Page 1 Control device : M150 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 Instructions for use M 50 M150 X200 INS / ATS Réf. constructeur : Réf. GPAO : 33502013301...
Page 32 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 1 1 0 0 1 1 2 2 1 1 1 1 1 1 5 5 2 2 3 3 1 1 3 3 1 1 4 4 INS/ATS M150 1 1 0 0 2 2 0 0 1 1 5 5 1 1 1 1 1 1 2 2 1 1 6 6...
Page 34 A – – D D ESCRIPTION The manual control panels and the automatic control boxes are equipped with various switchgear and standard indicators. The following figures define the functions of the different switchgear. The key has 4 positions : - S S TARTING A A ND S S TOPPING K K EY: :Position of the key when the generator set is not running.
Page 35 1 1 2 2 - V V OLTMETER (A50-M M 150): It allows selection of the operating mode : - O O PERATING S S ELECION S S WITCH ( ( A50): -STOP : manual operation from the console M50 1 1 3 3 S S T T O O P P A A U U T T O O...
Page 36 - Let the generator set run empty for several minutes depending on the ambient temperature. - M50 : Close the circuit breaker. - From this moment the generator set is outputting to the installations. B) N N ORMAL O O PERATION - During operation of the generator set, carry out a regular inspection to ensure there are no anomalies.
Page 37 I I V V – – R R E E V V E E R R S S E E R R O O F F N N O O R R M M A A L L / / E E M M E E R R G G E E N N C C Y Y S S O O U U R R C C E E S S I I N N S S / / A A T T S S : : The reverser of normal / emergency sources allows the installation to be supplied by the generator set as soon as mains supply disappears.
Page 38 I I I I - A A U U T T O O M M A A T T I I C C S S 1. STOP 2. CONTACT 3. PREHEATING OF PLUG 4. STARTING STRAP TO POSITION IF NO A50 BOX CONNECTED 9 POINT CONNECTOR 9 POINT MALE CONNECTOR...
Page 77 C10-MOT 09-01 09-01...
Page 78 C10-MOT 09-01 09-01...
Page 79 C10-MOT 09-01 09-01...
Page 83 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 84 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 85 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 86: 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 87 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 88 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 89 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 90: 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 91: 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 92: 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 93: 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 94: And 12-Litre Engines
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 95: 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 96: 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 97: 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 98: 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 99 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 100: 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 101: 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 102: 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 103: 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 104: 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 105: 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 106 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 107: 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 108 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 109 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 110: 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 111 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 112: 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 113 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 114 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 115 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 116 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 117 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 118: 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 119: Bleeding The Fuel System
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 120 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 121: 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 122 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 123: 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 124 Maintenance Wiring diagram (6–12 litre engines) “Not for TD/TAD720”...
Page 125 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 126 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 127 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 128 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 129: 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 130: 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 131: 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 132: General
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 133: 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 134: Lubrication System
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 135 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 136 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 137 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 138: 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 139: Fuel Injection System
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 140: 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 141 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 142: Disengageable Clutches
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")
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Page 149 GENERATOR PARTS LISTS GENERATOR MODEL G220 G220 07/09/01 CPN 85053023 (33519011001)
Page 150 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 151 BATTERY ELECTROLYTE ..................20 ELECTRIC STARTER M413B ISOLATED ASSEMBLY ........21 EXHAUST SYSTEM M413BESI ASSEMBLY ............22 FRAME M413B VO TWD7L ASSEMBLY..............23 G220 DECALS......................... 24 SAFETY DECALS ASSEMBLY................... 25 MISCELLANEOUS CANOPY ASSEMBLY............... 26 RETENTION BUND M413 BESIL ................27 M413BESIL CANOPY ASSEMBLY ................
