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HTC 2500 iX v2 Instructions Manual

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Page 1 Instructions HTC 2500 iX v2 Starting Procedure Maintenance Schedule HTC 2500 Manual HTC 2500 Education Perkins 1104 Engine Manual Particle Filter Datasheet Generator Manuals HTC 86D Manual HTC 55C Manual Gear Unit Manual...
Page 2 Startup procedure HTC 2500 iX v2 1. Switch on battery power (Battery main switch) 2. Press the start button on the InteliNano generator control panel (The engine will start after a few seconds once the button is released) 3. Turn on the ignition key – wait for the control system to boot up 4.
Page 3 Fuel system primary filter/water separator – drain .........Perkins Manual, page 70 Walk-around inpection ................Perkins Manual, page 77 Grinding heads – inspect ............. HTC 950 RX manual, Chapter 5.5 Hoses – inspect ..........................Sock filters – inspect ................HTC 86D Manual, page 10 Pneumatic system –...
Page 4 Every 100 hours or 1 year Grinding heads – inspect ............. HTC 950 RX manual, Chapter 5.7 Every 250 hours or 1 year Engine oil and filter – change ..............Perkins Manual, page 65 Every 500 hours or 1 year Engine air cleaner element – clean/replace ..........Perkins Manual, page 61 Engine ground –...
Page 5 Manual...
Page 7 HTC 2500 iX grinding machine is in a class of its own, an industrialised grinding system for really large areas. The HTC 2500 iX is packed with technology and features, and our designers have done everything possible to optimise the floor grinding work.
Page 8 Important information Read through this manual carefully so that you know how to use and maintain the HTC 2500 iX before using it. For service work other than that described in this manual, contact HTC for parts and service. Liability •...
Page 9 CE marking............................... 12 Declaration of conformity ........................13 Introduction to the HTC 2500 iX ......................14 Technical specification for the HTC 2500 iX ....................14 The technology and its benefits ......................... 15 Safety instructions ..........................16 Operating the machine on a sloping surface........................16 Machine description –...
Page 10 Presentation ............................. 24 System description ................................24 Presentation ............................. 25 System location – Right-hand side ............................ 25 Presentation ............................. 26 System description ................................26 Presentation ............................. 27 System description – Interface touch-screen ........................27 Presentation ............................. 28 System description – Interface touch-screen – Service ....................28 Presentation .............................
Page 11 Operation ..............................41 Operation ..............................41 Mist Cooler System ................................41 Operation ..............................41 Grinding pressure ................................41 Presentation ............................. 42 Suction system ..................................42 Schematic diagram..........................43 Suction system ..................................43 Operation ..............................44 Suction system ..................................44 Operation ..............................45 Stopping the engine ................................
Page 12 Control cabinet - AS2 ..........................56 Control cabinet - AS3 ..........................57 Control cabinet - AS4 ..........................58 Appendix 1 – Additions to manual for HTC 2500 iX ................59 Appendix 2 – Maintenance intervals for HTC 2500 iX ................58...
Page 13 Warranty This warranty only covers manufacturing defects. HTC bears no responsibility for damage that arises or occurs during trans- portation, unpacking or use. In no case and under no circumstances shall the manufacturer be held responsible for damage and defects caused by incorrect use, corrosion or use over and above the prescribed specifications. The manufacturer is not responsible for indirect damage or costs under any circumstances.
Page 14 The manual In addition to general functions, this manual deals with areas of application and maintenance for the HTC 2500 iX grinding machine. A number of symbols are used in the manual to highlight the most important sections, see below. In order to avoid both personal injury and material damage as much as possible, it is extremely important to read and understand the text next to these symbols particularly carefully.
Page 15 If the machine is stored in a cold environment, it should be left to warm up for at least two hours before use. The machine may only be used when the splash guards are fitted. Only HTC original tools and spare parts may be used. If the mechanical locking of the grinding heads is not working, take care when working with these.
Page 16 Vibration and noise The machine has been tested in accordance with the ISO 8662-4 and ISO 11202 standards for vibration and noise. For vi- brations, the average value is 1.01 m/s², which applies when the machine is being accelerated. The sound level at the ma- chine during operation is approx.
Page 17 Example of machine name plate The machine name plate is located inside the front hatch, on the right-hand side of the cab. The serial number can also be found inside the left-hand hatch, on the frame above the lifting point. 1: Serial number 2: Engine number 3: Generator number...
Page 18 The Manufacturer’s Declaration of Conformity, which shows that the HTC 2500 iX grinding machine is harmonised with the EMC Directive, can be found on the following pages. The HTC 2500 iX is classified for use in environments such as heavy...
