Ingersoll-Rand G270 Users Manual And Maintenance Manual
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Ingersoll-Rand G270 Users Manual And Maintenance Manual

Ingersoll-Rand G270 Users Manual And Maintenance Manual

Control device: intellisys
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Users guide and maintenance
manual for the generating sets
Model(s) : G270
Control device : Intellisys
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Réf. GPAO : 33501190701NE
Réf. constructeur : 33501190701
Revised (10-12)

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  • Page 1 Control device : Intellisys Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative...
  • Page 3 Users guide and maintenance manual All generating sets General considerations Safety instructions Réf. constructeur : MUE-IR A Réf. GPAO : 33522051901 - 1 -...

  • Page 4: Table Of Contents

    1. Preamble ..........................4 1.1. Introduction ........................4 1.1.1 General recommendations..................4 1.1.2. Structure of the reference material ................5 1.2. Pictograms and their meanings..................5 1.3. Safety instructions and regulations ................7 1.3.1 General advice......................7 1.3.2 Risks related to feed gas (concerns gas sets)............. 9 1.3.3 Risks related to exhaust gases and fuels..............
  • Page 5 Attached documents User manual for the control unit User and maintenance manual for the engine User and maintenance manual and spare parts catalogue for the alternator Wiring diagrams (supplied with the electrical generating set) Genset parts catalog. - 3 -...

  • Page 6: Preamble

    1. P REAMBLE 1.1. Introduction 1.1.1 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. Read the safety instructions carefully in order to prevent any accident, incident or damage. These instructions must always be followed.

  • Page 7: Structure Of The Reference Material

    1.1.2. Structure of the reference material The reference material delivered with the generating sets enables you to get to know the equipment, operate it and maintain it, both on a daily basis and periodically. The reference material for the engines and alternators fitted to the sets consists of engine user and maintenance manuals (from the manufacturer) and alternator user and maintenance manuals (from the manufacturer).
  • Page 8 Warning, rotating or moving parts (risk of Lifting point required getting caught in the machinery) Stacking point required Warning, corrosive product Naked flames and Warning, risk of explosion unprotected lights prohibited. No smoking Exctinction by water Entry prohibited to non- prohibited authorised persons When on a trailer,...

  • Page 9: Safety Instructions And Regulations

    1.3. Safety instructions and regulations THESE SAFETY PRECAUTIONS 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.
  • Page 10 Disconnect the battery and pneumatic starter (if there is one) before carrying out any repair, to prevent the engine from starting accidentally. Fit a panel over the controls to prevent any attempt at starting. Do not modify the engine. Only use the correct techniques for turning the crankshaft to rotate the crankshaft manually.

  • Page 11: Risks Related To Feed Gas (Concerns Gas Sets)

    1.3.2 Risks related to feed gas (concerns gas sets) WARNING – DANGER The gas is explosive. It is forbidden to smoke, go near or create sparks when the tank is being filled and near to the generating set. Request the user technical notes and LPG or NG safety data sheets from your gas supplier.

  • Page 12: Risks Related To Toxic Products

    1.3.4 Risks related to toxic products WARNING – DANGER The corrosion inhibitor contains alkali. This substance should not come into contact with the eyes. Avoid any prolonged or repeated contact with skin. It should not be swallowed. In the event of skin contact, wash thoroughly with water and soap. In the event of contact with eyes, rinse immediately with plenty of water for at least 15 minutes.

  • Page 13: Risks Related To Electrical Networks

    Good ventilation is required for your generating set to work properly. Without ventilation, the engine will quickly reach an excessive temperature that could lead to accidents or damage to the equipment and surrounding items. Do not take off the radiator cap when the engine is hot and the coolant is pressurised due to risk of burns.

  • Page 14: Dangers Presented By Electric Currents (First Aid)

    1.3.7 Dangers presented by electric currents (first aid) First aid In the event of an electric shock, cut off the voltage immediately and activate the set's emergency stop. If the voltage has not yet been cut off, move the victim out of contact with the live conductor as quickly as possible.

  • Page 15: Recommendation For The Operator And Environment

    1.3.9 Recommendation for the operator and environment Operating personnel should be aware of the safety and operating instructions. These will be regularly updated. Operating should be monitored, directly or indirectly, by someone designated by the operator who is familiar with the installation and dangers and problems regarding products stored and used in the installation.

  • Page 16: Identifying Sets

    1.4. Identifying sets generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documents contained in this manual. Examples of identification plates generating set Engines - 14 -...
  • Page 17 Alternator - 15 -...

  • Page 18: Installation

    2. I NSTALLATION 2.1. Unloading 2.1.1 Safety during unloading In order to unload generating sets from their transport mountings, under optimum conditions of safety and efficiency, you should check that the following points are being followed correctly. - Suitable lifting vehicles or equipment for the work. - Slings positioned in the rings provided for this procedure or lifting arms resting fully underneath the frame cross beams.

  • Page 19: Fork Lift Truck

    2.1.3.2 Fork lift truck - position the arms of the fork lift under the frame, making sure that only the cross beams are resting on the arms. - lift and handle the equipment carefully. - set down the generating set in its unloading position. It is recommended to use a fork lift truck with arms that are longer than the width of the frame - 17 -...

  • Page 20: Installation Of Mobile Site Sets

    3. I NSTALLATION OF MOBILE SITE SETS 3.1 Specific arrangements An area will be reserved to install the generating set. Its should be flat and strong enough so that the generator does not sink into it. It could be made of concrete or even large planks fitted together.

  • Page 21: Road Trailer

    4. R OAD TRAILER 4.1 Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly. WARNING – DANGER Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents.

  • Page 22: Check Before Towing

    4.2 Check before towing Before towing carry out the following checks: - wheel torquing - lock trailer hook - tyre pressure - light signals working - cover doors closed - parking brake off - front wheels and rear supports lifted. - tightening and fixing the draw bar arms locking levers - brake test for "road"...

  • Page 23: Implementation For Installation

    4.5 Implementation for installation Procedures to be carried out: - check that the ground is strong enough for the assembly not to sink into it - using the front wheel, position the set as horizontally as possible - engage the handbrake. - lower the rear trailer supports and lock them - 21 -...

  • Page 24: Battery Maintenance

    5. B ATTERY MAINTENANCE WARNING – DANGER install the battery so that it has the correct ventilation never place the battery close to a flame or fire use only insulated tools never use sulphuric acid or acid water to top up the electrolyte level. PROCEDURE FOR TESTING STARTER BATTERIES TEST TYPE PROCEDURE...

  • Page 25: Fuel And Consumables

    6. F UEL AND CONSUMABLES All specifications (product features) are given in the engine and alternator maintenance manuals attached to this manual. 6.1 Circuit capacities – Mitsubishi engines Engines S4L2-SD S4Q2 (series SL) (series SQ) (series SS) CIRCUIT AND TANK CAPACITY MODEL G 16...

  • Page 26: Circuit Capacities - John Deere Engines

    6.2 Circuit capacities – john Deere engines Engines CIRCUIT AND TANK CAPACITY G 66 MODEL G 44 G 77 G 110 G 130 G 160 G 200 LUBRICATION (in litres) 13.5 13.5 21.5 21.5 31.5 COOLING 16.1 23.6 20.2 27.3 25.8 25.8 (in litres)

  • Page 27: Circuit Capacities - Volvo Engines

    6.3 Circuit capacities – Volvo engines ENGINES TWD 740 TAD 740 TAD 1032 TAD 1242 TAD 1631 CIRCUIT AND TANK CAPACITY MODEL G 220 G 270 G 330 G 440 G 550 LUBRICATION (in litres) COOLING (in litres) 41.9 36.9 37.3 FUEL (in litres)
  • Page 31 User’s manual Ingersoll Rand Control unit Intellisys Level 1 1.06F Réf. constructeur Réf. GPAO : 33502013801...

  • Page 32: Safety S S Ymbols

    SAFETY S S YMBOLS Caution : danger Caution, refer to the publications supplied with the Genset Protective clothing required. Caution : risk of electric shock Eye and hearings protection necessary Caution : toxic substances Periodic maintenance required Caution : pressuried fluids Check battery charge Caution : high temperature (risk of burning) Recommended Lifting point...