Page 152 A breakdown view exists for this item A supplier spare parts documentation exists for this item. Some items drawing on the breakdown view are not mounted on this genset, so they are not in the part list. G220 07/09/01 CPN 85053023 (33519011001)
Page 153 ENGINE ASSEMBLY F01025 G220 07/09/01 CPN 85053023 (33519011001)
Page 154 AUTOMOBILE RELAY BASE 160300 85408920 MOULDED CASE CIRCUIT BREAKER 1x16A 162560 85412989 2 POLE CONNECTOR 162570 85412997 2 POLE CONNECTOR 165120 85410652 INTELLISYS WIRING LOOM 010 L1=3500 L2=400 166240 85427268 ELECTRICAL SHAFT D29 162860 85427276 CLIP D29 G220 07/09/01 CPN 85053023 (33519011001)
Page 155 ELECTRIC STARTER 301860 85401404 CHARGING ALTERNATOR 302470 85426161 WATER PUMP REPAIR KIT 301960 85401990 PRESSURE SWITCH 302000 85402147 TEMPERATURE SWITCH 302050 85402196 THERMOSTAT SEAL 302030 85402170 THERMOSTAT SEAL 302010 85402154 THERMOSTAT 302440 85502797 ROCKER COVER GASKET G220 07/09/01 CPN 85053023 (33519011001)
Page 156 ALTERNATOR ASSEMBLY F02006 Item Part number Description Quantity Units 020150 85416626 LS 462M5 ALTERNATOR G220 07/09/01 CPN 85053023 (33519011001)
Page 157 ALTERNATOR DETAILS F30049 Item Part number Description Quantity Units 302210 85425577 VOLTAGE REGULATOR 302310 85425916 BEARING 302350 85425940 DRIVE DISC 302380 85426179 DIODE BRIDGE 302090 85402444 SURGE SUPPRESSOR G220 07/09/01 CPN 85053023 (33519011001)
Page 158 PIPE UNION REDUCER MALE/MALE 3/4" GAS 180930 85423093 PIPE UNION ELBOW 90° MALE/FEMALE 3/4" GAS 181050 85417749 HOSE CLIP D25/40 181160 85421758 GASKET D26x32 Th2 181170 85421725 GASKET D22x27 Th1.5 181220 85424885 2 WAY VALVE 181270 85424836 FLEXIBLE HOSE D25x32 G220 07/09/01 CPN 85053023 (33519011001)
Page 159 Part number Description Quantity Units 080330 85403848 AIR CLEANER CLAMP D330 080340 85403863 RAIN CAP D154 080350 85403921 AIR FILTER HEAVY DUTY 080700 85423887 AIR FILTER BRACKET VOLVO TxD740G 080710 85424257 HEAVY DUTY INLET PIPE BRACKET G220 07/09/01 CPN 85053023 (33519011001)
Page 160 F30014 Item Part number Description Quantity Units 300200 85400737 OUTER AIR FILTER 300210 85400786 INNER AIR FILTER 300120 85501229 VACUATOR VALVE 300230 85501294 DUST CUP 080340 85403863 RAIN CAP D154 181680 85501872 HOSE CLIP D140/160 G220 07/09/01 CPN 85053023 (33519011001)
Page 161 OUTPUT CABLES ALTERNATOR 80A<=480A ASSEMBLY F16004 Item Part number Description Quantity Units 160420 85406742 CABLE OUTLET PLATE NW UCD224/UC274 160500 85406874 FOAM CABLE PROTECTION 170x40x40 G220 07/09/01 CPN 85053023 (33519011001)
Page 162 RADIATOR VOLVO TWD740G 130990 85422798 ALTERNATOR PROTECTION 180910 85423242 PIPE UNION REDUCER MALE/MALE 3/4" GAS 180930 85423093 PIPE UNION ELBOW 90° MALE/FEMALE 3/4" GAS 180970 85423168 PIPE UNION 3/4 G 181530 85427110 PIPE UNION REDUCER FEMALE/MALE 1/4G G220 07/09/01 CPN 85053023 (33519011001)
Page 163 301260 85500809 LEFT FAN PROTECTION 301270 85500932 RIGHT FAN PROTECTION 301300 85501013 PLENUM 301310 85501096 RADIATOR RIGHT UPRIGHT 301320 85501179 RADIATOR LEFT UPRIGHT 180100 85409316 PLUG 1/2G 180820 85502540 PIPE UNION REDUCER MALE/MALE 1/4" GAS G220 07/09/01 CPN 85053023 (33519011001)
Page 164 85403517 FUEL FILLER BASE FUEL TANK 050120 85403509 LEVEL SENSOR ADAPTER 110100 85404572 LEVEL SENSOR 180130 85409068 SQUARE FLANGE GASKET 95x95 Th3 180140 85409076 ROUND FLANGE GASKET 36x56 Th1 181230 85417632 NON RETURN VALVE D10 G220 07/09/01 CPN 85053023 (33519011001)