Page 19 In accordance with the Machinery Directive, 98/37/EC, the EMC Directive, 89/336/EEC, the Low Voltage Directive, 73/23/ EEC including supplements, and in accordance with the CE Marking Directive, 93/68/EEC Type of equipment Grinding machine Make HTC Trademark HTC 2500 iX Serial number ___________________ Manufacturer HTC Sweden AB Box 69 SE-614 22 Söderköping...
Page 20 Introduction to the HTC 2500 iX Technical specification for HTC 2500 iX The HTC 2500 iX entails a new way of looking at floor • Engine: 4 cyl. Perkins Diesel 4.4 litres grinding. An “industrialised grinding” system, incorporating • Engine output: 157 hp (117 kW) everything from grinding heads, a dust separator and its •...
Page 21 = Industrialised system, X = Four grinding discs/grinding make tool replacement easy and provide good access. head • The HTC 2500 iX is easy to operate, with joysticks • The cab on the HTC 2500 iX is hydrobox-mounted, and a touch-screen integrated in the operator’s cab.
Page 22 Safety instructions Operating the machine on a sloping surface Driver motors’ release lever – when towing Under no circumstances may the machine be operated on surfaces that affect its lateral incline, as there is then a risk of tipping (see figure 1). If the machine is to be lifted, this is performed with forks un- der the machine, and each fork may only be inserted at the indicated points.
Page 23 Machine description – Front view...
Page 24 Description of machine components – front 1. Lighting ramp. 2. Entrance to the operator’s cab. 3. Left-hand engine cover. 4. Splash guard. 5. Cover for grinding head. 6. MCS™ (Mist Cooler System). 7. Electric motor for grinding head. 8. Suction hose for dust separator. 9.
Page 25 Machine description – Rear view...
Page 26 Description of machine components – rear 1. Exhaust pipe from diesel engine. 2. Right-hand engine cover. 3. Loading ramp for dust and grinding waste. 4. Dust waste bag. Longopac®. 5. Air cannon/Filter cleaner. 6. Pre-separator. 7. Filter cyclone.
Page 27 Presentation Cab – location of controls Grinding Speed Main Power Warning HTC 2500 iX...
Page 28 Presentation Cab – function of controls 1. Reversing monitor and dust waste monitor. Two cameras 10. Emergency hammer. This is only used in an emergency as a tool to break the window glass to allow rapid evacu- are installed in the rear part of the machine to monitor dust waste bags from the dust separators and to monitor the ma- ation of the cab or when the regular evacuation route, the chine when e.g.
Page 29 Presentation System location – left-hand side...
Page 30 Presentation System description 12. Diesel engine’s cooling unit. 1. Exhaust, dust separator. 13. Topping up the cooler water. The cooler water is topped 2. Control cabinet 2. Frequency converter. up under the cover. Note that topping up may only take place when the engine is cold, in order to avoid burns as 3.
Page 31 Presentation System location – right-hand side...
Page 32 Presentation System description 1. Generator 2. Intake filter 3. Refuelling, diesel. 4. Fan motor for dust separator. 5. Inspection hole for mist cooler pump. 6. Braking resistor. Note that this surface may be hot. Pay attention in order to minimise the risk of burns. Contains high voltage components, do not touch.
Page 33 Presentation System description – Interface touch-screen The HTC 2500 iX is equipped with a touch-screen. The machine’s systems can be checked and regulated via the screen. The software version is displayed when the machine is started up. Press “CONTINUE” to come to the “OPERATION MENU”.
Page 34 Presentation System description – Interface touch-screen – Service Under the “service menu” (see fi gure 1) there are a number of control buttons, from where some of the machine’s func- tions are controlled. In the upper left-hand fi eld there is a button for turning the machine’s headlights on and off.
Page 35 Presentation System description – CanOpen components’ status Error messages can be displayed in the “CANOpen” menu. The messages from this menu can be interpreted by au- thorised service personnel. Contact your retailer for further information. See the error code overview later in this manual. The CANOpen menu...
Page 36 Presentation System description – Interface touch-screen The ALARM menu contains e.g. a series of indicators that display any faults. The green indicator lights as long as the system in question is in normal mode. Faults are indicated with a red lamp, and may be of the following types: CHAIR SWITCH: The indicator glows red when the driver is not sitting down on the driver’s seat.
Page 37 Operation Check the coolant level. Maintain the coolant level within Before the starting engine 13 mm (0.5 inch) of the bottom of the filler pipe. NOTICE: Only use antifreeze/coolant mixtures recom- Inspect the drive belts of the main alternator and vacuum mended in the coolant specifications that are in the Opera- fan for cracks, breaks and other damage.
Page 38 Allow the electric starter motor to cool for two min- utes before cranking the engine again. 1. Ensure that the main switch (see figure below) has been engaged for at least 5 seconds. Grinding Speed Main Power Warning HTC 2500 iX...
Page 39 Grinding Speed 11. Press the ”CONTINUE” button on the control display. Main Power Warning HTC 2500 iX Grinding Speed Main Power Warning HTC 2500 iX 5. When the engine starts, release the key and allow it to return.
