clothing Naked flames and unprotected lights prohibited No smoking Warning toxic Your eyes and ears Entry prohibited to non materials must be protected authorised persons Warning Periodic maintenance pressurised fluids must be carried out Jet washing prohibited
287. 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 hex bolts up to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 mm long and for all other types of bolts and screws of any length 4 ubricated means coated with a lubricant such as engine oil fasteners with phosphate and oil coatings or 7 8 in and larger fasteners with JDM F13C F13F or F13J zinc flake coating Dry means plain or zinc plated without any lubrication or 1 4 to 3 4 in fasteners with JDM F13B F13E or F13H zinc flake coating DX TORQ1 19 12JAN11 1 1 60 3 200 260 020811 PN 122 Specifications Metric Bolt and Screw Torque Values TS1670 UN 01MAY03
288. various adjustments during tests must be made by a qualified engineer The screwdriver for making adjustments must be suitable for use with electrical equipment It is essential that the drive speed specified on the genset nameplate is reached before commencing adjustment The AVR is used to make any adjustments to the alternator Access to the AVR adjustments is via the panel provided for this purpose After operational testing replace all access panels or covers LEROY SOMER 5 219 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i LSA 43 2 44 2 4 POLE ALTERNATORS 4 SERVICING MAINTENANCE 4 1 Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the alternator in its original state All such operations performed on the alternator should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanical components who must wear the appropriate personal protective equipment for mechanical and electrical hazards Before carrying out any work on the alternator ensure that it cannotbe started by a manual or automatic system by isolating the power in any cabinet or enclosure and make sure you have understood the operating principles of the system 4 2 Regular maintenance 4 2 1 Checks after start up After approximately 20 hours
289. verheats Problem Improper type of oil Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Engine overloaded Injection nozzles dirty Engine out of time Turbocharger not functioning Engine overloaded Low coolant level Faulty radiator cap Stretched poly V belt or defective belt tensioner Continued on next page Solution Drain fill crankcase with oil of proper viscosity and quality Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine distributor Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner Reduce load See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your 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
290. ves and No 1 and 3 intake valves Rotate flywheel 360 Lock No 1 piston at TDC exhaust stroke E O RG6307 UN 03AUG92 d Adjust valve clearance on No 3 exhaust valve and No 2 intake valve Specification Valve Clearance Engine Cold Intake c cceeccceeecceeeeeeeeeeeneeeeeeeeesenaeeeseeeenae 0 35 mm 0 014 in Exhaust E EE foersecediae vier E 0 45 mm 0 018 in 4 If valves need adjusting loosen the locknut on rocker arm adjusting screw Turn adjusting screw until feeler gauge slips with a slight drag Hold the adjusting screw from turning with screwdriver and tighten locknut A to 27 N m 20 lb ft Recheck clearance after tightening locknut Readjust clearance as necessary 5 Reinstall rocker arm cover and crankcase vent tube A Adjusting Locknut D No 1 Piston at TDC B Exhaust Valve Compression Stroke C Intake Valve E No 1 Piston at TDC Exhaust Stroke F Front of Engine E 4 CD31263 Valve Clearance Adjustment on 3029 Engines CD31263 UN 16DEC10 CD03523 00002C8 19 23DEC10 2 2 020811 40 1 PN 90 168 260 Maintenance 2000 Hours 2 Years Check and Adjust Engine Valve Clearance 4045 and 6068 Engines Adjust engine valve clearance as follows or have your authorized servicing dealer or engine distributor adjust the engine valve clearance 1 Remove rocker arm cover and crankcase vent tube Z 2 Using JDE83 or JD
291. wer the operating conditions do not allow optimum running of the engine The main causes are as follows v The low volume of fuel burned in the combustion chamber leads to incomplete combustion the resulting thermal energy means that the optimum engine operating temperature cannot be reached v Overheated engines have lower compression ratios low compression ratio without turbocharging which are defined for full load and not suitable for good combustion at low load All of these factors lead to choking of the engine in particular the piston rings and valves which leads to v Accelerated wear and glazing of the cylinder liners y Loss of sealing of seats and sometimes sticking of valve stems Consequently operating any turbocharged engine at low load lt 30 can only have adverse repercussions on an engine s operation and its service life Maintenance intervals will have to be shortened to accompany harsh operating conditions Shortening draining intervals among other things will enable you to change the oil more frequently which will tend to be choked with unburnt particles and contaminated with fuel Adding a load bench is generally used to limit low load phases and obtain the periodic full loads necessary to unchoke the engine Finally when operating under load we advise vigilance towards the oil breather circuit and more particularly towards engines which have the crankcase vent connected to the turbocharger inlet risk of oil