Page 165 FUEL FILLER 050110 DETAILS F30019 Item Part number Description Quantity Units 181750 85503035 TANK PLUG 050420 85431120 FUEL FILTER G220 07/09/01 CPN 85053023 (33519011001)
Page 166 FUEL PREFILTER KIT ASSEMBLY F05015 Item Part number Description Quantity Units 050360 85421451 DECANTATION CARTRIDGE FILTER 050370 85424299 3 WAY FUEL VALVE BRACKET G220 07/09/01 CPN 85053023 (33519011001)
Page 167 SEPARATOR FILTER BOWL RETAINER RING 301400 85502961 SEPARATOR FILTER CENTRIFUGE 301000 85502979 SEPARATOR FILTER BLIND SCREW 301210 85502987 SEPARATOR FILTER BOWL 301220 85502995 SEPARATOR FILTER O-RING 301280 85503001 SEPARATOR FILTER DRAIN COCK 301290 85503019 SEPARATOR FILTER GASKET POSITION 14 G220 07/09/01 CPN 85053023 (33519011001)
Page 168 BATTERY ELECTROLYTE F99002 Item Part number Description Quantity Units 070150 85403756 BATTERY ELECTROLYTE G220 07/09/01 CPN 85053023 (33519011001)
Page 169 070180 85403731 STARTING BATTERY 12V 100Ah 450A 161150 85417293 BATTERY CABLE(+) 50mm2 L1000 RED 161160 85417244 BATTERY CABLE(-) 70mm2 L1000 BLACK 160820 85426351 BATTERY CABLE 70mm2 L700 RED 161300 85417202 BATTERY CABLE 50mm2 L195 BLACK G220 07/09/01 CPN 85053023 (33519011001)
Page 170 Description Quantity Units 090250 85423606 29dB MUFFLER 090300 85422772 MUFFLER EXTENSION D114XL170 090220 85404341 EXHAUST RAIN FLAP D114 090350 85421857 EXHAUST PIPE M413B D102 VOLVO 181020 85417798 HOSE CLAMP D105 180500 85409381 HOSE CLAMP D120 G220 07/09/01 CPN 85053023 (33519011001)
Page 171 ENGINE SUPPORT VOLVO 6/7L LEFT RIGHT SIDE 130820 85417392 RECTANGULAR ENGINE SHIM 7L VOLVO ENGINE 130790 85417624 M413BESI FRAME TANK FOR VOLVO 7L 130420 85401883 ANTI-VIBRATION MOUNT 330daN 3.5mm 161270 85423846 ELECTRIC WIRING BRACKET T921 G220 07/09/01 CPN 85053023 (33519011001)
Page 172 G220 DECALS F18035 Item Part number Description Quantity Units 181600 85428019 RECTANGULAR STICKER 450x600 181900 85500213 ROUND STICKER D385 182020 85503845 RECTANGULAR STICKER 1100x325 G220 07/09/01 CPN 85053023 (33519011001)
Page 173 SAFETY DECALS ASSEMBLY F99008 Item Part number Description Quantity Units 183040 85506467 SAFETY DECAL G220 07/09/01 CPN 85053023 (33519011001)
Page 174 MISCELLANEOUS CANOPY ASSEMBLY F13024 Item Part number Description Quantity Units 141560 85424588 RADIATOR PANEL M413B VOLVO TWD7L 160110 85406940 WIRING BRACKET 160890 85406460 GROUND WIRES 16mm2 G220 07/09/01 CPN 85053023 (33519011001)
Page 175 RETENTION BUND M413 BESIL F99006 Item Part number Description Quantity Units 130830 85416808 HIRETECH RETENTION BUND M413 BESIL G220 07/09/01 CPN 85053023 (33519011001)
Page 176 M413BESIL CANOPY ASSEMBLY F14007 G220 07/09/01 CPN 85053023 (33519011001)
Page 177 CANOPY DOOR M413BESI HINGE ON LEFT 160900 85406437 CONTROL PANEL HOUSING 160910 85406445 REAR PLATE M403 CONTROL PANEL HOUSING 161340 85423952 SLIDE BRACKET T9000/M216B/214B 160920 85407138 RACK CLOSURE PANEL 160930 85407369 CONTROL PANEL HOUSING R3000 G220 07/09/01 CPN 85053023 (33519011001)
Page 178 CENTRAL LIFTING BAIL ASSEMBLY F14009 Item Part number Description Quantity Units 141380 85422228 LIFTING FRAME 3500daN M403BL/M413BL CANOPY 141390 85417988 LADDER M403BL 141400 85422541 LADDER PROTECTION PANEL M403BL G220 07/09/01 CPN 85053023 (33519011001)