Page 40 If Grinding Speed the directions in this manual and the attached manuals are followed, costs can be minimised and component service life can be maximised. Grinding Speed Main Power Warning HTC 2500 iX...
Page 41 POWER ON button has been pressed in, the MAIN POWER or AMP-right will not exceed the recommended power output ON lamp (3) lights up. Grinding Speed Main Power Warning HTC 2500 iX Grinding Speed Grinding Speed Main Power Warning HTC 2500 iX...
Page 42 The current angle of the articulated joint can easily be moni- tored in the display, which makes reversing easier. Grinding Speed Main Power Warning HTC 2500 iX...
Page 43 Operation Grinding heads...
Page 44 A green lamp in front of the relevant lever indicates that this function is activated. HTC recom- The sensor on the machine’s lifting device indicates the position of mends that this function is always used during grinding.
Page 45 GRINDING in the OPERATION menu. If any of the indica- tors is within the red fi eld, reduce the grinding speed. Grinding Speed Grinding Speed Main Power Warning HTC 2500 iX...
Page 46 When replacing a tool, pay attention to the crushing risk when folding the grinding heads up/down. Figure 2. With a The HTC 2500 iX is equipped with our new patented tool few light taps, it is system with a registered design, EZchange™. This com- then possible to prises wings bearing diamond grinding tools.
Page 47 Operation Operation Mist Cooler System A concrete floor should ideally be ground according to the following pattern (see figure below). If the mist system is to be used, the pump is activated/ deactivated via the display. Press the MIST button under the SERVICE page.
Page 48 Presentation Suction system...
Page 49 Schematic diagram Function: Suction system Grinding cover. The grinding dust is vacuumed up here. Hose for transporting grinding dust. Collection hose for transporting grinding dust. Valve Pre-separator that takes care of coarse grinding residue. The filter cyclone takes care of fine grinding dust. The air cannon/filter cleaner produces pulses of compressed air to clean the filter cyclone’s filter.
Page 50 GRINDING means that emptying takes place at short inter- vals. Pay attention to the level to which the Longopac bags below the cyclones are filled, so that they are replaced at the right time. Grinding Speed Main Power Warning HTC 2500 iX...
Page 51 CY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure. 1. Press the Main Power button OFF 2. Turn the key to the OFF position. Grinding Speed Main Power Warning HTC 2500 iX Grinding Speed Main Power Warning HTC 2500 iX...
Page 52 Operation After stopping engine ant for the correct antifreeze protection. The cooling system WARNING: Always let the engine cool before inspecting must be protected against freezing to the lowest expected outside temperature. If necessary, add the correct coolant/ the coolant level. Failure to do so can result in personal injury.
Page 53 Care and maintenance Cleaning the machine The grinding heads and their mechanical mountings can be washed and cleaned by thoroughly flushing them with water. The cab can be cleaned with water, but with the restriction that water must not penetrate via the moulding around the entrance door to the cab.
Page 54 Felkoder i kontrollpanel Frekvensomriktare: Felkod 0 - 14 Felkod: Visas i display: Förklaring: No fault Reserved [Control EEprom] Internal memory fault, control card. (EEF1) [Incorrect config] Option card changed or removed. Control card replaced by a control card configured on a (CFF) drive with a different rating.
Page 55 Felkoder i kontrollpanel Frekvensomriktare: Felkod 15 - 28 Felkod: Visas i display: Förklaring: [PTC1 overheat] Overheating of the PTC1 probes detected. (OtF1) [Drive overheat] Drive temperature too high. (OHF) [Motor overload] Triggered by excessive motor current. (OLF) [Overbraking] Braking too sudden or driving load. (ObF) [Mains overvoltage] Line voltage too high.
Page 56 Felkoder i kontrollpanel Frekvensomriktare: Felkod 29 - 42 Felkod: Visas i display: Förklaring: [Internal MFG area] Internal data inconsistent. (InF4) [Power EEprom] Internal memory fault, power card. (EEF2) [Impedant sh. circuit] Impedant short-circuit. (SCF2) [Ground short circuit] Ground short-circuit. (SCF3) [3 output phase loss] Motor not connected or motor power too low.
Page 57 Felkoder i kontrollpanel Frekvensomriktare: Felkod 43 - 56 Felkod: Visas i display: Förklaring: [Encoder coupling] Break in the mechanical coupling of the encoder. (ECF) [Torque/current lim] Switch to torque limitation. (SSF) [HMI com.] Fault communicating with the graphic display terminal. (SLF3) [Power removal] Fault with the drive’s Power removal safety function.