  • Page 33: Presentation

    PRESENTATION ENGLISH Control u u nit Generating set programmable control- Panel l l ight i i ndicator Lighting for wall mounted or free stan- ding panel Emergency S S top The genset shuts down immediately and the control unit goes into STOP mode MICS A A MPG Device for electrical value display...
  • Page 34 F F O O R R E E W W O O R R D D Control u u nit u u pgrade: The software compatibility is ensured with the old interface boards, meaning it is possible to reprogram, on site, an interface board having a software index 1.01B with a software having an index 1.04D and 1.05E.
  • Page 35 CONTENTS Safety s s ymbols ................................... . Presentation .

  • Page 36: Presentation A A Nd T T Echnicals C C Haracteristics

    PRESENTATION A A ND T T ECHNICALS C C HARACTERISTICS 1. Oil pressure fault/shutdown (red LED on). 2. Water Tº fault/shutdown (red LED on). 3. Overcranking fault/shutdown (red LED on). 4. Overspeed fault/shutdown (red LED on). 5. Genset on load or ready to take the load (green LED on). 6.
  • Page 37 1 - F F eatures ! Display module (DM) ! Interface board available in 2 versions (CB, CB12) depending on customer optional equipment. ! Option 3 module, option 4 module and option 5 module (OPT 3 3 45) ! Block building system enabling multiple combinations. Note: DM required in all combinations 2 - D D isplay m m odule (Fig.
  • Page 38 5 - O O ption 3 3 , 4 4 a a nd 5 5 m m odules ( ( OPT345) ! Modular case, dimensions : 160x90x58 ! Programming specific to each module (dip-switch) ! 8 allocated inputs and 10 programmable outputs on option 3 for remote volt free contacts ! 8 programmable inputs and 10 programmable outputs on option 4 , with 24 preprogrammed options ! Specific programming of some entries 6 - A A lternator c c urrent i i nput...
  • Page 39 16 - O O ptions c c onnected t t o t t he i i nterface Option description CB12 external start-up command auto predisposition + external command 3ph+neutral or 1ph+N mains connection battery charger (3 possible ratings) water heater (3 poss. depending on supply V) hooter RS485 for monitoring or remote management...

  • Page 40: Precautions

    1 1 . . F F O O R R E E W W O O R R D D 1.1. P P recautions " The control unit is connected to various AC voltage sources (alternator, mains, ...). While the generating set is idle, any work inside the control equipment is strictly forbidden as some parts of the electric and elec- tronic equipment stay live (mains voltage available).
  • Page 41 1.5. C C ontrol u u nit f f irst p p ower-u u p If the battery is connected and the electrolyte level correct, control unit powers up automatically and the initialisation screen below appears. ! This screen is visible for eight seconds. All LEDs are lit and will go out after 3 seconds except the Power button LED.
  • Page 42 If neither Enter nor Exit is pressed, the " overview " screen appears after three minutes. There, the time and date will be those of the pre- vious screen (before going automatically to the " overview " screen). Note : Not until the appearance of the " overview " screen will it be possible to start the generating set, however all engine protection shut- downs stay active (example: appearance of a fault).
  • Page 43 ! In this operating mode, any event appearance (alarm, fault, external command, ...) is signalled on screen. However, the generating set is stopped and automatic start-up is not possible. ! When the generating set is running and whatever the current mode (Auto, T T est, M M anu), press the Stop Ph./ph.

  • Page 44: Test Mode

    Example of " overview " screen in Test mode Fuel Level(%) 5 5 0 0 There are two minutes and thirty seconds of operation left before the generating set stops and the control unit goes into Auto mode. E.Speed(RPM) 2 2 4 4 Batt.

  • Page 45: Voltages

    4 4 . . V V I I E E W W I I N N G G T T H H E E E E L L E E C C T T R R I I C C A A L L V V A A L L U U E E S S 4.1.

  • Page 46: Currents

    4.2. C C urrents To view the various AC currents, press the A button successively. The values are expressed in true root mean square Amps. Depending on the client's needs (type of electrical installation), several screens are possible: ! 3 phase with neutral (3ph+N) ! 3 phase without neutral (3ph) ! 2 phase (2ph+N) ! 1 phase (1ph+N)
  • Page 47 5 5 . . V V I I E E W W I I N N G G T T H H E E E E N N G G I I N N E E P P A A R R A A M M E E T T E E R R S S To view the engine parameters, press the Engine button successively.
  • Page 48 All these LEDs are identified by an ISO symbol. The last two LEDs are flashing lights. The " general fault " LED flashes on appearance of any fault and the " general alarm " LED flashes on appearance of any alarm. "...
  • Page 49 ! If a fault appears on screen 3, the message on the second line disappears from the screen, the message on the first line slides down to the second line and the fault message takes the first line. ! If a third fault appears on screen 4, the message on the second line disappears from the screen, the message on the first line slides down to the second line and the third fault message takes the first line.
  • Page 50 - ATS toggle delay: Mains*Stand-by and Stand-by*Mains, and closure confirmation of the Mains and Stand-by contactors- Motorised C/B opening and closure - Engine cooling down time in Auto mode - Operating time in Test mode - Delayed shutdown on water temperature fault or overload/short-circuit fault - Appearance of commands ;...

  • Page 51: Introduction

    APPENDIX - SOFTWARE VERSION 1.05E OR LATER: "INTERNATIONAL" LANGUAGE 1 - I I ntroduction Software version 1.05E or later used with interface boards CB and CB12 enable you to use the Intellisys in a language which is different from the four standard languages already implemented.
  • Page 52 The Ampere is the unit if measurement of the currents output by the alternator (screen display: Amps). (Amps) ! Press the Hz key to display the generating set frequency and running hours and minutes. (Symbol 1) (Hz) Hz is the abbreviation for Hertz. Symbols 1 and 2 are represented in the table below. 50.2 (Symbol 2) (Symbol 2)

  • Page 53: Other Symbols

    All the symbols related to the engine parameters are represented in the table below. Symbol number Pictogram Description Symbol 3 Fuel level in daily tank (fuel pump) Symbol 4 Engine speed (galvanometer) Symbol 5 Battery voltage (generating set battery) Symbol 6 Engine oil pressure (oil can) Symbol 7...
  • Page 54 ! Spark plug preheating (symbol 11) If the generating set is ready to be started on an external command and if the "spark plug preheating" parameter is set to 1 (Factory menu), a symbol representing a solenoid appears on the screen during the spark plug preheating period prior to the first startup and also between two startup attempts.
  • Page 55 The alarms and faults are displayed in the same way as for versions 0.01B and 1.04D: Up to two codes (max.) displayed on screen Fault takes priority over alarm Faults are reset in order of appearance For more details, refer to paragraph 8. All the alarms and faults which can appear on the Intellisys screen are listed in the table below.a.
  • Page 56 Wording Alarm Fault Generated on MTU engine general alarm 52-0 impossible module 5 QST30 engine overspeed impossible 53-1 module 5 QST30 engine general fault impossible 54-1 module 5 QST30 engine general alarm 55-0 impossible module 5 Engine oil high level 56-0 impossible module 4...
  • Page 59 Use and maintenance manual Volvo Generating set and industrial engines 4 - 6 litre (non-EDC) TAD 740 GE / 1032 GE / 1630 GE / 1631 GE - TWD 740 GE / 1210 GE / 1232 GE / 1630 GE Réf.
  • Page 60 Preface Volvo Penta industrial engines are used all over the world, in both mobile and stationary applications, in all conceivable service conditions. This is not a coincidence. After 90 years of manufacturing engines, the name Volvo Penta has come to symbolise reliability, technical innovation, first class perform- ance and long life.
  • Page 61 Contents Safety Information ..........2–5 Maintenance schedule ........21–22 Safety Information ..........2 Maintenance schedule ........21 Introduction ............6–7 Maintenance ............ 23–45 Responsibility for the environment ....... 6 Engine, general ..........23 Running-in ............6 Lubrication system ..........26 Fuel and oil types ..........

