SDMO R44C3 User And Maintenance Manual
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SDMO R44C3 User And Maintenance Manual

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User and maintenance manual
for generating sets
R44C3
33504024301NE_0_1

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Summary of Contents for SDMO R44C3

  • Page 1 User and maintenance manual for generating sets R44C3 33504024301NE_0_1...

  • Page 3: Table Of Contents

    1. Preface ........................................3 1.1. General recommendations ............................... 3 1.2. Pictograms and their meanings ..............................4 1.3. Instructions and safety regulations ............................6 1.3.1 General advice ..................................6 1.3.2 Risks related to exhaust gases and fuels ..........................7 1.3.3 Risks related to toxic products ..............................7 1.3.4 Risk of fire, burns and explosion ...............................
  • Page 4 6. Using the generator set ..................................36 6.1. Pre-Start Inspection ................................36 6.2. Generator set with NEXYS control panel ..........................39 6.2.1 Control panel presentation ..............................39 6.2.1.1. Introduction to pictograms ............................40 6.2.2 Manual starting ..................................41 6.2.3 Switching off ..................................42 6.2.4 Alarms and faults ...................................

  • Page 5: Preface

    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.

  • Page 6: Pictograms And Their Meanings

    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.
  • Page 7 Battery isolating Fuel External fuel connections switch Retention container Inspection hatch Fuel drainage drainage Oil drainage Oil filling Coolant filling Coolant drainage Forklift required Bulk tank level high lifting Rinse any splashes of acid on the During any operation on the skin or in the eyes using clean water.

  • Page 8: Instructions And Safety Regulations

    1.3. Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction.

  • Page 9: Risks Related To Exhaust Gases And Fuels

    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.

  • Page 10: Risk Of Fire, Burns And Explosion

    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 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).

  • Page 11: Dangers Presented By Electric Currents (First Aid)

    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. 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.

  • Page 12: General Description

    2. General description Overview Figure 2.1.1 : General description of the generating set Acces to maintenance area Acces to control unit Lifting ring Acces to power connections Forklift grooves Drawbar 10/202...
  • Page 13 Figure 2.1.2 : General description of the generating set Protective grille Alternator External fuel supply combined tap Battery isolating switch (optional) Starter battery Charging alternator 11/202...
  • Page 14 Control Figure 2.1.3 : General description of the generating set Control unit Working hours counter Emergency stop Power circuit breaker Socket control panel Connection terminal block Note : Photo presented with the Nexys control unit. 12/202...

  • Page 15: Technical Specifications

    2.1. Technical specifications Range / Generating set type RENTAL POWER / R44C3 Weights and Dimensions Dimensions with high autonomy tank Dimensions l x w x h 2200 mm x 1000 mm x 1528 mm Weight: 1150 kg dry weight / 1350 kg in operating configuration...
  • Page 16 Alternator data ● Compliant with NEMA MG21 standards, UTE NF C51 111, ● The alternator is protected against short circuits ● Vacuum impregnation, epoxy winding, IP23 protection rating VDE 0530, BS 4999, IEC 34.1, CSA Type LEROY SOMER LSA43.2S159 Number of phases Power factor (cos Phi) Number of poles Excitation type...

  • Page 17: Identifying Sets

    2.2. Identifying sets Generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documentation contained in the appendices of this manual. 1 - Generating set 9 - Maximum ambient temperature for the rated power 2 - Manufacturer name...

  • Page 18: Fluid Retention

    2.3. Fluid retention Any outflow of the fluids contained in the generating sets (fuel, oil and coolant, or rainwater or condensation) will be collected in a retention container. The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected. Diagram 2.3: Fluid retention container The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached.

  • Page 19: Specifications

    2.4.1 Specifications 2.4.1.1. Oil grades Engine Make Type Make Type John Deere John Deere PLUS-50 John Deere GenPARTS GENLUB TDX 15W40 MITSUBISHI GenPARTS GENLUB TDX 15W40 Volvo 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: Particularly suited to more modern engines with or without turbochargers, intercoolers, or sophisticated injection systems (e.g.

  • Page 20: Specifications Of Coolants

    2.4.1.2. Specifications of coolants Engine Coolants Make Type Make Type John Deere GenPARTS GENCOOL PC -26°C Mitsubishi MITSUBISHI GenPARTS GENCOOL PC -26°C Volvo 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.

  • Page 21: Installation-Connections

    PACKAGING/STORAGE: GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings. It can be stored for 2 years in its original container and packaging. Avoid zinc coated containers. RECOMMENDATIONS FOR USE: Compatible with the original fluid. It is recommended that the cooling system is completely drained when replacing the fluid.

  • Page 22: Instructions For Unloading

    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.

  • Page 23: Choice Of Location

    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 disturbance caused by the noise. However, it is important to take into account the fuel supply, the evacuation of burnt gases, the direction of these gases and evacuation noises.

  • Page 24: Connections

    3.4. Connections 3.4.1 Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country.

  • Page 25: Power Connections

    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 1. Open the access hatch to the power section. 2.

  • Page 26: Battery Installation

    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.

  • Page 27: Earthing System Principle

    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, moist compact ballast Lean arable land, Gravel, coarse ballast To obtain an equivalent length, you can use several earthing rods...

  • Page 28: Tt System

    3.5.3 TT system Ph 1 Ph 1 Ph 2 Ph 2 Ph 3 Ph 3 Neutral connected Ground connected to earth T to earth T Neutral Ground earth 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).

  • Page 29: Adjusting The Genset Differential Protection

    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.

  • Page 30: Connection Summary

    Identify its earthing system 3.6. Connection summary Option « Application EDF » France uniquement Mark the type of differential protection Fixed genset differential protection Adjustable genset differential protection 30 mA 300 mA 30 mA 300 mA No operation required: Add differential protection No operation required: Add differential protection terminal circuits protected...

  • Page 31: Special Arrangements

    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.

  • Page 32: Operation

    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"...

  • Page 33: Implementation For Installation

    4.5. Implementation for installation Operations to be carried out: Ensure that the ground is strong enough for the assembly not to sink into it. Unhitch the trailer. Immobilise the trailer by placing chocks under the wheels. Fully engage the parking brake (if fitted). Using the front wheel, position the generating set as close to horizontal as possible.
  • Page 34 Figure 4.3: Braking transmission Figure 4.4: Cross bar fitting Figure 4.5: Tandem bearing fitting 32/202...