Page 179 CANOPY DOOR LOCK KEY LOCK 140340 85406155 DOOR HINGE h100XL125 140350 85406189 ANTI-VIBRATION MOUNT 140daN 15mm 140910 85406262 STRIKER PLATE M216/413BL CANOPY MCPS DOOR 140920 85406296 CONTROL PANEL DOOR M216SIL 180530 85409498 CLIP-ON BRACKET 180540 85409506 CLIP-ON BRACKET G220 07/09/01 CPN 85053023 (33519011001)
Page 180 EMERGENCY STOP PANEL ASSEMBLY F16015 Item Part number Description Quantity Units 161080 85406726 BRACKET CLOSURE PANEL 161070 85407294 EMERGENCY STOP PANEL G220 07/09/01 CPN 85053023 (33519011001)
Page 181 EARTH ROD WITH CABLE M100/200 CANOPY ASSEMBLY F16006 Item Part number Description Quantity Units 160140 85408227 NEUTRAL/EARTH SYSTEM CABLE 25mm2 L10000 Gr/Ye 160150 85408334 EARTH ROD L1000 180120 85409191 CLIP-ON BRACKET G220 07/09/01 CPN 85053023 (33519011001)
Page 182 85424414 CIRCUIT BREAKER PROTECTION PANEL 162160 85424612 ISOLATION PANEL MCPS 250A 161840 85423937 CABLE FIXING BRACKET MCPS M403BL 161920 85423945 CABLE FIXING BRACKET MCPS M403BL 181590 85418085 WING NUT 162200 85418051 CIRCUIT BREAKER PROTECTION PLATE G220 07/09/01 CPN 85053023 (33519011001)
Page 183 DOOR HINGE h50XL50 162180 85422756 TERMINAL CONNECTION DOOR M403BL CANOPY 160760 85407708 HINGE FIXING PLATE M214BL 180460 85409225 1/4 TURN SCREW D9 180470 85409233 CAPTIVE NUT FOR 1/4 TURN BOLT 180480 85409241 WASHER FOR 1/4 TURN FASTENER G220 07/09/01 CPN 85053023 (33519011001)
Page 184 160770 85408342 INSULATION PIN 160520 85408391 RUBBER GROMMET D47 162410 85424679 CURRENT TRANSFORMER 400/5 162430 85417905 COMPACT CIRCUIT BREAKER 4x400A 162470 85415479 GLAND NUT PG29 165190 85413284 GLAND NUT PG29 162610 85422442 RUBBER GROMMET D79 G220 07/09/01 CPN 85053023 (33519011001)
Page 185 COPPER BAR 10x30 MCPS M403BL 161880 85416998 COPPER BAR 10x30 MCPS M403BL 161890 85417004 COPPER BAR 10x30 MCPS M403BL 161930 85418077 PHASE ISOLATOR M403BL 162360 85413706 INSULATION PIN 162370 85421675 INSULATION PIN 162390 85423598 CABLE CLAMP 120/240mm2 G220 07/09/01 CPN 85053023 (33519011001)
Page 186 CIRCUIT BREAKER ACCESSORIES F16036 Item Part number Description Quantity Units 162450 85408573 CIRCUIT BREAKER SHUNT RELEASE COIL 200/280VAC Part number listed is the only part used in this model. G220 07/09/01 CPN 85053023 (33519011001)
Page 187 166430 85402592 INTELLISYS CB12 CARD 166370 85504033 INTELLISYS WIRING LOOM C35S 166440 85426112 FUSE CYLINDRICAL 12A 166470 85426120 FUSE CYLINDRICAL 10A 166450 85426138 FUSE CYLINDRICAL 1A 166460 85426146 FUSE CYLINDRICAL 2,5A 303240 85505154 CR2032 CELL G220 07/09/01 CPN 85053023 (33519011001)
Page 188 INTELLISYS OPTION SPEED POTENTIOMETER F30047 Item Part number Description Quantity Units 302980 85504207 CLAMP D4.7 303050 85504215 LOCK AXE SYSTEM 166510 85503993 INTELLISYS WIRING LOOM C105 L540 303070 85504223 POTENTIOMETER 4.7kOHMS G220 07/09/01 CPN 85053023 (33519011001)
Page 189 INTELLISYS OPTION USING PLATEN F30051 Item Part number Description Quantity Units 166030 85408854 STOP 303120 85504256 WIRING LOOM SUPPORT L40XW80 0.21 303170 85504306 USING TERMINAL G220 07/09/01 CPN 85053023 (33519011001)
Page 190 INTELLISYS OPTION TENSION POTENTIOMETER F30052 Item Part number Description Quantity Units 302980 85504207 CLAMP D4.7 303050 85504215 LOCK AXE SYSTEM 166520 85504009 INTELLISYS WIRING LOOM C106 L560 303130 85504264 POTENTIOMETER 1kOHMS G220 07/09/01 CPN 85053023 (33519011001)