  • Page 62: Safety Information

    Safety Information Read this chapter carefully. It concerns your safety. This chapter describes how safety information is presented in the Instruction Manual and on the engine itself. It also gives a general account of basic safety precautions to be taken when maintaining the engine. Check that you have the correct Instruction Manual before you read on.
  • Page 63 Safety Information Safety precautions for operation and maintenance Daily checklist Starting lock Make a habit of checking the engine and engine com- If the instrument panel does not have an ignition partment visually before operating (before the engine switch, the engine compartment must be lockable to is started) and after operating (after the engine has prevent unauthorised persons from starting the en- been stopped).
  • Page 64 Safety Information Safety precautions for operation and maintenance (cont.) Lifting the engine Batteries When lifting the engine, use the lifting eyes installed The batteries contain and give off oxyhydrogen gas, on the engine. Always check that lifting equipment is especially during charging. This gas is easily ignited in good condition and is strong enough for the lift (en- and highly flammable.
  • Page 65 Safety Information Cooling system Welding Avoid opening the coolant filler cap when the engine is Remove the positive and negative leads from the bat- hot. Steam or hot coolant can spray out and cause teries. Then remove all leads to the generator. burns.

  • Page 66: Introduction

    Introduction This Instruction Manual has been compiled to help you get the most from your Volvo Penta industrial engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the Instruction Manual carefully and learn how to operate the engine, controls and other equipment safely. IMPORTANT! This Instruction Manual describes engines and equipment sold by Volvo Penta.

  • Page 67: Certified Engines

    Introduction Certified engines No modifications to the exhaust pipes and air sup- If you own an engine certified for any area where ply ducts for the engine may be undertaken. exhaust emissions are regulated by law, the fol- lowing is important: Seals may only be broken by authorised person- nel.

  • Page 68: Presentation

    Presentation The charge air cooler (CAC) reduces the temperature The instruction book covers industrial and generator of the intake air. This provides the cylinders with set engines from 4 to 16 liter swept volume. greater volumes of air. This makes a high power out- The engines are four-cycle, 6-cylinder in-line diesel put possible while keeping the combustion and ex- engines with direct diesel injection (420/520 are 4-...

  • Page 69: And 7-Litre Engines

    Introduction Examples of 6 and 7-litre engines Fan hub Gear-driven coolant pump Lifting lug Double fuel filter Turbocharger Air-cooled exhaust manifold Lifting lug Coolant pipe, inlet Pump coupling guard 10. Smoke limiter 11. Oil cooler 12. Fuel line for tank connection 13.
  • Page 70 Presentation Examples of 10 and 12-litre engines Fan hub Lifting lug Double fuel filter Gear driven circulation pump Turbocharger Air-cooled exhaust manifold Lifting lug Pump coupling guard Injection pump 10. Fuel line for tank connection 11. Muffler 12. Double air filters 13.

  • Page 71: 16-Litre Engines

    Presentation Examples of 16-litre engines Radiator Charge air cooler (CAC) Bracket for radiator Gear-driven coolant pump Coolant filter Turbocharger Air-cooled exhaust manifold Lifting lug Coolant pipe, inlet 10. Lubricating oil filter, part flow 11. Oil cooler 12. Double lubricating oil filter, full flow 13.

  • Page 72: Identification Numbers

    Presentation Identification numbers The engines are supplied with two engine identification plates. One of these is supplied uninstalled so that it can be mounted in a suitable site close to the engine. The other plate is riveted to the cylinder block (see il- lustration).

  • Page 73: Instrumentation

    Instrumentation This chapter describes the instrument box and the instrumentation in Volvo Penta’s range. Variations in the ap- pearance of instrumentation may occur in certain applications (mobile for example). If this is the case, see the In- struction Manual for the relevant application. WARNING! If the instrument box does not have an ignition switch, the engine / operator compartment must have a lock to prevent unauthorised persons starting the engine.

  • Page 74: Starting The Engine

    Starting the engine Make a habit of checking the engine and engine compartment before starting the engine. This will help you to quickly detect anything unusual that has happened or is about to happen. Check that the instrument readings are normal after starting the engine.
  • Page 75 Starting the engine 2. If the engine is hot: Press the “Interlock button” (1) and hold it in while pressing the Starter button (2). If the engine is cold: Press the Interlock button (1) and hold it in for approximately 50 seconds to preheat the engine. Then press the “Start button”...

  • Page 76: Starting The Engine In Extremely Cold Conditions16

    Starting the engine 3. Allow the engine to run at 500–700 rpm for the first 10 sec- onds. Then warm up the engine at low speed and low load. IMPORTANT! Do not race the engine while it is cold. NOTE! Generating set engines automatically rev up to the pre-set engine speed (1500 or 1800 rpm).

  • Page 77: Starting The Engine Using Auxiliary Batteries

    Starting the engine Starting the engine using auxiliary batteries WARNING! The batteries (auxiliary batteries in particular) con- tain extremely explosive oxyhydrogen gas. One spark, which may be formed if the auxiliary batteries are connected incor- rectly, is sufficient to cause a battery to explode and cause damage and injury.

  • Page 78: Operation

    Operation Correct operation is the key to fuel economy and engine service life. Always allow the engine to achieve normal operating temperature before running it at full power. Avoid opening the throttle too quickly and running the engine at high engine speeds. IMPORTANT! An automatic shut-off for oil pressure and engine coolant temperature (ECT) must be installed during unattended operation where the Volvo Penta instrument box is not being used.

  • Page 79: Disengageable Clutch

    Operation Disengageable clutch The clutch is disengaged when the control lever is in position “N” and engaged when the lever is in position “E”. IMPORTANT! The engine speed must not exceed 1000–1200 rpm during engagement and disengagement. Operation at low loads Avoid running the engine at idling speed or low loads for long periods.

  • Page 80: Stopping The Engine

    Stopping the engine In the case of extended inactivity, the engine must be run to operating temperature at least once every 14 days. This prevents corrosion in the engine. If the engine will not be used for more than two months, inhibiting should be carried out: Refer to chapter “Shut down”.

  • Page 81: Maintenance Schedule

    Maintenance schedule To achieve maximum operating safety and service life, it is vital that the engine is regularly serviced. By following the service recommendations, engine quality is retained and unnecessary environmental damage avoided. WARNING! Read the chapter on “Maintenance” carefully before starting service work. It contains instructions on how to carry out the work safely and correctly.
  • Page 82 Maintenance schedule EVERY 400 HOURS (420–720, EVERY 500 HOURS) Drive belts. Checking and adjusting ............not shown Fuel tank (sludge collector). Drain .............. not shown EVERY 500 HOURS Coolant (Anti-corrosion mixture). Addition ..........page 28–29 Add half a litre of anti-corrosion agent if the cooling system is filled with an anti-corrosion mixture. EVERY 800 HOURS (420–720, EVERY 1000 HOURS) Fuel filter.

  • Page 83: Maintenance

    Maintenance This chapter describes how to carry out the above maintenance. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter above. Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Information, be- fore starting work.
  • Page 84 Maintenance Idling speed. Adjustment First check that the air filter is not clogged and that the throttle arm (1) on the fuel injection pump is against the idling speed stop (2) when the throttle mechanism is in idling position. Check also that the throttle arm presses against the max stop (3) when the throttle control is in the wide open throttle (WOT) position.
  • Page 85 Maintenance Drive belts. Checking and adjusting Inspection and adjustment should be carried out after running the engine when the belts are warm. Undo the screws (A) before tensioning the generator belts. It should be possible to depress the belts 10 mm between the pulleys.

  • Page 86: Lubrication System

    Maintenance Lubrication system Oil change intervals can vary between 40 and 500 hours depending on the quality of the lubricant and the sul- phur content of the fuel. Note that the oil change interval should never be longer than 12 months. If longer intervals are required than those stated in the table below, the condition of the oil must be tested regular- ly by the oil manufacturer.
  • Page 87 Maintenance Oil level. Check Ensure that the level lies between MIN and MAX markings. IMPORTANT! In continuous use the oil level should be checked every 8 hours When checking the oil level on a stationery engine, read off the side of the dip stick marked “STOP” (at earliest 3 minutes after engine stop).