  • Page 35: Faults And Repairs

    4.7. Faults and repairs Fault observed Origin Solutions Erratic braking of trailer - Faulty shock absorber Replace the shock absorber - Jaws worn Replace the jaws - Jaws not run in Fault will disappear only after running in - Incorrect linkage setting Adjust the setting Braking too weak - Significant friction on the slide...

  • Page 36: Electrical Connection Diagram

    4.8. Electrical connection diagram 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 R 13 70 T 145 R 13 75 T 155 R 13 79 T...

  • Page 37: Preparation Before Operating The Set

    5. Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents.

  • Page 38: Using The Generator Set

    6. Using the generator set 6.1. Pre-Start Inspection • Inspecting the engine compartment Make sure there is no combustible material near the engine or battery. Also, check to make sure that the engine and battery are clean. If combustible materials or dust are found near the engine or battery, remove them.
  • Page 39 • Checking the coolant level Remove the radiator filler cap only after the engine has cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release internal pressure.
  • Page 40 • Checking the fuel filters When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire. Danger Drain water for the fuel filter if the warning of water draining for fuel filter is occurred. Place a drip tray under the drain hose.

  • Page 41: Generator Set With Nexys Control Panel

    6.2. Generator set with NEXYS control panel 6.2.1 Control panel presentation 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...

  • Page 42: Introduction To Pictograms

    Fig. 6.2 – Description of the LEDs A lit LED indicates: Module being supplied (green, lights up and remains lit) Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit) Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to generate (green, lights up and remains lit) General alarm (orange, flashing) General fault (red, flashing).

  • Page 43: Manual Starting

    6.2.2 Manual starting 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) All of the LEDs light up for 2 seconds, to confirm that they are operating correctly. If the LEDs do not light up, check the protection fuse and replace it if necessary.

  • Page 44: Switching Off

    6.2.3 Switching off trigger the circuit breaker located at the base of the centre console Let the motor run under no load for 1 to 2 minutes to allow it to cool. press the "STOP" button to stop the generating set. switch off the MICS Nexys module by switching the key to "OFF"...
  • Page 45 List of faults which will cause the generating set to stop and generate a fault code Associated message Low coolant level fault: indicates that the level of coolant is low in the radiator (linked to a two second time delay). 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...

  • Page 46: Generator Set With Telys Control Panel

    6.3. Generator set with TELYS control panel 6.3.1 Control panel presentation 6.3.1.1. View of the front panel 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.
  • Page 47 Fig. 6.5 – Description of the LEDs A lit LED indicates: Alarm activated (flashing yellow). Fault found (flashing red). Module on (green, on continuously). Fig. 6.6 – Close-up of USB ports USB key connection (HOST): file transfer between USB key and TELYS and vice versa. Connection for microcomputer (DEVICE): file transfer between PC and TELYS and vice versa, main module power supply.

  • Page 48: Description Of The Screen

    6.3.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones. SERIAL No.: 08030010000 SOFTWARE: 5.3.5 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz 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...

  • Page 49: Description Of The Pictograms In Zone 1

    6.3.1.3. Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms Display Activation conditions Fixed TELYS in manual mode (MANU) For 5 seconds when switching from Flashing AUTO mode to MANU mode "MANU" Mode Fixed TELYS in automatic mode (AUTO) For 5 seconds when switching from Flashing MANU mode to AUTO mode...

  • Page 50: Description Of The Pictograms In Zone 3

    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 low fuel level high fuel level Coolant level / temperature indicator Alarm...

  • Page 51: Description Of The Pictograms In Zone 3

    6.3.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples. Generating set stopped Screen Pictograms Data displayed Fuel Level Indicator Indication of Temperature of High Temperature coolant (HT) (units according to settings menu) Indication of Battery Voltage...
  • Page 52 Screen Pictograms Data displayed V1 Alternator single Voltage Indicator V2 Alternator single Voltage Indicator V3 Alternator single Voltage Indicator Alternator Frequency Indicator U12 Alternator composite Voltage Indicator V2 Alternator single Voltage Indicator V1 Alternator single Voltage Indicator Alternator Frequency Indicator V1 Alternator single Voltage Indicator Single phase Alternator current indicator Alternator Frequency Indicator...

  • Page 53: Display Of Messages In Zone 4

    Screen Pictograms Data displayed Fuel Level Indicator 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 appearance 3P+N 2P+N 1P+N Change screens by using the scrolling and selection wheel. When the wheel is rotated clockwise, the screens scroll upwards and vice-versa.
  • Page 54 Generating set stopped Screen Screen Data displayed OPERATION MANUAL Operating mode - generating set in Manual Mode Press START ready to start to start Date and time (depending on settings) 24/08/2005 13:12 OPERATION AUTO Operating mode - generating set in Auto Mode WARNING ready to start START-UP POSSIBLE...
  • Page 55 Screen Screen Data displayed AIR PREHEATING Operating phase - air preheating prior to starting generating set Countdown for air preheating delay Date and time (depending on settings) 10 seconds 24/08/2005 13:12 Generating set started Screen Screen Data displayed AVAILABLE POWER Operating phase –...
  • Page 56 Generating setstop Screen Screen Data displayed Generating set stop in progress G 11 IN PROGRESS Date and time (depending on settings) 24/08/2005 13:16 Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand) Screen Screen Data displayed Start Demand AUTO Do you wish to change...

  • Page 57: Starting

    6.3.2 Starting 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 lamp does not light up, check and replace the fuse if necessary) Test the Alarm and Fault LEDs (menu 15 –...

  • Page 58: Switching Off

    6.3.3 Switching off Open the circuit breaker manually by selecting menu 12 "CONTROL LOAD" The following display will disappear (supply stopped) Press the STOP button The following screen is displayed and the generating set will stop IN PROGRESS 24/08/2005 13:12 Switch TELYS off by turning the key to "OFF"...

  • Page 59: Activation Of An Alarm Or Fault

    Faults All faults will cause: the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit) the red LED to flash "General fault". In conjunction with this LED: a flashing pictogram appears on the LCD screen message on graphic display (example) representing the circuit affected by the fault and the FAULT...

  • Page 60: Activation Of An Alarm And A Fault

    6.3.4.3. Activation of an alarm and a fault The appearance of an alarm and a fault causes: The yellow and red LEDs to flash the related screen to be displayed (example below) FAULTS 1/2 FAULT Emergency Stop If several faults are present, the number of faults is 25/12/05 15:30 displayed at the top of the screen.