292. wing an overload or short circuit gt Engine speed Underspeed fault Overspeed fault Non starting fault 54 260 6 3 1 5 EN Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised The pictograms below are given as examples Generating set stopped Indication of Battery Voltage Screen Pictograms Data displayed no A H Ht J Fuel Level Indicator Indication of Temperature of High Temperature ey i i c coolant HT units according to settings menu P1 2 a 7S ry ie Indication of Oil Temperature units according to settings menu Generating set start up or generating set started or generating set switching off in progress Pressure units according to Screen Pictograms Data displayed no O H n n RPM Engine Speed Indication Indication of Temperature of High Temperature O 4 m c coolant units according to settings menu P2 i Indication of Oil 0 BAR Li a i settings Indication of Oil Temperature units according to settings menu Generating set started Screen Pictograms Data displayed no at H t Fuel Level Indicator P3 4 n l y Alternator composite Voltage Indicator Default screen in Lf operation k Total Active Power Indicator 5 Hi H Alternator Frequency Indicator 4 n n U12 Alternator composite Voltage Indicato
293. xcitatrice Series connection shunt excitation Parallel connection AREP or PMG excitation White White AN Single phase dedicated SHUNT version R 251 AVR no connection for 2000 2 wire output without terminal block LEROY 8 SOMER 218 260 LEROY SOMER INSTALLATION AND MAINTENANCE 3434 en 2010 10 i 3 3 2 Sch ma de connexion des options LSA 43 2 44 2 4 POLE ALTERNATORS CR 791 T interference suppression kit standard for CE marking Voltage potentiometer N Connections OOO O W O T1 T1 TL TL TL T2 T2 T2 T2 72 T9 T4 T3 T3 T3 T3 T3 T3 NJN e J LY Je xs ST4 Voltage adjustment by remote potentiometer Anti condensation heater Thermistor PTC temperature 101 102 LSA 43 2 44 2 130 C 103 2S Ph1 Blue a Pho 10C E Black xH Ph3 180 C 104 Red white D 3 3 3 Connection checks Electrical installations must comply with the current legislation in force in the country of use Check that The residual circuit breaker complies with legislation on protection of personnel in force in the country of use and has been correctly installed on the alternator power output as close as possible
294. you understand and take notice of the different warning symbols used CAUTION Warning symbol for an operation capable of damaging or destroying the alternator or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics ofits products at any time in order to incorporate the latest technological developments The information contained in this document may therefore be changed without notice LSA 43 2 44 2 4 POLE ALTERNATORS WARNING SYMBOLS We would like to draw your attention to the following two safety measures that must be complied with a During operation do not allow anyone to stand in front of the air outlet guards in case anything is ejected from them b Do not allow children younger than 14 to go near the air outlet guards A set of self adhesive stickers depicting the various warning symbols is included with this maintenance manual They should be positioned as shown in the drawing below once the alternator has been fully installed WARNING The alternators must not be put into service until the machines in which they are to be incorporated have been declared compliant with Directives EC plus any other directives that may be applicable Copyright 2004 MOTEURS LEROY SOMER This document is the property of MOTEURS LEROY SOMER It may not be reproduced in any form wit
295. ys sic 22st aa a a a a the ac a a aa a NE 65 6 3 4 5 Horn reset 7 Maintenance schedule 7A RemInGe r OrUS s cccsscccctetiegh a a bie a SEa e ede Boshi dee ee itn ea vee ea T2 Maintenance satety instiUctions onin a a a a ec ee eh ea ee ee eed 66 7 3 Fable of maintenance operatii S iepenen a a a e a a a a a a e a a E 67 7 4 COMIMOM SPare t l AE TTA E E AOT A eeuetuassbteses severe 68 TS Ae are PEFEA A A E ease Vat atin sath cea ade duet Gy acucbads EA 70 7 6 No load and under load tests wicca tesco i a EL ee Eat cle dee eevee dliterecioliee ele 70 BS IBAttery sacs sl eins AEE ET EE TE ed lace Seog A ei ee de ide ieee E ve ed ee de ee 71 8 1 Storage and TANSPOM sez ce cde T a E a a eee doesn ep Oyseen dis aae EAS eviews eel AOA ES aina ies 71 8 2 Balt ry Setting iIMtO SOnviGe at ates artes leis creda en Pac paaa ccleaner pnd cents a ease eager een eee de Mange 72 8 3 CHECK arena A a a Les he hee eae Ne i Tee a Une en i Piatt NS an 73 8 4 Load preconizat OM feck Re I a SL cd ed en LE Ea E 73 8 5 Faults amd remedies sisene a iy A ed a 74 9 Appendix vested cs ea ceed ie Seb a cei beaeckl Sue Sepa eden ra eaa NANa os AAE Te ubue dante a dues ducceenen Seen uuncesddenden suede tate aaa aad apaa ananena anaphase 75 9 1 Appendix A Engine user and maintenance Manual ceeesceeeeeneeeeeeeeeeeeeneeeeeeaeeeeeeaaeeeeeaeeeesaeeeeesaaeeesaeeesenaeeeeneeeeeeaes 75 9 2 Appendix B Alternator user and maintenance manual eeee
296. z a 1 Connection using terminal or 2 Connection using clamp Access hatch N LO Li L2 L3 ou ou ou ou N2 R2 S2 T2 Use Ensure that the direction of rotation of the phases is identical on the genset and the installation Our gensets are factory set with a conventional direction of phase rotation Warning 23 260 3 4 4 Battery installation Install the battery or batteries in the immediate vicinity of the electric starter motor The cables will be connected directly from the battery terminals to the starter motor terminals The primary instruction to follow is to ensure that the polarities between the battery and starter motor match Never reverse the positive and negative battery terminals when connecting them This could cause severe damage to the electrical equipment The minimum cross section of the cables will be 70 mm It varies according to the power of the starter motor but also the distance EN between the batteries and the set voltage drops on the line 3 5 Protection for individuals and equipment 3 5 1 Earth connection For effective protection against electric shocks the generating set needs to be earthed To do this use a copper wire with a minimum cross section of 25 mm for a stripped cable and 16 mm for an insulated cable connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground generating set earth socket The

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