  • Page 88: Cooling System

    Maintenance Cooling system The cooling system must be filled with a coolant that protects the engine against internal corrosion and from freezing if the climate requires it. Never use water alone. The anti-corrosion additives become less effective over time. The coolant must be therefore be re- placed.
  • Page 89 Maintenance If there is a risk of freezing Use a mixture of 50% Volvo Penta antifreeze (gly- col) and 50% pure water (according to ASTM D4985). This mixture will protect against freezing to a temperature of approx. –40°C and should be used all year round.
  • Page 90 Maintenance Coolant. Checking and topping up WARNING! Except in an emergency, do not open the engine coolant system filler cap when the engine is still hot. Steam or hot coolant may spray out. Check the coolant level daily before starting. Top up coolant if necessary.
  • Page 91 Maintenance Coolant. Draining Before draining the coolant, the engine must be stopped and the filler cap unscrewed. WARNING! Except in an emergency, do not open the engine coolant system filler cap when the engine is still hot. Steam or hot coolant may spray out.
  • Page 92 Maintenance 10–12 litre engines Drain cocks (K): – at the rear of the left-hand side of the cylinder block – charge air cooler, front (only TWD) Drain plugs (P): – under the radiator – under the oil cooler – 2 (at front and rear) on the air compressor, if in- stalled (accessory) Bleed cock (V): –...
  • Page 93 Maintenance Cooling system. Flushing Cooling performance is reduced by deposits in the radiator and cooling channels. The cooling system must therefore be flushed through when the coolant is replaced. 1. Drain the coolant as above. 2. Insert a hose in the radiator filler opening and rinse out with freshwater until the water which runs out is completely clear.

  • Page 94: Fuel Injection System

    Maintenance Fuel injection system Only use recommended quality fuels according to the specifications below Always observe strict cleanliness when refuelling and working on the fuel injection system. All work on the engine injection pump or injectors must be carried out at an authorised workshop. If the injec- tion pump lead seal is broken, all warranties are invalid.
  • Page 95 Maintenance Fuel pre-filter. Drain water (standard on 420–721) The fuel pre-filter is an optional extra. Position a con- tainer under the fuel filter. Drain off water and contami- nants using the cock/plug at the bottom. IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter.
  • Page 96 Maintenance Venting engines with fuel shut-off valve connected to supply voltage during operation: Is there “automatic stop in the event of too low oil pressure” with a Volvo Penta oil pressure switch? When the engine is off, this switch is closed (“Nc”- Normally closed).

  • Page 97: Electrical System

    Maintenance Electrical system WARNING! Always stop the engine and break the current using the main switch before working on the electrical system. Isolate battery charger, or other accessories mounted on the engine. NOTE! NO ELECTRICAL SYSTEM AVAILABLE FOR ENGINES 420–721. Fuses The engine has automatic fuses located in the junc- tion box.
  • Page 98 Maintenance Battery. Maintenance and care WARNING! Risk of fire and explosion. Never al- low an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion. WARNING! The battery electrolyte contains ex- tremely corrosive sulphuric acid.

  • Page 99: Wiring Diagram

    Maintenance Wiring diagram, proposal (TD/TAD520, 720 engines) 1. Battery 18. Signal horn Cable area 2. Main switch 46. Water level switch (720-models) 3. Starter motor 52. Start button 90 mm 70 mm 4. Alternator 52a. Start relay 10 mm 2.5 mm 8.
  • Page 100 Maintenance Wiring diagram (6–12 litre engines) “Not for TD/TAD720”...
  • Page 101 Cable areas in mm (indicated after the colour codes in the wiring dia- grams). If no cable area is stated, the default is 1.5 mm² Cable colour BL = Blue LBL = Light blue BN = Brown LBN= Light brown GN = Green GR = Grey OR = Orange...
  • Page 102 Maintenance Instrument box 1. Location for level switch relay: coolant (access- 5. Terminal block for automatic stop and extra pow- ory) er output (maximum 16 A) 2. Relay for automatic stop: engine coolant tem- 6. Negative (–) for extra power output (black cable) perature (ECT) switch, oil pressure switch and 7.
  • Page 103 Maintenance Alarm separator for the instrument box (accessory) 1. Relay for engine coolant level switch (accessory) 8. Warning lamp, low engine coolant level (access- ory) 2. Relay for engine coolant temperature (ECT) switch, oil pressure switch 9. Warning lamp, low lubrication oil pressure (ac- cessory) 3.
  • Page 104 Maintenance Time relay kit for engagement of the starter element (accessory) 1. Time relay 2. Connector. 8 pin 3. Ignition switch 4. Temperature switch (access- ory) 5. Starter element 6. Indicator lamp (engaged starter element) 7. Battery...

  • Page 105: Disengageable Clutch

    Maintenance Disengageable clutch and compressor Disengageable clutch Lubrication Use lithium based grease, Mobilux EP2, Statoil Uni- way EP2N, Texaco Multifak EP2, Q8 Rembrandt EP2 for example Main bearing and clutch mechanism Lubricate inner support bearing (when a grease nipple is installed), main bearings, disengaging shaft and moving parts of clutch.

  • Page 106: Shut Down

    Shut down Inhibition should be carried out to ensure that the engine and other equipment are not damaged while shut down. It is important that this is done properly and that nothing is forgotten. We have therefore provided a checklist covering the most important points. Before shutting down for a long period, an authorised Volvo Penta workshop should inspect the engine and other equipment.

  • Page 107: Fault Tracing

    Fault tracing A number of symptoms and possible reasons for engine problems are described in the table below. In case of faults or mishaps which you cannot solve, always contact the Volvo Penta dealership. In the event of engine interference related to the GAC governor (Generating set engines), refer to the documentation delivered with the GAC governor.
  • Page 108 Technical Data General Designation No. of cylinders Cylinder displacement (litres) Weight (kg)* TD420VE 4,04 380** TAD420VE 4,04 380** TD520GE 4,76 550** TD520VE 4,76 430** TAD520GE 4,76 575** TAD520VE 4,76 532** TAD620VE 5,07 495** TWD630VE 5,48 TD640VE 5,48 TD71A 6,73 TWD710V 6,73 TD730VE 6,73...

  • Page 109: Technical Data

    Technical Data General Designation Low idling speed (rpm) Valve clearance, intake/exhaust (mm)* TD420VE 875±50 0,35/0,55 TAD420VE 875±50 0,35/0,55 TD520GE 875±50 0,35/0,55 TD520VE 875±50 0,35/0,55 TAD520GE 875±50 0,35/0,55 TAD520VE 875±50 0,35/0,55 TAD620VE 875±50 0,35/0,55 TWD630VE 725±25 0,40/0,55 TD640VE 700±10 0,40/0,55 TD71A 600±25 0,40/0,55 TWD710V...
  • Page 110 Technical Data Oil pressure* Desigantion At normal running engine speed (kPa) At idling speed (kPa) TD420VE min. 80 TAD420VE min. 80 TD520GE min. 150 TD520VE min. 80 TAD520GE min. 150 TAD520VE min. 80 TAD620VE min. 80 TWD630VE 300-500 min. 150 TD640VE 300-500 min.

  • Page 111: Lubrication System

    Technical Data Oil change capacity* for standard oil pan Designation Without oil filter (litres) With oil filter (litres) Volume difference (MIN-MAX)** TD420VE TAD420VE TD520GE TD520VE TAD520GE TAD520VE TAD620VE TWD630VE TD640VE TD71A TWD710V TD730VE TWD731VE TAD730V TWD710G TD720GE TD720VE TAD720GE TAD720VE TAD721VE TAD730G TWD740GE/VE...
  • Page 112 Technical Data Oil change capacity* for (shallow 10°) oil Pan Designation Without oil filter (litres) With oil filter (litres) Volume difference (MIN-MAX)** TD610V TD630VE TWD630VE TD71A TID71A TD730VE TWD731VE Oil change capacity* for (shallow) oil pan for large inclinations Designation Without oil filter (litres) With oil filter (litres) Volume difference (MIN-MAX)**...
  • Page 113 Technical Data Oil change capacity* for (vehicle type) oil pans Designation Without oil filter (litres) With oil filter (litres) Volume difference (MIN-MAX)** TD71A TID71A TD730VE TWD731VE Oil change capacity* for (laminated) oil pan (soundproofed) Designation Without oil filter (litres) With oil filter (litres) Volume difference (MIN-MAX)** TD630VE TWD630VE...