  • Page 61: Engine Fault Codes Display

    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.

  • Page 62: Horn Reset

    In the event of a fault, the screen will display the following message: FAULT Engine fault code. ALARM Pressing OK will display fault finding information. In addition, appendix D indicate the meaning of the ENGINE GENERAL 110 18 code. The checking and maintenance operations to 25/12/2005 15:30 carry out in order to solve the fault are included in the...

  • Page 63: Table Of Maintenance Operations

    7.3. Table of maintenance operations 10 h 20 000 h OPERATIONS 250 h 500 h 1000 h 1500 h 3000 h 2 years Daily 3 years Generator set • Check the general condition ● • Check the tightening torques ● •...

  • Page 64: Fault Finding

    7.4. 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. 7.5. No load and under load tests Notes on operation at no load and under load: When operating at no load or low load (<...

  • Page 65: Battery

    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.

  • Page 66: Battery Setting Into Service

    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.

  • Page 67: Load Preconization

    8.4. Load preconization 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.

  • Page 68: Faults And Remedies

    8.5. Faults and remedies Fault observed Probable origin Measures or observations - Incorrect composition - Cool The acid heats up when a new battery is - Incorrect storage - Load filled - Prolonged storage in a damp place - Check the acid density The acid escapes through the filler holes - Overfilled battery - Reduce the battery fluid level...

  • Page 69: Appendix

    9. Appendix 9.1. Appendix A – Engine user and maintenance manual 67/202...
  • Page 70 68/202...
  • Page 71 User guide and maintenance manual 99610-29120 33522051001_3_1 01/07/2009 69/202...
  • Page 72 70/202...
  • Page 73 OPERATION & MAINTENANCE MANUAL 199610-29120 The operator and supervisor are requested to read this Oper- ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance. Never operate the engine or conduct maintenance work with- out completely understanding this manual. July 2009 Pub.
  • Page 74 INTRODUCTION This operation and maintenance manual contains detailed operation, inspection and maintenance information for engines from Mitsubishi Heavy Industries, Ltd. Please read this manual thoroughly before proceeding with operation, inspection, and maintenance work for correct use and servicing. Failure to follow directions in this manual may result in serious accidents. 72/202...

  • Page 75: Limited Warranty

    FOREWORD Limited warranty Mitsubishi Heavy Industries, Ltd. will repair or replace parts returned to us when we judges that the parts are defec- tive in material and/or workmanship after conducting inspection. Mitsubishi Heavy Industries, Ltd.'s warranty is limited to the compensation work of repair or replacement of parts. The warranty coverage is effective for the original purchaser only.
  • Page 76 FOREWORD Emission warranty The following warranty applies to the engines that are approved of the emission regulation of the U.S. Environ- mental Protection Agency. Warranty coverage Mitsubishi Heavy Industries, Ltd. warrants to the first owner and each subsequent purchaser of a new non-road die- sel engine that the emission control system of your engine: is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S.
  • Page 77 FOREWORD California emission control warranty statement your warranty rights and obligations The following warranty applies to the engines that are approved of the emission regulation of the California Air Resources Board (CARB). The California Air Resources Board (CARB) is pleased to explain the emission control system warranty on you 2008 or later engine.In California, new heavy-duty off-road engines must be designed, built, and equipped to meet the State's stringent anti-smog standards.Mitsubishi Heavy Industries, Ltd.
  • Page 78 FOREWORD Warranty coverage (a) The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser. (b) Mitsubishi Heavy Industries, Ltd. warrants to the ultimate purchaser and each subsequent purchaser of the en- gine registered in the state of California that the engine is: (1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board.
  • Page 79 FOREWORD (10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or modified p arts shall be grounds for disallowing a warranty claim. Mitsubishi Heavy Industries, Ltd. shall not be liable to warrant failures of warranted parts caused by the use of a non- exempted add-on or modified part.
  • Page 80 FOREWORD (9) Miscellaneous items used in above systems (A) Vacuum, temperature, and time sensitive valves and switches. (B) Electronic control units, sensors, solenoids, and wiring harnesses. (C) Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices, and mount- ing hardware.

  • Page 81: Important Information

    FOREWORD Important information To avoid the potential hazard, accident prevention To prevent an accident, do not attempt to carry out activities must be planned methodically and con- any operation other than those described in this man- ducted continually by considering all aspect of ual, and do not use the engine for any unapproved engine operation, maintenance and inspection.All purpose.
  • Page 82 FOREWORD Warning indication The following means are used to call the attention of the operators and maintenance personnel to potential dangers of the engine. Warning statements in the manual Warning labels affixed on the engine Warning statements The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine, using the following 5 classifications to indicate the degree of potential hazard.
  • Page 83 FOREWORD Units of measurement Measurements are based on the International System of Units (SI), and they are converted to the metric system units in this manual using the following conversion rates. Pressure :1 MPa = 10.197 kgf/cm Torque :1 N·m = 0.10197 kgf·m Force :1 N = 0.10197 kgf Horsepower :1 kW = 1.341 HP = 1.3596 PS Meter of mercury :1 kPa = 0.75 cmHg...
  • Page 84 CONTENTS Do not add coolant immediately after a sudden Chapter 1 stop due to overheating........1-5 BASIC SAFETY PRECAUTIONS Avoid immediate restart after abnormal stop..1-5 Fire and explosions ......1-1 Avoid continuous engine operation at low oil Keep flames away..........1-1 pressure ............
  • Page 85 CONTENTS Chapter 3 Chapter 6 OPERATION COOLANT Preparations for operation ....3-1 Recommended water for coolant ..6-1 Long life coolant (LLC)......6-1 Engine external - Inspect ......... 3-1 Battery electrolyte level - Inspect ..... 3-1 Genuine LLC........6-1 Fuel tank oil level - Check ........ 3-2 Other brand LLCs .......
  • Page 86 CONTENTS Chapter 8 Chapter 10 PERIODIC INSPECTION AND TRANSPORTATION Lifting the engine....... 10-1 MAINTENANCE PROCEDURES Basic engine ........8-1 Belt and belt tension - Inspect and Adjust..8-1 Chapter 11 Fuel system .........8-2 TROUBLESHOOTING Fuel tank - Drain water........8-2 General precautions......11-1 Fuel filter - Drain water........
  • Page 87 CONTENTS Fig. 8-6 Fuel filter - Bleed air ......8-4 List of illustrations Fig. 8-7 Fuel injection pump - Bleed air....8-4 Fig. 2-1 Engine left view ........2-1 Fig. 8-8 Fuel filter - Bleed air (1)......8-5 Fig. 2-2 Engine right view ........2-1 Fig.
  • Page 88 CONTENTS List of tables Table 3-1 Standard values at rated speed....3-5 Table 4-1 Recommended limit and use limit of fuel property..........4-2 Table 5-1 Engine oil properties ....... 5-4 Table 6-1 Water quality standards ......6-1 Table 6-2 LLC specification ........6-3 Table 6-3 Recommended LLC concentration ..
  • Page 89 87/202...