Page 58 Felkoder i kontrollpanel Frekvensomriktare: Felkod 57 - 70 Felkod: Visas i display: Förklaring: [Torque time-out] Torque control function time-out. (SrF) [Out. contact. stuck] The output contactor remains closed although the opening conditions have been met. (FCF1) [Out. contact. open.] The output contactor remains open although the closing conditions have been met. (FCF2) [Internal-time meas.] Fault on the electronic time measurement component.
Page 59 Felkoder i kontrollpanel Frekvensomriktare: Felkod 71 - 73 Felkod: Visas i display: Förklaring: [AI3 4-20 mA loss] Loss of the 4-20 mA reference on analog input AI3. (LFF3) [AI4 4-20 mA loss] Loss OF the 4-20 mA reference on analog input AI4. (LFF4) [Cards pairing] The [CARDS PAIRING] (PPI-) FUNCTION has been configured AND a drive card has...
Page 60 Control cabinet - AS1 Inst. Function: no.: Fuse – Frequency converter 4 Fuse – Frequency converter 5 Fuse - 24VDC unit AS4 11 12 13 Electrical socket 1 Electrical socket 2 Fuse – Terminal box 67 24 VDC FIN Fuse – Terminal box 69 24 VDC FIN Fuse –...
Page 61 Control cabinet - AS1 Inst. Function: Inst. Function: no.: no.: Residual current device – Transformer 1 Control RELAY K7 secondary Control RELAY K40, AS4 Residual current device – Transformer 2 Control RELAY secondary Control RELAY Contactor – Frequency converter 4 Control RELAY K2 Contactor –...
Page 62 Control cabinet - AS2 Inst. Function: no.: Inductance 1 Inductance 2 Inductance 3 Inductance 4 Inductance 5 Frequency converter 1 Frequency converter 2 Frequency converter 3 EMC Filter 1 EMC Filter 2 EMC Filter 3 EMC Filter 4 EMC Filter 5 Frequency converter 4 Frequency converter 5 Cooling element 1...
Page 63 Control cabinet - AS3 Inst. Function: no.: Relay, fuel pump Relay, fuel delay Relay, starter motor Relay, ignition Relay, headlight, roof Relay, fan, cab Relay, condenser, AC system Relay, fresh air fan Relay, Cab lighting Relay, radio mode PC, Radio, LCD, cam- eras CanOpen module Relay, RPM diesel engine...
Page 64 Control cabinet - AS4 Inst. Function: no.: Filter Contactor – actuator 1 Down Contactor – actuator 1 Up Contactor – actuator 2 Down Contactor – actuator 2 Up Contactor – actuator 3 Down Contactor – actuator 3 Up Fuse - 24VDC CanOpen Contactor - Cooling AS2 DC unit Relay, actuator DC unit Relay, actuator...
Page 65 Appendix 1 – Additions to manual for HTC 2500 iX Transportation of the machine The engine must not be in operation and the electrical system must be disconnected. A freight container is recommended for transporting the ma- • Remove the cover and top up the tank.
Page 66 Image 1...
Page 67 Appendix 2 – Maintenance intervals for HTC 2500 iX Daily 50h 500h 1,000h 2,000h 2 years 3,000h 4,000h Fan drive belts – Check / Adjustment / Replacement Coolant level – check Driving functions – check Engine air filter Engine oil – check Fuel filter –...
Page 70 HTC Sweden AB Box 69 SE-614 22 Söderköping - Sweden Tel: +46 (0) 121-294 00 Fax: +46 (0) 121-152 12 www.htc-sweden.com...
Page 71 HTC Sweden AB HTC 2500 IX Education Material November 2007 Professional Floor Systems...
Page 72 HTC Sweden AB Concept Description of HTC 2500 IX Short startup time Everything integrated Better working environment High Capacity Professional Floor Systems...
Page 73 HTC Sweden AB Fun facts of HTC 2500IX • The machine contains more wires than a normal house • The output is 105 kW, that is equal to 7 normal houses • The machine has a virtual waist that is computer controlled •...
Page 74 HTC Sweden AB Systems in the machine • Grinding system • Lift system • Air system • Power system • VAC system • Driving system • Control System • Water system • Engine system Professional Floor Systems...
Page 75 HTC Sweden AB Grinding system 950 Grinding heads • The grinding system i basically 3 HTC 950 units connected together • There are one inverter for each grinding head • The inverters are controlled via Control System the control system in the cabin •...
Page 76 HTC Sweden AB Lifting System Lifting Cylinders • The lift system is electrical (24V) and controlled from the cabin Pneumatic • Each cylinder is controlled System individually from the cabin Control System Power System 24 V Power Professional Floor Systems...
Page 77 HTC Sweden AB Air System Pressure Cylinders • Air system is controlled from the cabin Pneumatic • Air is used to start the VAC System through the pneumatic clutch • Air is used to unlock the heads Control System when lowering them •...