  • Page 114: Cooling System

    Technical Data Cooling system Designation Coolant volume (litres)* Thermostat begins to open/fully open at (°C) TD420VE 83/95** TAD420VE 83/95** TD520GE 83/95** TD520VE 87/102** TAD520GE 83/95** TAD520VE 87/102** TAD620VE 83/95** TWD630VE 75/88** TD640VE 75/88** TD71A 75/88** TWD710V 75/88** TD730VE 75/88** TWD731VE 75/88** TAD730V 75/88**...
  • Page 115 Technical Data Fuel system*. Injectors Designation Opening pressure (MPa) Adjusting pressure (MPa) Nozzle hole diameter (mm) TD420VE 22,0 23,0 +0,8 6 st 0,203 TAD420VE 22,0 23,0 +0,8 6 st 0,203 TD520GE 25,0 26,0 +0,8 5 st 0,30 TD520VE 25,0 26,0 +0,8 5 st 0,30 TAD520GE 25,0...

  • Page 116: Electrical System

    Technical Data Electrical system Designation System voltage (V) Maximum battery capacity 24 V/12 V (Ah) TD420VE 24 alt. 12 2x110/2x88 TAD420VE 24 alt. 12 2x110/2x88 TD520GE 24 alt. 12 2x110/2x88 TD520VE 24 alt. 12 2x110/2x88 TAD520GE 24 alt. 12 2x110/2x88 TAD520VE 24 alt.
  • Page 117 Technical Data Generator. Voltage/Amperage/Power (V/A/W) Designation Alt. 1* Alt. 2* Alt. 3* Alt. 4* Alt. 5* TD420VE 14/55/770 28/35/980 – – – TAD420VE 14/55/770 28/35/980 – – – TD520GE 14/55/770 28/35/980 – – – TD520VE 14/55/770 28/35/980 – – – TAD520GE 14/55/770 28/35/980...
  • Page 118 Technical Data Disengageable clutch (accessory) Desigantion Type Gear ratio Size (mm) Weight (kg) AP S11A2 Single plate 292 (11 1/2") AP D11A2 Double plate 292 (11 1/2") AP T14A2 Triple plate 355 (14")
  • Page 119 ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 120 ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 125 GENERATOR PARTS LISTS GENERATOR MODEL G270 EDITION: JUNE2002 CPN 85623031 33519009601 ind1...
  • Page 126 SALES OFFICES Sales Office United Kingdom Ingersoll-Rand European Sales Ltd Facility details Swan Lane Hindley Green Wigan WN2 4EZ United Kingdom Phone +44 (0) 1942 257 171 +44 (0) 1942 523 417 Structure de l'Organisation en France Ingersoll-Rand Portable Power Coordonnées du Site...
  • Page 127 FUEL TANK M424 ASSEMBLY ................20 ELECTRIC STARTER ISOLATED ASSEMBLY............21 EXHAUST MUFFLER M424 ASSEMBLY..............22 FRAME M424 VO 740 ASSEMBLY ................. 23 G270 ACCESSORY ASSEMBLY ................24 M424 MISCELLANEOUS ASSEMBLY..............25 RETENTION BUND M424..................26 CANOPY M424 ASSEMBLY ................... 28 CENTRAL LIFTING ARCH ASSEMBLY ..............
  • Page 128 3 WAY FUEL VALVE OPTION 3 WAY FUEL VALVE ASSEMBLY ................49 AUTO START OPTION AUTO START OPTION.................... 50 COOLANT HEATER 700W ASSEMBLY ..............51 INTELLISYS OPTION BATTERY CHARGER 24V/3A ..........52 INTELLISYS OPTION WATER PREHEATING............53 EXPLOSIVE ATMOSPHERE OPTION AIR SHUT OFF VALVE VO TAD740 ASSEMBLY ..........

  • Page 129: Engine Function Tad740

    G270 Item Part Number Description Quantity Units F01051 ENGINE FUNCTION TAD740 010200 85422020 ENGINE VOLVO TAD740 SAE 2/11.5 Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 5 -...

  • Page 130: Engine Vo Tad740 Detail

    G270 Item Part Number Description Quantity Units F30030 ENGINE VO TAD740 DETAIL 301950 85401891 OIL FILTER 302420 85426864 BY PASS OIL FILTER 301940 85401636 FUEL FILTER 301930 85401610 FAN BELT 301930 85620813 FAN BELT 302460 85502771 ALTERNATOR BELT 302180 85425502...

  • Page 131: Oil Sump Drain Pump Assembly

    G270 Item Part Number Description Quantity Units F04010 85509768 OIL SUMP DRAIN PUMP ASSEMBLY 040170 85422616 HYDRAULIC MANUAL PUMP 181270 85622181 FLEXIBLE HOSE D25x32 040180 85424034 OIL SUMP PUMP BRACKET VO 740G 180910 85423242 PIPE UNION MAL/MAL 3/4G 180930 85423093 PIPE UNION ELBOW 90°...

  • Page 132: Oil Sump Drain Tap Assembly

    G270 Item Part Number Description Quantity Units F04006 85421154 OIL SUMP DRAIN TAP ASSEMBLY 180700 85423119 PIPE UNION ELBOW 90° 3/4BSP 180860 85424893 BANJO SCREW 7/8SAE L45 180910 85423242 PIPE UNION MAL/MAL 3/4G 181050 85417749 HOSE CLIP D25/40 181160 85421758...

  • Page 133: Air Filter Heavy Duty Assembly

    G270 Item Part Number Description Quantity Units F08021 85419547 AIR FILTER HEAVY DUTY ASSEMBLY 080330 85403848 AIR CLEANER CLAMP D330 080340 85403863 RAIN CAP 080350 85403921 AIR FILTER HEAVY DUTY 080700 85423887 AIR FILTER BRACKET VO 740G 080710 85424257 HEAVY DUTY INLET PIPE BRACKET...

  • Page 134: Air Filter 080350 Detail

    G270 Item Part Number Description Quantity Units F30014 AIR FILTER 080350 DETAIL 300200 85400737 FILTER CARTRIDGE 300210 85400786 FILTER CARTRIDGE 300120 85501229 VACUATOR VALVE 300230 85501294 DUST CUP 080340 85403863 RAIN CAP 181680 85501872 HOSE CLIP D140/160 Part numbers listed are the only parts used in this model...

  • Page 135: Governor Function Tad740

    G270 Item Part Number Description Quantity Units F06019 GOVERNOR FUNCTION TAD740 162050 85425270 ELECTRONIC REGULATOR HOUSING BRACKET 160980 85407237 ELECTRONIC REGULATION HOUSING 160990 85407245 HOUSING ELECTRONIC REGULATION 161000 85407336 ELECTRONIC REGULATOR BRACKET 161020 85408706 STOP 162520 85423366 RELAY 24V 10/20A...

  • Page 136: Engine Wiring Loom Tad740

    G270 Item Part Number Description Quantity Units F16212 ENGINE WIRING LOOM TAD740 162220 85421352 ENGINE WIRING LOOM VOLVO 740 162230 85423697 WIRING BRACKET VO TxD740G 160270 85408078 COPPER BAR 5x25 162520 85423366 RELAY 24V 10/20A 162530 85413292 AUTOMOBILE RELAY BASE...

  • Page 137: Output Cables Alternator Assembly

    G270 Item Part Number Description Quantity Units F16004 85407484 OUTPUT CABLES ALTERNATOR ASSEMBLY 160420 85406742 CABLE OUTLET PLATE 160500 85406874 FOAM CABLE PROTECTION Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 13 -...

  • Page 138: Alternator Ls 462L Assembly

    G270 Item Part Number Description Quantity Units F02007 ALTERNATOR LS 462L ASSEMBLY 020160 85416600 ALTERNATOR LS 462L Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 14 -...

  • Page 139: Alternator Ls 462L6 Sae 2/11,5 Detail

    G270 Item Part Number Description Quantity Units F30183 85416600 ALTERNATOR LS 462L6 SAE 2/11,5 DETAIL 320640 85508810 WOUND STATOR ASSEMBLY 320770 85509123 WOUND ROTOR ASSEMBLY 320600 85508877 N.D.E BRACKET 302310 85425916 BEARING LSA 462/471 319880 85509065 WAVY WASHER 320610 85508927...

  • Page 140: Radiator Vo Tad740G Assembly

    G270 Item Part Number Description Quantity Units F03013 85419901 RADIATOR VO TAD740G ASSEMBLY 180890 85415701 PIPE UNION REDUCER MAL/MAL M14x150 3/8G 180340 85409258 PIPE UNION MAL/MAL 3/8G 180350 85409308 PIPE UNION ELBOW 90° MAL/FEM 3/8G 180450 85410298 GASKET D14x18 181210...