  • Page 90: Basic Safety Precautions Fire And Explosions

    Chapter 1 BASIC SAFETY PRECAUTIONS Fire and explosions Keep flames away Use explosion-proof lighting Do not use flames near the engine (in apparatus the engine room). Fuel vapor or other When inspecting fuel, engine oil, coolant, battery elec- gas can catch fire and produce dan- trolyte, etc., use a flameproof light.

  • Page 91: Stay Clear Of All Rotating And Moving Parts

    Chapter 1 BASIC SAFETY PRECAUTIONS Stay clear of all rotating and moving parts Install protective covers around Lockout and tagout rotating parts Be sure to lockout and tagout before starting inspec- Make sure the protective covers of tion and maintenance. the engine are correctly installed.

  • Page 92: Be Careful Of Exhaust Fume Poisoning

    Chapter 1 BASIC SAFETY PRECAUTIONS Be careful of exhaust Be careful of falling down fume poisoning Lift engine carefully To lift the engine, use slings capable Operate engine in a well-venti- of supporting the weight of the lated area engine. If the engine is installed in an Attach the wire rope to the hangers enclosed area, and the exhaust gas...

  • Page 93: Protect Ears From Noise

    Chapter 1 BASIC SAFETY PRECAUTIONS Protect ears from noise Be careful of burns Wear ear plugs Do not touch the engine during Always wear ear plugs when entering or immediately after operation the machine room (engine room). To avoid burns, do not touch the Combustion sound and mechanical engine during or immediately after noise generated by the engine can...

  • Page 94: Be Careful When Handling Fuel, Engine Oil Or Llc

    Chapter 1 BASIC SAFETY PRECAUTIONS Be careful when handling When abnormality occurs fuel, engine oil or LLC Do not add coolant immediately after a sudden stop due to over- Use only specified fuel, engine heating oil and LLC If the engine stops suddenly or if you have no choice Use fuel, oil and LLC specified in this manual, and but stop the engine suddenly due to overheating, do handle them carefully.

  • Page 95: Service Battery

    Chapter 1 BASIC SAFETY PRECAUTIONS Service battery Handle the battery correctly Never use flames or allow sparks to generate near the battery. The bat- tery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity could cause an explosion.

  • Page 96: Other Cautions

    Chapter 1 BASIC SAFETY PRECAUTIONS Other cautions Never modify engine Perform all specified pre-opera- Unauthorized modification of the engine will void our tion inspections and periodic warranty. inspections Modification of the engine may not only cause engine Conduct the pre-operation inspections and periodic damage but also produce personal injuries.

  • Page 97: Conduct Cooling Operation Before Stopping The Engine

    Chapter 1 BASIC SAFETY PRECAUTIONS Conduct cooling operation Use of tools optimum for each before stopping the engine work Before stopping the engine, let it idle in low gear for 5 Always keep in mind to select most appropriate tools to 6 minutes to cool down.

  • Page 98: Name Of Parts

    Chapter 2 NAME OF PARTS Engine external diagrams The external diagram is for the standard type of the engine. The installed equipment and shapes differ according to the engine type. S4S in-line type fuel injection pump left view Governor Fuel filter Fuel injection nozzle Stop solenoid Air inlet...
  • Page 99 Chapter 2 NAME OF PARTS S4S-DT in-line type fuel injection pump left view Governor Stop solenoid Fuel filter Fuel injection nozzle Glow plug Water pump (coolant inlet) Oil cooler Front Rear Fuel return port Coolant drain plug Fuel injection pump Fuel feed pump Oil level gauge Crankshaft pulley...
  • Page 100 Chapter 2 NAME OF PARTS S4S distoributor type fuel injection pump left view Fuel inlet Fuel injection nozzle Fuel filter Air inlet Fuel return port Water pump (coolant inlet) Magnetic valve (stop solenoid) Front Rear Coolant drain plug Crankshaft pulley Oil level gauge Flywheel Fuel injection pump...
  • Page 101 Chapter 2 NAME OF PARTS S4S-DT distoributor type fuel injection pump left view Fuel inlet Fuel injection nozzle Fuel filter Glow plug Oil cooler Fuel return port Water pump (coolant inlet) Magnetic valve (stop solenoid) Rear Front Coolant drain plug Crankshaft pulley Oil level gauge Fuel injection pump...
  • Page 102 Chapter 2 NAME OF PARTS S6S in-line type fuel injection pump left view Governor Fuel filter Stop solenoid Air inlet Fuel injection nozzle Water pump (coolant inlet) Front Rear Coolant drain plug Fuel injection pump Fuel feed pump Oil filter Fuel inlet Flywheel Fuel return pipe...
  • Page 103 Chapter 2 NAME OF PARTS S6S distoributor type fuel injection pump left view Fuel inlet Magnetic valve Air inlet Fuel filter (stop solenoid) Fuel injection nozzle Fuel return port Water pump (coolant inlet) Coolant drain plug Rear Front Oil filter Fuel injection pump Flywheel Oil level gauge...
  • Page 104 Chapter 2 NAME OF PARTS S6S-T distributor type fuel injection pump left view Fuel injection nozzle Magnetic valve (Stop solenoid) Oil cooler Fuel filter Water pump Coolant (Coolant inlet) drain plug Front Rear Fuel injection pump Oil filter Relief valve Flywheel Oil level gauge Oil drain plug...

  • Page 105: Equipment And Instrument

    Chapter 2 NAME OF PARTS Equipment and instrument The installed equipment and shapes differ on the engine type. Starter switch The starter switch is used to start the engine. HEAT HEAT When the key is turned to this position, the glow plugs START become hot and allow easy startup of a cold engine.