Page 191 Part number Description Quantity Units 303090 85504249 FLASK 164080 85413482 CYLINDRICAL FUSE 5A 166500 85503985 INTELLISYS WIRING LOOM C39 L2000 303150 85504280 EARTH LEAKAGE RELAY 24V 303110 85423473 TORE MG 50437 303080 85504231 FUSE HOUSING G220 07/09/01 CPN 85053023 (33519011001)
Page 192 INTELLISYS WIRING LOOM C11 L460 166380 85504041 EARTHING INTELLISYS WIRING LOOM 166400 85412021 INTELLISYS DISPLAY LEXAN IR 303060 85504983 INTELLISYS PLASTIC PLATE 303030 85504090 LAMP 302990 85426781 EMERGENCY STOP SWITCH 303020 85426773 EMERGENCY STOP BUTTON G220 07/09/01 CPN 85053023 (33519011001)
Page 193 302890 85504116 LEFT HOUSING 302900 85504124 ROTOR 302910 85504132 SLAM SHUT DOOR LATCH 302920 85504140 LOCK PLATE 302930 85504157 RING 302940 85504165 SCREW M6X16 302950 85504173 STOP 302960 85504181 DOOR 302970 85504199 GROUND WIRES 10mm2 G220 07/09/01 CPN 85053023 (33519011001)
Page 194 INTELLISYS OPTION EMERGENCY STOP F30055 Item Part number Description Quantity Units 166490 85503977 INTELLISYS WIRING LOOM C11 L2000 G220 07/09/01 CPN 85053023 (33519011001)
Page 195 166790 85427979 INTELLISYS WIRING LOOM 106 166800 85410520 INTELLISYS WIRING LOOM 006 166810 85417129 INTELLISYS WIRING LOOM 119 166820 85411460 INTELLISYS WIRING LOOM 120 Part numbers listed are the only parts used in this model. G220 07/09/01 CPN 85053023 (33519011001)
Page 196 Part number Description Quantity Units 050300 85424174 EXTERIOR FILLING CONNECTION BRACKET 050130 85403491 3 WAY FUEL VALVE LEVER 3/8G 180990 85423283 PIPE UNION FEM/FEM D10 180200 85409464 HOSE CLAMP D36 180220 85409530 3 WAY FUEL VALVE G220 07/09/01 CPN 85053023 (33519011001)
Page 197 SINGLE BASE PLATE OPTION F99005 Item Part number Description Quantity Units 141520 85424497 HOOD UNDERSHEETING M413B G220 07/09/01 CPN 85053023 (33519011001)
Page 198 SOCKET TYPE 3 OPTION F16144 Item Part number Description Quantity Units 167670 85408300 SOCKET GERMAN 230V 16A 2S+G 165330 85506087 DIFFERENTIAL SWITCH 2POLE 25A 30mA 660170 85506459 MOULDED CASE CIRCUIT BREAKER 2x16A G220 07/09/01 CPN 85053023 (33519011001)
Page 199 SOCKET TYPE 7 OPTION F16150 Item Part number Description Quantity Units 165330 85506087 DIFFERENTIAL SWITCH 2POLE 25A 30mA 167810 85506111 SOCKET EC 110V 16A 2S+G 660170 85506459 MOULDED CASE CIRCUIT BREAKER 2x16A G220 07/09/01 CPN 85053023 (33519011001)
Page 200 SOCKET TYPE 10 OPTION F16157 Item Part number Description Quantity Units 167740 85506079 MOULDED CASE CIRCUIT BREAKER 2x10A 167810 85506111 SOCKET EC 110V 16A 2S+G G220 07/09/01 CPN 85053023 (33519011001)
Page 201 SIMPLIFIED RETENTION TANK AND BASE PLATE OPTION F13068 Item Part number Description Quantity Units 131830 85507572 RETENTION BUND M413 G220 07/09/01 CPN 85053023 (33519011001)
Page 202 304390 85506673 BUTTON 304400 85506681 POTENTIOMETER 200kOHMS 167460 85506566 INTELLISYS WIRING LOOM 124 167470 85506574 INTELLISYS WIRING LOOM 125 304410 85506699 POTENTIOMETER SUPPORT 304420 85506707 KEY BUTTON 304430 85506582 EMERGENCY STOP SWITCH 304440 85506715 SWITCH G220 07/09/01 CPN 85053023 (33519011001)