Page 78 HTC Sweden AB VAC System Security HEPA Valve Pump • The VAC system contains of 1 Filter 110DAP with 2 preseparators • Clean air is described as blue To Grinding heads lines while dirty air is dark olive green Valves Fiters &...
Page 79 HTC Sweden AB Water System Lifting Cylinders • The HTC 2500IX is equipped with the patented MIST system to improve the efficiency • The system is controlled from the cabin Water Tank Control System • The water level can be monitored...
Page 80 HTC Sweden AB Driving system Control System • Propulsion is made by 2 motors and are controlled by 2 inverters • Break resistors are connected to the inverters to enable the machine to drive in slopes (max Propulsion Motors 10 degrees in 2 minutes) •...
Page 81 HTC Sweden AB Power system • Power is generated by the generator located above the diesel engine Control System • Main power switch is located in Generator the cabin • Main power is protected by frequency and voltage relay’s •...
Page 82 HTC Sweden AB Engine system Control System • Diesel engine has a special air filter for dirty environments • The engine is equipped with a Diesel Engine System Diesel Tank Dinex particle filter that is turnable and cleanable and can be used for...
Page 83 HTC Sweden AB Control System Pneumatic System 12 V System • The machine is controlled from a computer located behind the touch screen in the cabin • The computer communicates with all other electronics through CAN Control System open bus network...
Page 84 HTC Sweden AB HTC 2500IX SAFETY INSTRUCTIONS November 2007 Professional Floor Systems...
Page 85 HTC Sweden AB Safety Instructions • The machine is equipped with a fire extinguisher in the cabin below the seat • The emergency break will break all electricity in the machine to all systems • DO NOT USE THE EMERGENCY BRAKE UNLESS IT’S ...
Page 86 HTC Sweden AB Safety Instructions 30 METERS • The machine has a safety area around it of 30 meters radius or in a safe area surrounded walls • The driver have limited control of the surrounding and no one is allowed to operate behind the machine or in it’s dead ...
Page 87 HTC Sweden AB Safety Instructions • As the machine has no mechanical brakes (it’s not a car) it’s vital that you do not drive the machines in slopes more than 120 seconds and more than 5.7 meters in height downhill – equal to 10 degrees •...
Page 88 HTC Sweden AB HTC 2500IX CONTROLS November 2007 Professional Floor Systems...
Page 89 HTC Sweden AB Cabin environment AC/FAN Control Sys. Fwd/Rew Steering Stereo Buttons Professional Floor Systems...
Page 90 HTC Sweden AB Cabin environment Control lights. Rew Camera Display Emergency Hammer Professional Floor Systems...
Page 91 HTC Sweden AB Starting the machine 1. Ensure that the main switch is turned on 2. The switch is located at the back behind the right cover at the bottom just beside the batteries Professional Floor Systems...
Page 92 HTC Sweden AB Starting the machine 1. Ensure that the EM-Stop is not pushed in, if so release it 2. Turn the key the full length to start the engine, do not stop half way as this will effect the control...
Page 93 HTC Sweden AB Starting the machine 1. Wait until the control display has started 2. When this is done the diesel engine will increase it’s speed 3. When this is done the yellow light goes on 4. Check that all switches and joysticks are in zero position 5.
Page 94 HTC Sweden AB Starting the machine 1. Wait until the control display has started 2. When this is done the diesel engine will increase it’s speed 3. When this is done the yellow light goes on 4. Check that all switches and joysticks are in zero position 5.
Page 95 HTC Sweden AB Handling the machine - driving 1. Check the joysticks – they got to be in their default center position if not the machine will start moving when you take the next step 2. You got to be seated to be able to...
Page 96 HTC Sweden AB Handling the machine - driving 1. The left joysticks controls the propulsion as shown at the picture 2. The right joystick controls the steering 3. When driving uphill, check the Operations Menu at the display for overload signs, if so decrease the...
Page 97 HTC Sweden AB Handling the machine - grinding 1. Make sure the tools are fastened to the grinding heads 2. Lower the heads by pulling the joysticks into forward position, the joystick should be positioned in forward position to enable the heads to float and this also enables you to start grinding.
Page 98 HTC Sweden AB Handling the machine - grinding 1. Start the Vac before you start grinding 2. When the switch is turned the clutch on the VAC is enabled 3. When the green light is turned on the VAC is ok...
Page 99 HTC Sweden AB Handling the machine - grinding 1. Before the grinding switch can be turned on the following steps has to done: 1. Steering has to be enabled 2. The grinding heads needs to be in floating position 2. Select the speed on the...
Page 100 HTC Sweden AB Planning your work • As the machine is bigger than a normal grinder it has to be driven in another pattern • The pattern is individual and must be adapted to the area that you work •...
Page 101 HTC Sweden AB Handling the machine – Control system – Service Menu • Mist and grinding pressure can be turned on before you start grinding, if so the light will turn yellow (stand by mode) and they will start working...