  • Page 106: Water Temperature Meter And Thermo Unit

    Chapter 2 NAME OF PARTS Water temperature meter and thermo unit The engine coolant temperature detected by the thermo unit is displayed by the water temperature meter. When the water temperature meter shows 95°C [203°F], idle the engine in low gear until the tempera- 80 120 ture becomes normal.

  • Page 107: Stop Solenoid

    Chapter 2 NAME OF PARTS Stop solenoid The stop solenoid operates for normal shutdown of engine operation. The stop solenoid moves the rack of fuel injection Stop solenoid (ETR) pump to cut the fuel, and consequently stops the engine. Two types of stop solenoids are available. RUN OFF (ETS: Energized To Stop) type Not energized while the engine is running.

  • Page 108: Engine Protection Devices

    Chapter 2 NAME OF PARTS Engine protection devices The engine protection device is a device to prevent the engine from the accident by generating the alarm when abnormality occurs. Stop the engine if the protection device is activated, investigate the cause of abnormality and restore it.
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  • Page 110: Preparations For Operation

    Chapter 3 OPERATION Preparations for operation Should an engine abnormality be observed during operation, stop the engine and correct the problem, or contact a dealer of Mitsubishi Heavy Industries, Ltd. Always conduct the following inspection before starting the engine. Engine external - Inspect Be sure to keep combustible materials away from the engine, especially from the hot engine parts such as exhaust manifolds, or the battery.

  • Page 111: Fuel Tank Oil Level - Check

    Chapter 3 OPERATION Fuel tank oil level - Check When working around fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire. Do not remove the strainer when filling the fuel tank. For fuel to be used, refer to "FUEL"...

  • Page 112: Coolant Level - Check

    Chapter 3 OPERATION Coolant level - Check Stand the lever to Turn the cap about Remove the radiator filler cap only after the engine the upright position half a turn has cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release inter- nal pressure.

  • Page 113: Starting

    Chapter 3 OPERATION Starting The starting method changes based on the application and specifications.Start the engine according to the specified procedure. Before starting the engine, check to make sure no one is near the engine and that tools are not left on or near the engine.In a loud voice, notify people in the area when starting the engine.

  • Page 114: Operation

    Chapter 3 OPERATION Operation Cautions when operating Inspection during operation Carefully check the exterior of engine such as piping joints for leaks. Do not approach rotating parts during operation. Check for abnormal engine noises or vibrations such Entanglement by rotating parts can cause serious as knocking.

  • Page 115: Stopping

    Chapter 3 OPERATION Stopping Stopping the engine abruptly while engine parts are hot due to high-speed operation can be a cause for heat up of the engine parts and shorten the engine life. Before stopping the engine, idle the engine in low gear immediately until the engine temperature becomes normal except in an emergency.

  • Page 116: Fuel

    Chapter 4 FUEL Recommended fuel Use a fuel specified in this manual only. Do not refill the fuel tank more than the specified level, as it may Diesel fuel result in a fire. equivalent Use a diesel fuel equivalent for "JIS K 2204 diasel fuel".

  • Page 117: Table 4-1 Recommended Limit And Use Limit Of

    Chapter 4 FUEL Table 4-1 Recommended limit and use limit of fuel property Properties Recommended limits Use limits Test method JIS K 2265 :2007 Flash point 50°C [122°F] or higher 45°C [113°F] ISO 3769 ISO 2719 Initial boiling point 170°C [338°F] or higher JIS K 2254 :1998 Distillation...
  • Page 118 Chapter 4 FUEL Table 4-1 Recommended limit and use limit of fuel property Properties Recommended limits Use limits Test method Foreign materials JIS B 9931 :2000 (foreign materials at engine fuel 5.0 mg/liter or less ISO 4405 inlet) Lubricity: MWSD (Measured mean 460 μm [0.02 in.] or less Wear Scar Diameter) by HFRR (calculated wear scar diameter at...
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  • Page 120: Engine Oil

    Chapter 5 ENGINE OIL Recommended engine oil Use only the engine oils recommended in this manual. Never use other oils. The use of inappropriate or inferior oils will result in sticking of piston rings, seizure between piston and cylinder, or premature wear of bearings and moving parts, and significantly shortens the service life of the engine.

  • Page 121: Engine Oil Performance Requirements

    Chapter 5 ENGINE OIL Abrasion powder in the engine oil also accelerates Engine oil performance deterioration as it can catalyze oxidation reaction. requirements Dust and dirt entered from outside deteriorate the en- Engine oil requires the following performances. gine oil as well. Contamination and deterioration pro- Excellent dispersion performance (the ability of oil to cess accelerates with operation time.

  • Page 122: Definition Of Properties Of Engine Oil

    Chapter 5 ENGINE OIL Definition of properties of engine oil Viscosity Water content Viscosity is a basic physical property of engine oil and Water in oil promotes corrosion/wear, and decreases is considered as the most important aspect when eval- lubricity in sliding parts. uating oil.

  • Page 123: Service Limits Of Engine Oil

    Chapter 5 ENGINE OIL Service Limits of engine oil Engine oil degrades through the use and by lapse of time. To determine the timing of engine oil replacement, analyze the used oil, and understand the condition of oil deterio- ration and oil defacement. It is also required to compare the oil analysis results and the engine analysis results including inside contamination and wear condition of engine, and to consider the engine operating condition.

  • Page 124: Recommended Water For Coolant

    Chapter 6 COOLANT Note: In this operation manual, the word "coolant" represents the liquid combined water and LLC. Recommended water for coolant Use soft water for the engine cooling system. The water quality must meet the requirements in the Table below. Basically, the water quality should be within the recommended value, however, up to the limit is acceptable.

  • Page 125: Other Brand Llcs

    Chapter 6 COOLANT Other brand LLCs Standard for other brand When using other brand LLCs by necessity, be sure to Never mix Mitsubishi Heavy Industries, Ltd. genuine use the LLC that meets following specification. Mit- LLC with other brand LLCs. Mixing with other brand subishi heavy industries, Ltd.