  • Page 141: Fuel Prefilter Kit Assembly

    G270 Item Part Number Description Quantity Units F05034 85501948 FUEL PREFILTER KIT ASSEMBLY 050360 85421451 DECANTATION CARTRIDGE FILTER 050460 85430551 3 WAY FUEL VALVE/SEPARATOR FILTER BRACKET 184920 85507937 BANJO CONNECTOR MALE D10 184910 85507945 BANJO SCREW M16X150 L28 183190 85509727...

  • Page 142: Decantation Cartridge Filter 050360 Detail

    G270 Item Part Number Description Quantity Units F30018 85421451 DECANTATION CARTRIDGE FILTER 050360 DETAIL 301330 85502557 SEPARATOR FILTER LID 301340 85502581 SEPARATOR FILTER LID GASKET 301350 85502599 SEPARATOR FILTER SPRING CASSETTE 301360 85401644 SEPARATOR FILTER CARTRIDGE 301370 85502946 SEPARATOR FILTER HOUSING...

  • Page 143: Fuel Tank M413 Assembly

    G270 Item Part Number Description Quantity Units F05053 85622058 FUEL TANK M413 ASSEMBLY 050210 85417434 FUEL SUCCION PIPE L410 D10 1/2G 050680 85622033 FUEL SUCCION PIPE L410 D10 1/2G 050110 85403517 FUEL FILLING FUNNEL BASE TANK 181750 85509222 PLUG TANK...

  • Page 144: Fuel Tank M424 Assembly

    G270 Item Part Number Description Quantity Units F05033 85496644 FUEL TANK M424 ASSEMBLY 050190 85417400 FUEL SUCCION PIPE L280 D10 1/2G 050220 85417426 FUEL SUCCION PIPE L310 D10 1/2G 050110 85403517 FUEL FILLING FUNNEL BASE TANK 181750 85509222 PLUG TANK...

  • Page 145: Electric Starter Isolated Assembly

    G270 Item Part Number Description Quantity Units F07027 85496701 ELECTRIC STARTER ISOLATED ASSEMBLY 070100 85403699 BATTERY FIXING BRACKET 070170 85403707 BATTERY ISOLATOR BRACKET 070120 85403723 BATTERY ISOLATOR SWITCH 070180 85403731 STARTING BATTERY 12V 100Ah 450A 161150 85417293 BATTERY CABLE(+) 50mm2 L1000 RED...

  • Page 146: Exhaust Muffler M424 Assembly

    G270 Item Part Number Description Quantity Units F09052 85622066 EXHAUST MUFFLER M424 ASSEMBLY 090120 85496750 40dB MUFFLER 090570 85496842 EXHAUST PIPE D102 VOLVO 090610 85496883 EXHAUST HOSE BRACKET 090530 85622074 EXHAUST RAIN FLAP D140 181020 85417798 HOSE CLAMP D105 181790...

  • Page 147: Frame M424 Vo 740 Assembly

    G270 Item Part Number Description Quantity Units F13018 85497022 FRAME M424 VO 740 ASSEMBLY 130810 85423960 ENGINE SUPPORT VO 6/7L LEFT RIGHT SIDE 130820 85417392 RECTANGULAR ENGINE SHIM 7L VOLVO ENGINE 130440 85497014 FRAME M424 130880 85401875 ANTI-VIBRATION MOUNT 0800daN 8.5mm...

  • Page 148: G270 Accessory Assembly

    G270 Item Part Number Description Quantity Units F18036 85428076 G270 ACCESSORY ASSEMBLY 050420 85431120 FUEL FILTER 144560 85509263 WBH LATCHE KEY 182030 85503852 RECTANGULAR STICKER 1100x325 181600 85428019 RECTANGULAR STICKER 450x600 181900 85500213 ROUND STICKER D385 Part numbers listed are the only parts used in this model...

  • Page 149: M424 Miscellaneous Assembly

    G270 Item Part Number Description Quantity Units F13019 85497030 M424 MISCELLANEOUS ASSEMBLY 030550 85496610 RADIATOR BRACKET VO TAD740 144570 85622124 RADIATOR UPPER PANEL M424 VO TAD740GE 144580 85622132 RADIATOR LOWER PANEL M424 VO TAD740GE 144590 85622140 RADIATOR LEFT/RIGHT PANEL M424 VO TAD740GE...

  • Page 150: Retention Bund M424

    G270 Item Part Number Description Quantity Units F99017 RETENTION BUND M424 132360 85622082 RETENTION BUND M424 Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 26 -...
  • Page 151 G270 EDITION: JUNE2002 - 27 -...

  • Page 152: Canopy M424 Assembly

    G270 Item Part Number Description Quantity Units F14056 85622199 CANOPY M424 ASSEMBLY 090550 85496826 MUFFLER BRACKET M424 131800 85497386 LIFTING BRACKET M424/425/426 141020 85416857 REAR BAND M404/407 142600 85497493 DOOR SCOPE M424 142610 85497501 BASEFRAME SIDE M424 142620 85497519 BASEFRAME FRONT/REAR M424...

  • Page 153: Central Lifting Arch Assembly

    G270 Item Part Number Description Quantity Units F14030 85498582 CENTRAL LIFTING ARCH ASSEMBLY 142820 85497675 LADDER M424 142830 85497683 LADDER PROTECTION PANEL M424 144330 85509511 LIFTING FRAME 4500daN M424 CANOPY 144340 85509529 LIFTING BRACKET M424 Part numbers listed are the only parts used in this model...

  • Page 154: Panel Window M404/407 Assembly

    G270 Item Part Number Description Quantity Units F14029 85420032 PANEL WINDOW M404/407 ASSEMBLY 141290 85422624 CONTROL PANEL DOOR M404/405/406/407 141330 85416790 DOOR STOP 140330 85406148 CANOPY DOOR LOCK KEY LOCK 140340 85406155 DOOR HINGE 140350 85406189 ANTI-VIBRATION MOUNT 140daN 15mm...

  • Page 155: Panel Door M424/425 Assembly

    G270 Item Part Number Description Quantity Units F14027 85498665 PANEL DOOR M424/425 ASSEMBLY 141330 85416790 DOOR STOP 140330 85406148 CANOPY DOOR LOCK KEY LOCK 140340 85406155 DOOR HINGE 140350 85406189 ANTI-VIBRATION MOUNT 140daN 15mm 143670 85501765 STRIKER PLATE M400 CANOPY MCPS DOOR...

  • Page 156: Emergency Stop Panel Assembly

    G270 Item Part Number Description Quantity Units F16015 85407187 EMERGENCY STOP PANEL ASSEMBLY 161080 85406726 SOCKET BRACKET CLOSURE PANEL 161070 85407294 EMERGENCY STOP PANEL Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 32 -...

  • Page 157: R3000 Bracket Assembly

    G270 Item Part Number Description Quantity Units F16216 85427862 R3000 BRACKET ASSEMBLY 168330 85427177 RUBBER GROMET SUPPORT 163330 85427193 INTELLISYS RACK BRACKET 160520 85408391 RUBBER GROMMET D47 Part numbers listed are the only parts used in this model EDITION: JUNE2002...

  • Page 158: Earth Rod With Cable Canopy Assembly

    G270 Item Part Number Description Quantity Units F16006 85407906 EARTH ROD WITH CABLE CANOPY ASSEMBLY 160140 85408227 NEUTRAL/EARTH SYSTEM CABLE 25mm2 L10000 Gr/Ye 160150 85408334 EARTH ROD L1000 180120 85409191 CLIP-ON BRACKET Part numbers listed are the only parts used in this model...