Page 102 HTC Sweden AB Handling the machine – Control system – Operations Menu • On the area for grinding you will see both frequency and power consumption. On this picture you also see the overload lights turned on. • The machine...
Page 103 HTC Sweden AB Handling the machine – Control system – Alarm Menu • This page shows alarms and error codes • You can also reset the inverter after overload • The inverter on/off section enables you to turn of each...
Page 104 HTC Sweden AB Handling the machine – Control system – CANopen Menu • This page shows the state of each CANopen unit • This page is only for support issues with HTC staff Professional Floor Systems...
Page 105 HTC Sweden AB Handling the machine – Emptying the VAC • The VAC has two different programs depending on the floor you grind, one for heavy with faster emptying cycle • If you want to empty the VAC manually you can...
Page 106 HTC Sweden AB Stopping the machine 1. Stop the propulsion by setting the joysticks into middle position 2. Turn of the grinding heads 3. Lift the heads from the ground 4. You can now drive the machine to a location where you want to park 5.
Page 107 HTC Sweden AB Stopping the machine 1. When the machine has stopped turn the main switch off to prevent the battery from getting discharged 2. This also prevents the motor from starting and it also prevents unauthorized use 3. If the machine is stored below 0...
Page 108 HTC Sweden AB HTC 2500IX SERVICE INSTRUCTIONS November 2007 Professional Floor Systems...
Page 109 HTC Sweden AB Service & Maintenance – Filling Diesel & Water 1. Make sure the machine is turned 2. Unscrew the cap and fill up 3. The level can be monitored inside the machine on the panel if ignition is on but the machine is turned off If Diesel of Category 2 &...
Page 110 HTC Sweden AB Service & Maintenance – Daily Control Schedule 1. Check the HEPA filter for the VAC system. If dust inside replace filter and check the other filters for leakage 2. Check oil level in diesel engine 3. Empty water in air system 4.
Page 111 HTC Sweden AB Service & Maintenance – Daily Control Schedule 1. Check the air filter for diesel and air system – clean if necessary and change if needed 2. Check oil level for VAC clutch valve 3. Check diesel run time watch for service maintenance 4.
Page 112 HTC Sweden AB Service & Maintenance – Daily Control Schedule 1. Check belt for motor generator and Air Condition and fans 2. Check cooling system level – the motor must not be hot or running! 3. Check water level in water separator for fuel system –...
Page 113 HTC Sweden AB Service & Maintenance – Diesel engine EVERY 500 hours EVERY 1000 hours • Test and refill cooling fluid in 1. Control tappet clearance, adjust motor EVERY 2000 hours • Air filter exchange 1. Control after cooler package •...
Page 114 HTC Sweden AB Service & Maintenance – Motor schematics 1. Engine Oil 2. Exhaust pipe 3. Generator 4. Turbo 5. Start motor 6. Turn wheel housing 7. Turn wheel (connected to belt for generator set) 8. Air intake Professional Floor Systems...
Page 115 HTC Sweden AB Service & Maintenance – Motor schematics 1. Valve cover 2. Crank case ventilator 3. Fuel filter 4. Fuel injection pump 5. Motor oil filter 6. Crank axel disc 7. Water pump 8. Fan wheel 9. Housing for water temp regulator...
Page 116 HTC Sweden AB HTC 2500IX TROUBLESHOOTING November 2007 Professional Floor Systems...
Page 117 HTC Sweden AB Troubleshooting – Power syst. Do not enter the electrical boxes when the machine is running! Fuses number 1 to 15 should always be on. Ground circuit brakers are number 17-22 and 25, 26 and 40-42 and should also always be on...
Page 118 HTC Sweden AB Troubleshooting – Inverter syst. Do not enter the electrical boxes when the machine is running! The inverters are placed in the following order from the bottom: 15. Right drive engine 14. Left drive engine 8. Right gridning head 7.
Page 119 HTC Sweden AB Troubleshooting – 12 V syst. Do not enter the electrical boxes when the machine is running! Contains relays and fuses. 14. Main fuse 15. Light fuse 16. Fuse maneuver 17. Fan A/C 18. Fresh air fan 19. Light inside cabin 20.
Page 120 HTC Sweden AB Troubleshooting – Inverter syst. Do not enter the electrical boxes when the machine is running! This box contains units for controling lifting system and 24V supply and cooling supply for Inverter system 8. Fuse for CANopen units...
Page 121 HTC Sweden AB Using the machines with 1 or 2 heads • In case of mechanical breakdown you can disable 1 or 2 grinding heads and continue working with the machine. To do this enter the alarm menu • Disable the left, center or right inverter.
Page 122 HTC Sweden AB Using the machine with 1 or 2 heads • Raise the head you have disabled until the green light turns on showing that the head is locked in the upright position and safe • When this is done the head is by-...