  • Page 126: Llc Specification

    Chapter 6 COOLANT LLC specification LLC shall examine according to JIS K2234 section 7 (examination methods), and satisfy this specification. General matters and the sample to the examination is shown in JIS K2234. Table 6-2 LLC specification Property Standard External Not precipitation Minimum 1.112 g/cm [69.4199 lb/ft...
  • Page 127 Chapter 6 COOLANT Table 6-2 LLC specification Property Standard Aluminum ±0.60 mg/cm Cast iron ±0.30 mg/cm Steel ±0.30 mg/cm Mass change Brass ±0.30 mg/cm Test piece Solder ±0.60 mg/cm Circulation Copper ±0.30 mg/cm metallic causticity (88±3°C External of test piece after the Not corrosion on surface excluding between [190±37°F], examination...

  • Page 128: Maintenance Of Llc

    Chapter 6 COOLANT Maintenance of LLC Should coolant or LLC be accidentally consumed, induce vomiting immediately and seek medical attention. If LLC should enter eyes, flush immediately with plenty of water and seek medical attention. LLC is toxic. Never dispose of coolant containing LLC drained from engine into regular sewage. For disposal of used coolant, consult LLC distributor.

  • Page 129: Importance Of Llc

    Chapter 6 COOLANT Importance of LLC Examples of abnormali- Today's trend is toward smaller and lighter engines ties caused by LLC (amine offering greater output, lower fuel consumption and type) lower exhaust emission levels. Conditions to which engine coolant is subjected, Pitting of iron parts therefore, are becoming severer due to longer operat- Amines are generally effective in suppressing the rust-...

  • Page 130: Maintenance Schedule

    Chapter 7 MAINTENANCE SCHEDULE How to use the maintenance schedule Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation. Be sure to conduct inspections and maintenance according to the maintenance schedule. The maintenance schedule shows the standard service intervals.

  • Page 131: Maintenance Schedule

    Chapter 7 MAINTENANCE SCHEDULE Maintenance schedule Table 7-1 Maintenance schedule Interval and Service item Page Fuel tank - Drain water Every 50 service hours Air cleaner - Check 8-14 First 50 service hours for Engine oil and Oil filter - Replace a new or overhauled Bolts and nuts on the engine - Retighten engine...

  • Page 132: Periodic Inspection And Maintenance Procedures

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic engine Belt and belt tension - Inspect and Adjust If defects such as cuts or surface separations are found during inspection, replace the belt. Keep oil and grease away from the belt. They may cause the belt to slip and shorten the service life. Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.

  • Page 133: Fuel System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system Fuel tank - Drain water When working around fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel completely. Spilled fuel can ignite and cause a fire. Do not remove the strainer when filling the fuel.

  • Page 134: Fuel Filter - Drain Water

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter - Drain water When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire. Drain water for the fuel filter if the warning of water draining for fuel filter is occurred.

  • Page 135: Fuel System (In-Line Type Fuel Injection Pump) - Bleed Air

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system (in-line type fuel injection pump) - Bleed air While depressing, When fuel overflow from the air vent plug, wipe thor- turn coockwise Turn counter- Move cap up oughly with a cloth. Spilled fuel causes fire hazard and down clockwise After bleeding, lock the priming pump securely.If the...

  • Page 136: Fuel System (Distributor Type Fuel Injection Pump) - Bleed Air

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system (distributor type fuel injection pump) - Bleed air When handling fuel, make sure there are no open flames or other fire hazards near the engine. When fuel overflows from the air vent plug, wipe thoroughly with a cloth.Spilled fuel can ignite and cause a fire. After replacing fuel filter or draining water from fuel fil- ter, or when running out of fuel, bleed the fuel system as follows:...

  • Page 137: Fuel Filter (In-Line Type Fuel Injection Pump) - Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter (in-line type fuel injection pump) - Replace Air vent plug When handling fuel, make sure there are no open Filter bracket flames or other fire hazards near the engine. Wipe off any spilled fuel completely.

  • Page 138: Fuel Filter (Distributor Type Fuel Injection Pump) - Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter (distributor type fuel injection pump) - Replace fuel filter. When handling fuel, make sure there are no open Body flames or other fire hazards near the engine.Wipe off any spilled fuel completely.Spilled fuel can ignite and Level sensor cause a fire.

  • Page 139: Lubricating System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubricating system Engine oil and Oil filter - Replace When draining oil or changing the oil filter, wear gloves. Hot engine oil and parts may cause burns. Do not dump waste oil. It is forbidden by law. For disposal of waste oil, consult a dealer of Mitsubishi Heavy Indus- tries, Ltd.
  • Page 140 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine oil - Refill 1. Make sure that the oil drain plug is tightened. Oil filler 2. Remove the oil filler cap. Oil level gauge 3. Fill the engine oil pan with specified engine oil to the specified level.
  • Page 141 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil filter - Change Do not use a dented filter cartridge. Filter damage or fule leakage may occur while engine is running and it can cause fire hazard. To avoid damage to the filter, do not use a filter wrench when installing.

  • Page 142: Cooling System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system Coolant - Change Stand the lever to Turn the cap about Remove the radiator filler cap only after the engine the upright position half a turn has cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release inter- nal pressure.
  • Page 143 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system - Clean Clean the cooling system when operating the engine Water drain plug first time, or restarting the engine after storage with coolant drained. 1. Close coolant drain cocks and plugs. 2.

  • Page 144: Radiator Fins - Check And Clean

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Radiator fins - Check and Clean When handling compressed air, wear safety goggles, a hardhat, gloves and other necessary protective gear. Works without wearing proper protective gear could result in serious injuries. Check the radiator fins for holes and cracks. To clean the radiator fins, blow compressed air from the opposite direction of the normal air flow.

  • Page 145: Inlet And Exhaust Systems

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet and exhaust systems Air cleaner - Check Reset button Checking procedure described below is a commonly Signal used procedure. Some application may be equipped (red) with different air cleaner. 1. Check the air cleaner indicator for the element clog.

  • Page 146: Pre-Cleaner - Clean, Inspect And Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Pre-cleaner - Clean, Inspect and Replace Mild Never service the pre-cleaner while the engine is detergent running. Servicing the air cleaner while the engine is running can cause particles of foreign matter to enter Water the engine and result in rapid wear of parts, leading (Wash)

  • Page 147: Air Cleaner Element - Clean, Check And Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air cleaner element - Clean, Check and Replace When handling compressed air, wear safety goggles, a dust mask, a hardhat, gloves and other necessary protec- tive gear. Works without wearing proper protective gear could result in serious injuries. Never service the air cleaner while the engine is running.