  • Page 159: Intellisys Assembly

    G270 Item Part Number Description Quantity Units F16200 INTELLISYS ASSEMBLY 168200 85411569 INTELLISYS OPTION CB CARD 168210 85412161 INTELLISYS OPTION SPEED POTENTIOMETER 168230 85427987 INTELLISYS OPTION ELECTRIC PACK 12V 168240 85412278 INTELLISYS OPTION EARTH LEAKAGE RELAY 168190 85412047 INTELLISYS PANEL ASSEMBLY...
  • Page 160 G270 Item Part Number Description Quantity Units F30045 85411569 INTELLISYS OPTION CB12 CARD 166390 85504058 RUBBER GROMMET 166430 85508604 INTELLISYS CARD CB12 166370 85504033 INTELLISYS WIRING LOOM C35S 166440 85426112 FUSE CYLINDRICAL 12A 166470 85426120 FUSE CYLINDRICAL 10A 166450 85426138...
  • Page 161 G270 Item Part Number Description Quantity Units F30047 85412161 INTELLISYS OPTION SPEED POTENTIOMETER 302980 85504207 CLAMP D4.7 303050 85504215 LOCK AXE SYSTEM 166510 85503993 INTELLISYS WIRING LOOM C105 L540 303070 85504223 POTENTIOMETER 4.7kOHMS Part numbers listed are the only parts used in this model...

  • Page 162: Intellisys Option Electric Pack 24V

    G270 Item Part Number Description Quantity Units F30052 85427987 INTELLISYS OPTION ELECTRIC PACK 24V 302980 85504207 CLAMP D4.7 303050 85504215 LOCK AXE SYSTEM 166520 85504009 INTELLISYS WIRING LOOM C106 L560 303130 85504264 POTENTIOMETER 1kOHMS Part numbers listed are the only parts used in this model...

  • Page 163: Intellisys Option Earth Leahage Relay

    G270 Item Part Number Description Quantity Units F30054 85412278 INTELLISYS OPTION EARTH LEAHAGE RELAY 303090 85504249 FLASK 164080 85413482 FUSE CYLINDRICAL 5A 166500 85503985 INTELLISYS WIRING LOOM C39 L2000 303150 85504280 EARTH LEAHAGE RELAY 24V 303110 85423473 TORE 303080 85504231...

  • Page 164: Intellisys Panel 24Vdc Assembly

    G270 Item Part Number Description Quantity Units F30046 85412047 INTELLISYS PANEL 24VDC ASSEMBLY 303010 85503522 WARNING LIGHT CYLINDRIC D22 302970 85504199 GROUND WIRES 10mm2 166350 85504017 INTELLISYS WIRING LOOM C3 L810 166360 85504025 INTELLISYS WIRING LOOM C11 L460 166380 85504041...

  • Page 165: Intellisys Option Emergency Stop

    G270 Item Part Number Description Quantity Units F30055 85411676 INTELLISYS OPTION EMERGENCY STOP 166490 85503977 INTELLISYS WIRING LOOM C11 L2000 Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 41 -...

  • Page 166: Intellisys Wiring Loom Function

    G270 Item Part Number Description Quantity Units F16103 INTELLISYS WIRING LOOM FUNCTION 166480 85411221 INTELLISYS WIRING LOOM 037/041 166630 85410546 INTELLISYS WIRING LOOM 001 166780 85411403 INTELLISYS WIRING LOOM 105 166790 85509321 INTELLISYS WIRING LOOM 106 166770 85410520 INTELLISYS WIRING LOOM 006...

  • Page 167: Edf Block Housing M400B-Loc Assembly

    G270 Item Part Number Description Quantity Units F16187 85420867 EDF BLOCK HOUSING M400B-LOC ASSEMBLY 161430 85417376 NEUTRAL/EARTH SYSTEM CABLE 25mm2 L125 Gr/Ye 161540 85416881 COPPER BAR 5x25 162360 85413706 INSULATION PIN 183290 85409084 RECTANGULAR STICKER 25X50 Part numbers listed are the only parts used in this model...

  • Page 168: Power Terminal Connections 400A Assembly

    G270 Item Part Number Description Quantity Units F16188 85495349 POWER TERMINAL CONNECTIONS 400A ASSEMBLY 161410 85417319 EARTHING CABLE D8xD10 25mm2 L2500 Gr/Ye 161420 85406601 EARTHING CABLE D8xD10 25mm2 L1800 Gr/Ye 169080 85493195 POWER CABLE SINGLE CORE 150mm2 L1800 161480 85416915...

  • Page 169: Terminal Connection Block Assembly

    G270 Item Part Number Description Quantity Units F16075 85418150 TERMINAL CONNECTION BLOCK ASSEMBLY 161700 85417079 COPPER BAR 10x90 161720 85416923 COPPER BAR 10x30 161730 85416931 COPPER BAR 10x30 161740 85416949 COPPER BAR 10x30 161750 85416956 COPPER BAR 10x30 161760 85418069...

  • Page 170: Terminal Block Housing 250

    G270 Item Part Number Description Quantity Units F16046 85419828 TERMINAL BLOCK HOUSING 250<I<=480A ASSEMBLY 161590 85423721 WIRE BIB OUTPUT BRACKET M400 161600 85417103 CABLE OUTPUT RUBBER SCREEN 161770 85424042 GLAND NUT PLATE TERMINAL CONNECTION M404/407 162070 85424398 CIRCUIT BREAKER PROTECTION PANEL...

  • Page 171: Panel Door M404/406 Assembly

    G270 Item Part Number Description Quantity Units F16055 85420099 PANEL DOOR M404/406 ASSEMBLY 140660 85406130 DOOR HINGE 162060 85422749 TERMINAL CONNECTION PERSPEX DOOR M400 160760 85407708 HINGE FIXING PLATE M214 180460 85409225 1/4 TURN SCREW D9 180470 85409233 CAPTIVE NUT FOR 1/4 TURN BOLT...

  • Page 172: Compact Circuit Breaker 100A

    G270 Item Part Number Description Quantity Units F16036 COMPACT CIRCUIT BREAKER 100A<I<630A ACCESSORIES 162450 85408573 CIRCUIT BREAKER SHUNT RELEASE COIL 200/280VAC Part numbers listed are the only parts used in this model EDITION: JUNE2002 - 48 -...

  • Page 173: Way Fuel Valve Option

    3 WAY FUEL VALVE OPTION G270 3 WAY FUEL VALVE OPTION Item Part Number Description Quantity Units F05025 85503290 3 WAY FUEL VALVE ASSEMBLY 050300 85424174 EXTERIOR FILLING CONNECTION BRACKET 050570 85507861 3 WAY FUEL VALVE LEVER 3/8G 182720 85429793...

  • Page 174: Auto Start Option

    AUTO START OPTION G270 AUTO START OPTION Item Part Number Description Quantity Units F16166 AUTO START OPTION 162460 85408581 AUXILARY CONTACT 166670 85411163 INTELLISYS WIRING LOOM 035 166650 85410835 INTELLISYS WIRING LOOM 013 166870 85426948 INTELLISYS WIRING LOOM 016 166720...

  • Page 175: Coolant Heater 700W Assembly

    AUTO START OPTION G270 AUTO START OPTION Item Part Number Description Quantity Units F03016 85420107 COOLANT HEATER 700W ASSEMBLY 030280 85401982 RESISTANCE HOUSING 700W 030300 85423655 PREHEATER HOUSING BRACKET VOLVO 7/10L 030310 85423291 COOLANT PREHEAT CONNECTION VO 740 030320 85421287...

  • Page 176: Intellisys Option Battery Charger 24V/3A

    AUTO START OPTION G270 AUTO START OPTION Item Part Number Description Quantity Units F30077 85412062 INTELLISYS OPTION BATTERY CHARGER 24V/3A 304380 85506665 CHARGER 167440 85506541 INTELLISYS WIRING LOOM 022/024 167450 85506558 INTELLISYS WIRING LOOM 009 Part numbers listed are the only parts used in this model...

  • Page 177: Intellisys Option Water Preheating

    AUTO START OPTION G270 AUTO START OPTION Item Part Number Description Quantity Units F30078 85412187 INTELLISYS OPTION WATER PREHEATING 167410 85506517 INTELLISYS WIRING LOOM 031/33/34 167420 85506525 INTELLISYS WIRING LOOM 100 167430 85506533 INTELLISYS WIRING LOOM 027 304360 85506640 SURGE SUPRESSOR BLOCK...

  • Page 178: Explosive Atmosphere Option

    EXPLOSIVE ATMOSPHERE OPTION G270 EXPLOSIVE ATMOSPHERE OPTION Item Part Number Description Quantity Units F08028 85425072 AIR SHUT OFF VALVE VO TAD740 ASSEMBLY 080720 85417657 AIR SHUT OFF VALVE D76 162520 85423366 RELAY 24V 10/20A 160180 85408912 AUTOMOBILE RELAY BASE Part numbers listed are the only parts used in this model...