Page 123 HTC Sweden AB November 2007 E.W & KT Updated 2007-11-20 Professional Floor Systems...
Page 124 HTC Sweden AB Professional Floor Systems...
Page 125 SEBU7833-03 September 2008 Operation and Maintenance Manual 1103 and 1104 Industrial Engines DC (Engine) DD (Engine) DJ (Engine) DK (Engine) RE (Engine) RG (Engine) RJ (Engine) RR (Engine) RS (Engine) RT (Engine) DF (Engine) DG (Engine) This document is printed from SPI². Not for Resale.
Page 126 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Page 127 SEBU7833-03 Table of Contents Table of Contents Foreword ..............4 Safety Section Safety Messages ............ 5 General Hazard Information ........6 Burn Prevention ............7 Fire Prevention and Explosion Prevention ....8 Crushing Prevention and Cutting Prevention ..10 Mounting and Dismounting ........10 Before Starting Engine ..........
Page 128 SEBU7833-03 Foreword Foreword Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment Literature Information of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, This manual contains safety, operation instructions, dusty, wet or freezing cold operating conditions, lubrication and maintenance information.
Page 129 SEBU7833-03 Safety Section Safety Messages Safety Section i03299360 Safety Messages There may be several speciﬁc warning signs on an engine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiar with all warning signs.
Page 130 SEBU7833-03 Safety Section General Hazard Information i02328435 General Hazard Information g01682820 Illustration 3 The ether warning label (2) is located on the cover of the inlet manifold. Refer to illustration 4. g00104545 Illustration 5 Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.
Page 131 SEBU7833-03 Safety Section Burn Prevention Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs. Perform maintenance on the engine with the equipment in the servicing position.
Page 132 SEBU7833-03 Safety Section Fire Prevention and Explosion Prevention Coolant All fuels, most lubricants, and some coolant mixtures are ﬂammable. When the engine is at operating temperature, the engine coolant is hot. The coolant is also under Flammable ﬂuids that are leaking or spilled onto hot pressure.
Page 133 SEBU7833-03 Safety Section Fire Prevention and Explosion Prevention Arcing or sparking could cause a ﬁre. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking. Inspect all lines and hoses for wear or for deterioration.
Page 134 SEBU7833-03 Safety Section Crushing Prevention and Cutting Prevention Repair any lines that are loose or damaged. Leaks i01372247 can cause ﬁres. Consult your Perkins dealer or your Mounting and Dismounting Perkins distributor for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks.
Page 135 SEBU7833-03 Safety Section Engine Starting Do not bypass the automatic shutoff circuits. Do not Note: The engine is equipped with an automatic disable the automatic shutoff circuits. The circuits are device for cold starting for normal conditions of provided in order to help prevent personal injury. The operation.
Page 136 SEBU7833-03 Safety Section Electrical System Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for speciﬁc starting instructions.
Page 137 SEBU7833-03 Product Information Section Model Views Product Information Section Model Views i01928892 Model View Illustrations 1104 Engine Model Views g01012280 Illustration 11 (1) Valve mechanism cover (4) Fuel injection pump (7) Water pump (2) Crankcase breather (5) Engine oil ﬁlter (8) Fan pulley (3) Fuel ﬁlter (6) Crankshaft pulley...
Page 138 SEBU7833-03 Product Information Section Model Views g01012281 Illustration 12 (1) Oil ﬁller cap (4) Turbocharger (7) Flywheel (2) Exhaust manifold (5) Starter motor (8) Air intake (3) Alternator (6) Flywheel housing This document is printed from SPI². Not for Resale.
Page 139 SEBU7833-03 Product Information Section Model Views 1103 Engine Model Views g01011348 Illustration 13 (3) Turbocharger oil supply (1) Alternator (5) Turbocharger (2) Fan pulley (4) Turbocharger oil drain (6) exhaust manifold This document is printed from SPI². Not for Resale.
Page 140 SEBU7833-03 Product Information Section Model Views g01011349 Illustration 14 (1) Fuel transfer pump (5) Dipstick (9) Water pump (2) Oil ﬁller cap (6) Oil ﬁlter (10) Water temperature regulator housing (3) Fuel ﬁlter (7) Oil pan (4) Starter motor (8) Crankshaft pulley •...
Page 141 SEBU7833-03 Product Information Section Model Views Table 2 1103 Industrial Engine Speciﬁcations Number of Cylinders 3 In-Line Bore 105 mm (4.134 inch) Stroke 127 mm (5.0 inch) Aspiration Turbocharged Naturally aspirated Compression Ratio NA 19.25:1 T 18.25:1 Displacement 3.3 L (201 in Firing Order 1 2 3 g00984281...
Page 142 SEBU7833-03 Product Information Section Model Views Engine Service Life Table 4 1103 Genset Speciﬁcations Engine efﬁciency and maximum utilization of engine Number of Cylinders 3 In-Line performance depend on the adherence to proper operation and maintenance recommendations. In Bore 105 mm (4.134 inch) addition, use recommended fuels, coolants and lubricants.