  • Page 148: Electrical System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical system Battery - Inspect If battery electrolyte is spilled on your skin, flush immediately with plenty of water. If battery electrolyte enters the eyes, flush them immediately with lots of fresh water and seek medical attention at once. Do not use open flames or other fire hazards near the battery.

  • Page 149: Starter - Inspect

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Starter - Inspect Visually check the starter for damage. If the starter is dusty, blow dirt using compressed air. Note: If the starter is defective, consult a dealer of Mit- subishi Heavy Industries, Ltd. Starter Fig.

  • Page 150: Long-Term Storage

    Chapter 9 LONG-TERM STORAGE Long-term storage The following describes how to store the engine in a non-operable condition for 3 months or more and in an opera- ble condition for 3 months or more. If the engine has been left unattended for 3 months or more, the internal engine parts can rust, and that may cause damage to the engine.

  • Page 151: Using The Engine After Storage

    Chapter 9 LONG-TERM STORAGE Using the engine after storage 1. Remove the cover from the engine. 2. Connect a fully charged battery. 3. Remove the covers from the starters and alternator. 4. Adjust the tension of belt. Note: Inspect and adjust V-belt tension. Refer to "Belt and belt tension - Inspect and Adjust" (8-XX). 5.

  • Page 152: Lifting The Engine

    Chapter 10 TRANSPORTATION Lifting the engine To lift the engine, use wire ropes, shackles and slings Rear hanger Front hanger capable of supporting the weight of the engine. Attach the wire rope to the hangers provided on the engine using a correct sling. Keep the engine balanced during lifting by consider- ing the engine's center of gravity.
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  • Page 154: Troubleshooting

    Chapter 11 TROUBLESHOOTING General precautions Contact a dealer of Mitsubishi Cautions against contamination Heavy Industries, Ltd. for repair Dust and foreign materials are the most common service cause of rapid wear of parts. Repairing a malfunctioning engine may require special When disassembling a component, take measures to equipment or involve potentially dangerous work, prevent dust and foreign materials from entering the...

  • Page 155: Troubleshooting

    Chapter 11 TROUBLESHOOTING Troubleshooting The starter does not crank or cranks slowly, resulting in start failure Table 11-1 The starter does not crank or cranks slowly, resulting in start failure Cause Remedies Check the DC fuse. Faulty wire connection Check wiring connection between battery, starter and starter switch.

  • Page 156: Output Decrease

    Chapter 11 TROUBLESHOOTING Output decrease Table 11-3 Output decrease Cause Remedies Improper fuel property Use appropriate fuel. (Refer to P4-1) Inspect and replace fuel filter. (Refer to P8-6) Clogged fuel filter (Refer to P8-7) Gauze filter - Clean Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 157: Exhaust Smoke Is White Or Blue

    Chapter 11 TROUBLESHOOTING Exhaust smoke is white or blue Table 11-4 Exhaust smoke is white or blue Cause Remedies Improper fuel property Check cetane index, and use appropriate fuel. (Refer to P4-1) Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 158: Exhaust Smoke Is Black Or Charcoal

    Chapter 11 TROUBLESHOOTING Exhaust smoke is black or charcoal Table 11-5 Exhaust smoke is black or charcoal Cause Remedies Improper fuel property Use appropriate fuel. (Refer to P4-1) Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 159: Fuel Consumption Is High

    Chapter 11 TROUBLESHOOTING Fuel consumption is high Table 11-6 Fuel consumption is high Cause Remedies Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd. Fuel system Improper fuel property Use appropriate fuel.

  • Page 160: Engine Oil Consumption Is High

    Chapter 11 TROUBLESHOOTING Engine oil consumption is high Table 11-7 Engine oil consumption is high Cause Remedies Fuel system Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd. Check oil leakage. Oil leakage to the outside of engine Consult a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 161: Overheating

    Chapter 11 TROUBLESHOOTING Overheating Table 11-8 Overheating Cause Remedies Check coolant leakage. Low coolant level Check coolant level. (Refer to P3-3) Faulty water pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd. Cooling sys- Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries, Ltd. Check and clean radiator and radiator filler cap.

  • Page 162: When Fuel Has Run Out

    Chapter 11 TROUBLESHOOTING When fuel has run out When fuel runs out while engine is running and the engine has stopped, restart the engine as described below. 1. Return the starter switch to the "OFF" position. 2. Add fuel to the fuel tank. For filling fuel tank, refer to "Fuel tank oil level - Check"...

  • Page 163: Main Specifications

    Chapter 12 MAIN SPECIFICATIONS Main specifications Table 12-1 Main specifications Item Specifications Engine model S4S-DT Water cooled, 4 stroke cycle 4-cycle water-cooled turbocharged Type diesel engine diesel engine No. of cylinders - arrangement 4 cylinder in-line Cylinder bore × stroke φ94 ×...

  • Page 164: Table 12-2 Main Specifications

    Chapter 12 MAIN SPECIFICATIONS Table 12-2 Main specifications Item Specifications Engine model S6S-DT Water cooled, 4 stroke cycle 4-cycle water-cooled turbocharged Type diesel engine diesel engine No. of cylinders - arrangement 6 cylinder in-line Cylinder bore × stroke φ94 × 120 mm [3.70 x 4.72 in.] Displacement 4.996 L [1.3 U.S.
  • Page 165 163/202...
  • Page 166 99610-29120 Printed in Japan Pub. No. 164/202...