  • Page 179: Spark Arrester Ineris Dn125 Assembly

    EXPLOSIVE ATMOSPHERE OPTION G270 EXPLOSIVE ATMOSPHERE OPTION Item Part Number Description Quantity Units F09038 85503357 SPARK ARRESTER INERIS DN125 ASSEMBLY 090620 85503340 INERIS SPARK ARRESTER DN125 181030 85417780 HOSE CLAMP D140 Part numbers listed are the only parts used in this model...

  • Page 180: Single Base Plate Option

    SINGLE BASE PLATE OPTION G270 SINGLE BASE PLATE OPTION Item Part Number Description Quantity Units F14021 85424976 SINGLE BASE PLATE M424 ASSEMBLY 142770 85429694 HOOD UNDERSHEETING M424 142780 85429751 HOOD UNDERSHEETING M424 Part numbers listed are the only parts used in this model...

  • Page 181: Socket Option Type 3

    SOCKET OPTION TYPE 3 G270 SOCKET OPTION TYPE 3 Item Part Number Description Quantity Units F16144 85507077 SOCKET PANEL EU M400 TYPE 3 ASSEMBLY 169090 85622678 INTELLISYS WIRING LOOM 135 169100 85622686 INTELLISYS WIRING LOOM 136 167670 85408300 SOCKET GERMAN 230V 16A 2S+G...

  • Page 182: Socket Panel Eu M400 Type 3 Assembly

    SOCKET OPTION TYPE 7 G270 SOCKET OPTION TYPE 7 Item Part Number Description Quantity Units F16150 85507275 SOCKET PANEL FR M400 TYPE 7 ASSEMBLY 165330 85506087 DIFFERENTIAL SWITCH 2P 40A 30mA 167810 85506111 SOCKET EC 110V 16A 2S+G 660170 85506459...

  • Page 183: Simplified Retention Bund And Base Plate Option

    SIMPLIFIED RETENTION BUND AND BASE PLATE OPTION G270 SIMPLIFIED RETENTION BUND AND BASE PLATE OPTION Item Part Number Description Quantity Units F13085 85623023 RETENTION BUND ASSEMBLY M424 040240 85622942 HYDRAULIC MANUAL PUMP 132440 85622959 OIL SUMP PUMP BRACKET 181550 85622967...
  • Page 187 Users guide and maintenance manual Leroy Somer Alternators LSA 46.2 / 47.1 Réf. constructeur : 2981 GB - 4.33/a - 04.00 Réf. GPAO : 33522035901...
  • Page 188 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS This manual concerns the alternator which We wish to draw your attention to the contents you have just purchased. of this maintenance manual. By following certain important points during installation, The latest addition to a whole new generation use and servicing of your alternator, you can...
  • Page 189 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS CONTENTS 1 - RECEIPT ............4 4 - SERVICING - MAINTENANCE ......15 Standards and safety measures Safety measures Inspection Regular maintenance Identification Checks after start-up Storage Cooling circuit Bearings...

  • Page 190: Receipt

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS RECEIPT 1 - RECEIPT 1.3 - Identification The alternator is identified by means of a nameplate fixed on the frame (see drawing). 1.1 - Standards and safety measures Make sure that the nameplate on the machine conforms to Our alternators comply with most international standards and your order.

  • Page 191: Technical Characteristics

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS TECHNICAL CHARACTERISTICS 2 - TECHNICAL CHARACTERISTICS 2.1 - Electrical characteristics LSA 46.2/47.1 alternators are machines without sliprings or revolving field brushes, wound as « 2/3 pitch»; 6 or 12-wire, with class H insulation and a field excitation system available in either AREP or "PMG"...

  • Page 192: Options

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS TECHNICAL CHARACTERISTICS 2.3 - Excitation system adjustable via potentiometer P4 - max. excitation current adjustment via P5 : 4 to 10A For both the AREP & PMG excitation systems, the alternator - 50/60 Hz selection via strap ST3.

  • Page 193: Frequency Compared With Voltage

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS TECHNICAL CHARACTERISTICS PMG excitation R448 Voltage Transient voltage drop (U/f) 2.3.3 - Frequency compared with voltage (without LAM) Frequency Max. speed drop Voltage Bend 57.5 Hz 48 Hz 100 %...

  • Page 194: Installation

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3 - INSTALLATION 3.1.3 - Location Ensure that the ambient temperature in the room where the 3.1 - Assembly alternator is placed cannot exceed 40°C for standard power ratings (for temperatures >...

  • Page 195: Terminal Connection Diagrams

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.3 - Terminal connection diagrams To modify the connections, change the position of the terminal links or shunts. The winding code is specified on the nameplate.
  • Page 196 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.3.2 - Terminal connection : LSA 46.2/47.1 - 6-wire Connection codes Voltage L.L Factory connection LSA 46.2 - 6-WIRE L1(U) 50 Hz 60 Hz Winding L3(W) 3-phase...
  • Page 197 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.3.3 - Option connection diagram Remote voltage potentiometer R 791 T interference suppression kit (standard for CE marking) Connections Black Black Black Voltage adjustment via remote potentiometer Blue White...
  • Page 198 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 3.4 - Commissioning 3.5.1 - R 448 settings The machine can only be started up and used if the installation has been set up in accordance with the regulations and instructions defined in this manual.
  • Page 199 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION Adjustments in standalone operation machines, try to cancel (or minimise) the current circulating between the machines. b) Install a D.C. analogue voltmeter (needle dial) cal. 100V on From now on, do not touch the voltage settings.
  • Page 200 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS INSTALLATION 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 <...

  • Page 201: Servicing - Maintenance

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4 - SERVICING - MAINTENANCE The factory lubrication is performed with grease : SHELL - ALVANIA G3. 4.1 - Safety measures Before using another grease, check for compatibility with the original one.

  • Page 202: Fault Detection

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 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 diagrams in the manuals...

  • Page 203: Electrical Faults

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.5 - 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.

  • Page 204: Checking The Diode Bridge

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.5.2 - Checking the diode bridge ASSEMBLY A DIODE BRIDGE Exciter field A n o d e A diode in good Rh.

  • Page 205: Dismantling, Reassembly

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.6 - Dismantling, reassembly 4.6.3 - Access to diodes (see sections 5.4.1. & 5.4.2.) - Open the air inlet louvre (51) - Disconnect the diodes.

  • Page 206: Replacing The De Bearing On

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.6.6 - Replacing the DE bearing on 4.6.9 - Reassembling the rotor two-bearing machines On single bearing machines : - Mount the rotor (4) in the stator (1) (see drawing below) - Remove the screws (31) and (62).

  • Page 207: Installation And Maintenance Of The Pmg

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE on the AVR. The 4 auxiliary winding wires X1.X2.Z1.Z2 should be isolated using the domino fitting supplied with the kit. Both exciter field wires (5/6) and the voltage sensing wires (2/3) remain in place.

  • Page 208: Table Of Characteristics

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SERVICING - MAINTENANCE 4.8 - Table of characteristics 4.8.2 - Average values for LSA 47.1 Resistances at 20°C (Ω) Table of average values Alternator - 4 poles - 50 Hz - Standard winding No. 6. LSA 47.1 Stator L/N Rotor...

  • Page 209: Spare Parts

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS 5 - SPARE PARTS 5.3 - Accessories 5.3.1 - Space heater for use when stopped 5.1 - First maintenance parts The space heater must start up as soon as the alternator Emergency repair kits are available as an option.

  • Page 210: Single Bearing

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS 5.4 - Exploded view, parts list 5.4.1 - Single bearing Ref. Description Ref. Description Stator assembly Terminal block with terminals Rotor assembly AVR support bracket Turbine Voltage regulator (AVR)

  • Page 211: Two-Bearing

    LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS 5.4.2 - Two-bearing Ref. Description Ref. Description Stator assembly Exciter armature Rotor assembly Crescent support Turbine Terminal support Balancing disc Console support Lifting ring Terminal block with terminals Shaft extension key...
  • Page 212 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS...
  • Page 213 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS...
  • Page 214 MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE Imprimerie MOTEURS LEROY-SOMER R C A N G O U L E M E B 6 7 1 8 2 0 2 2 3...

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