Page 203 EXPLOSIVE ATMOSPHERE KIT OPTION SPARK ARRESTER INERIS DN100 ASSEMBLY F09013 Item Part number Description Quantity Units 090160 85404325 INERIS SPARK ARRESTER DN100 180500 85409381 HOSE CLAMP D120 G220 07/09/01 CPN 85053023 (33519011001)
Page 204 AIR SHUT OFF VALVE VO TWD740 ASSEMBLY F08025 Item Part number Description Quantity Units 080740 85425064 AIR SHUT OFF VALVE D51 160160 85408367 RELAY 12V/24V 75A 162520 85423366 RELAY 24V 10/20A 160180 85408912 AUTOMOBILE RELAY BASE G220 07/09/01 CPN 85053023 (33519011001)
Page 205 Quantity Units 166930 85507614 INTELLISYS WIRING LOOM 100 162460 85408581 AUXILARY CONTACT 166670 85411163 INTELLISYS WIRING LOOM 035 166650 85410835 INTELLISYS WIRING LOOM 013 166870 85426948 INTELLISYS WIRING LOOM 016 166720 85411486 INTELLISYS WIRING LOOM 121 G220 07/09/01 CPN 85053023 (33519011001)
Page 206 SPACER Th10 D15 d9 180900 85423267 PIPE UNION REDUCER MALE/MALE 1/2" GAS 180940 85423051 PIPE UNION ELBOW 45° MALE/FEMALE 1/2" GAS 181040 85417756 HOSE CLIP D16/27 181200 85421766 O RING D40x2.5 181280 85424844 FLEXIBLE HOSE D16x26 G220 07/09/01 CPN 85053023 (33519011001)
Page 207 INTELLISYS OPTION BATTERY CHARGER 24V/3A F30077 Item Part number Description Quantity Units 304380 85507606 CHARGER 167440 85506541 INTELLISYS WIRING LOOM 022/024 167450 85506558 INTELLISYS WIRING LOOM 009 G220 07/09/01 CPN 85053023 (33519011001)
Page 208 OPTION WATER PREHEATING F30078 Item Part number Description Quantity Units 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 304370 85507598 RELAY G220 07/09/01 CPN 85053023 (33519011001)
Page 211 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 212 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 213 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 214: 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 215: 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 216: 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 217: 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 218: 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 219: 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 220 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 221 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 222 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 223 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 224 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 225: 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 226: 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 227: 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 228: 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 229: 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 230: 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 231: 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 232: 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 233: 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 234: 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 235: 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 236 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS...
Page 237 LEROY-SOMER INSTALLATION AND MAINTENANCE Ref. 2981 GB - 4.33/a - 04.00 LSA 46.2 / 47.1 ALTERNATORS SPARE PARTS...
Page 238 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...

Ingersoll-Rand G220 Users Manual And Maintenance Manual

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