  • Page 167: Appendix B - Alternator User And Maintenance Manual

    9.2. Appendix B - Alternator user and maintenance manual 165/202...
  • Page 168 166/202...
  • Page 169 User guide and maintenance manual & & & & 3434 i 33522059401_6_1 01/10/2010 167/202...
  • Page 170 168/202...
  • Page 171 3434 en - 2010 .10 / i LSA 43.2/44.2 - 4 poLe ALTeRNAToRS Installation and maintenance 169/202...
  • Page 172 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS This manual concerns the alternator which you WARNING SYMBOLS have just purchased. We would like to draw your attention to the following two safety measures that must be complied with: The latest addition to a whole new generation of alternators, this range benefits from the...
  • Page 173 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 .......... 10 1.2 - Inspection ............4 4.2 - Regular maintenance ........
  • Page 174 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 1 - RECEIPT 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 1.1 - Standards and safety measures nameplate below.
  • Page 175 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 2 - TECHNICAL 2.2 - Mechanical characteristics - Steel frame CHARACTERISTICS - Cast iron end shields - Protected ball bearings, greased for life 2.1 - Electrical characteristics - Mounting arrangements: PARTNER LSA 43.2/44.2 alternators are generators without...
  • Page 176 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 3 - INSTALLATION 3.1.2.2 - Two-bearing alternator - Semi-flexible coupling Careful alignment of the alternator and the heat engine is Personnel undertaking the various operations discussed recommended, checking that the differences in concentricity in this section must wear the appropriate personal and parallelism of the two parts of the coupling do not exceed...
  • Page 177 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 3.2.2 - Mechanical checks 3.3 - Terminal connection diagrams Before starting the machine for the first time, check that: To modify the connection, change the position of the terminal - the fixing bolts on the feet are tight, cables.
  • Page 178 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS Connection codes L.L. voltage Factory connection Winding 50 Hz 60 Hz L1(V) L3(W) 110 - 120 1 phase 3 phases 120 - 130 110 - 120 L2(V) R 250 voltage sensing:...
  • Page 179 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 3.3.2 - Schéma de connexion des options R 791 T interference suppression kit (standard for CE marking) Voltage potentiometer Connections Black Black Black Voltage adjustment by remote potentiometer Blue...

  • Page 180: Fault Detection

    LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 4 - SERVICING / MAINTENANCE 4.2.4 - Electrical servicing Cleaning product for the windings. 4.1 - Safety measures CAUTION use: trichlorethylene, perchlorethylene, trichloroethane or any alkaline products. Servicing or troubleshooting must be carried out strictly Certain strictly defined pure volatile degreasing agents can be in accordance with instructions so as to avoid the risk of...
  • Page 181 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 bearings (temperature >...
  • Page 182 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS compatible with the field excitation power of the machine (see 4.5.1 - Checking the winding the genset nameplate). You can check the winding insulation by performing a high voltage test.
  • Page 183 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS remove the connector from the exciter and the R 791 module. 4.6.1 - Tools required - Remove the 4 nuts on the tie rods To fully dismantle the machine, we recommend using the tools - Remove the NDE shield [36] using a puller: eg.
  • Page 184 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 and operation at rated load with separate field excitation. All values are given at ± 10% (for exact values, consult the test 4.6.7.1 - Dismantling report) and are subject to change without prior warning.
  • Page 185 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: Field excitation current i exc (A) -400 V -50 Hz «i exc»: excitation current of the exciter field 4-pole, SHUNT excitation (60 Hz only) LSA 44.2 no load...
  • Page 186 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 LSA 43.2/44.2 - SHUNT Code...
  • Page 187 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 43.2/44.2 44.2 coupling PMG option N° Description N° Description Stator assembly Terminal block support (AREP) Rotor assembly Terminal block Voltage regulator (AVR)
  • Page 188 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 LSA 44.2 PMG option N° Description N° Description Stator assembly Exciter field Rotor assembly Exciter field fixing screw Exciter armature Fixing screws (44.2 only) Diode crescent support...
  • Page 189 LeRoY-SoMeR INSTALLATION AND MAINTENANCE 3434 en - 2010.10 / i LSA 43.2 / 44.2 - 4-poLe ALTeRNAToRS 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.
  • Page 190 188/202...
  • Page 191 3971 en - 2010.11 / f 140 mm X1 Z2 E+ E- 0V 110 220 380 AREP 50Hz 60Hz R 438 ST10 T.I. R438 13 % 25 % Ph.1 ST11 A.V.R. R731 Installation and maintenance 189/202...
  • Page 192 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.
  • Page 193 LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. CONTENTS 1 - SUPPLY ..........................4 1.1 - AREP excitation system ....................4 1.2 - PMG excitation system ....................5 1.3 - SHUNT or separate excitation system ................5 2 - R438 A.V.R......................... 6 2.1 - Characteristics ......................

  • Page 194: Supply

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 1 - SUPPLY to that of the alternator (characteristic Shunt), the second has a voltage in propor- 1.1 - AREP excitation system tion to the stator current (compound charac- For both AREP &...

  • Page 195: Pmg Excitation System

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 1.2 - PMG excitation system alternator winding. As a result the machine has a short-circuit current capacity and This excitation system consists of a «PMG» good immunity to distortions generated by (permanent magnet generator).

  • Page 196: R438 A.v.r

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 2 - R438 A.V.R. Setting potentiometers 2.1.2 - function 2.1 - Characteristics - Storage : -55°C ; +85°C Delivrery Pot. Function - Operation : -40°C ; +70°C position - Standard power supply: AREP or PMG.

  • Page 197: Typical Effects Of The Lam With A Diesel Engine With Or Without A Lam (U/F Only)

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 2.4 - Typical effects of the LAM with - LAM : action eliminated by cutting the ST5 jumper. a diesel engine with or without a LAM (U/F only) Voltage Underspeed and LAM ST5 disconnected...

  • Page 198: R438 A.v.r. Options

    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 VA CL 1. - Remote voltage adjustment potentiometer: 470 Ω, 0.5 W min: adjustment range ± 5% (range limited by internal voltage potentio- meter P2).

  • Page 199: Installation - Commissioning

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 3 - INSTALLATION - COMMISSIONING a) Initial potentiometer settings (see table below) 3.1 - Electrical checks on the AVR - Remote voltage adjustment potentiometer : - Check that all connections have been centre (ST4 jumper removed).
  • Page 200 LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. The best response times are obtained at the 3.2.2 - Max. excitation setting (excitation limit of the instability. If no stable position ceiling) can be obtained, try disconnecting or repla- Depending on cing the ST2 jumper (normal/fast).
  • Page 201 LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. Checking the internal protection : The exciter is switched off by disconnecting Open switch (D) : the excitation current the AVR power supply (1 wire on each auxi- should increase to its preset ceiling, remain liary winding) - contact rating 16 A - 250V at that level for ≥...

  • Page 202: Electrical Faults

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 3.3 - Electrical faults Fault Action Effect Check/Cause The alternator builds up and its voltage is still correct when the - Lack of residual magnetism battery is removed. Connect a new battery The alternator builds up but its - Check the connection of the voltage...

  • Page 203: Spare Parts

    LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 A.V.R. 4 - SPARE PARTS 4.1 - Designation Description Type Code A.V.R. R 438 AEM 110 RE 017 4.2 - Technical support service Our technical support service will be happy to provide any information you require.
  • Page 204 LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f R438 NOTES 202/202...

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