Page 143 SEBU7833-03 Product Information Section Product Identiﬁcation Information Product Identiﬁcation i01940474 Serial Number Plate Information i02280116 Engine Identiﬁcation Perkins engines are identiﬁed by a serial number. This number is shown on a serial number plate that is mounted on the left hand side of the engine block. An example of an engine number is RE12345U090001H.
Page 144 SEBU7833-03 Product Information Section Product Identiﬁcation Information Engine Full Load rpm _________ ____________________________ Primary Fuel Filter _________ ________________________________ Water Separator Element _________ _______________________ Secondary Fuel Filter Element _________ _________________ Lubrication Oil Filter Element _________ __________________ Auxiliary Oil Filter Element _________ ______________________ Total Lubrication System Capacity _________ ____________ Total Cooling System Capacity...
Page 145 SEBU7833-03 Product Information Section Product Identiﬁcation Information g01173630 Illustration 17 This typical example of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic fuel injection pumps. g01156733 Illustration 18 This typical example of a label is installed on engines that have mechanical fuel injection pumps. This document is printed from SPI².
Page 146 SEBU7833-03 Product Information Section Product Identiﬁcation Information Label for engines that comply with MSHA emissions g01381316 Illustration 19 Typical example The label that is shown in illustration 19 is for engines that operate in underground coal mines in North America. The label is installed on engines that comply with the Mine Safety and Health Administration (MSHA) emissions.
Page 147 SEBU7833-03 Product Information Section Product Identiﬁcation Information g01157127 Illustration 21 This typical example of a label is installed on engines that are stationary engines. This document is printed from SPI². Not for Resale.
Page 148 SEBU7833-03 Operation Section Lifting and Storage Operation Section Some removals require lifting the ﬁxtures in order to obtain correct balance and safety. To remove the engine ONLY, use the lifting eyes that Lifting and Storage are on the engine. Lifting eyes are designed and installed for speciﬁc engine arrangements.
Page 149 SEBU7833-03 Operation Section Lifting and Storage • Renew the canister(s) of the lubricating oil ﬁlter. 4. Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator. • Fill the oil pan to the Full Mark on the dipstick If the radiator does not have a tap or a drain plug, with new, clean lubricating oil.
Page 150 SEBU7833-03 Operation Section Lifting and Storage General Items • If the lubricating oil ﬁller is installed on the rocker cover, remove the ﬁller cap. If the lubricating oil ﬁller cap is not installed on the rocker cover, remove the rocker cover. Spray 1762811 POWERPART Lay-Up 2 around the rocker shaft assembly.
Page 151 SEBU7833-03 Operation Section Gauges and Indicators Gauges and Indicators 1. Reduce the load and the engine rpm. 2. Inspect the cooling system for leaks. i02164190 3. Determine if the engine must be shut down Gauges and Indicators immediately or if the engine can be cooled by reducing the load.
Page 152 SEBU7833-03 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. i02194223 Before Starting Engine •...
Page 153 SEBU7833-03 Operation Section Engine Starting When Group 2 diesel fuel is used, the following items i02198348 provide a means of minimizing starting problems Starting the Engine and fuel problems in cold weather: engine oil pan heaters, jacket water heaters, fuel heaters, and fuel line insulation.
Page 154 SEBU7833-03 Operation Section Engine Starting 3. Connect one negative end of the jump start cable i02177935 to the negative cable terminal of the electrical Starting with Jump Start source. Connect the other negative end of the Cables jump start cable to the engine block or to the chassis ground.
Page 155 SEBU7833-03 Operation Section Engine Operation Engine Operation i02330149 Fuel Conservation Practices i02176671 Engine Operation The efﬁciency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efﬁciency in all applications. Follow the recommended procedures Correct operation and maintenance are key factors in order to attain optimum performance for the life in obtaining the maximum life and economy of...
Page 156 SEBU7833-03 Operation Section Engine Stopping Engine Stopping i01903608 After Stopping Engine i01929389 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE •...
Page 157 SEBU7833-03 Operation Section Cold Weather Operation Cold Weather Operation • Install the correct speciﬁcation of engine lubricant before the beginning of cold weather. • Check all rubber parts (hoses, fan drive belts, etc) i02717265 weekly. Cold Weather Operation • Check all electrical wiring and connections for any fraying or damaged insulation.
Page 158 SEBU7833-03 Operation Section Cold Weather Operation • In cold weather, check the coolant often for the Free operation of the valves is prevented. correct glycol concentration in order to ensure • adequate freeze protection. Valves become stuck. • Pushrods may become bent. Engine Block Heaters •...
Page 159 SEBU7833-03 Operation Section Cold Weather Operation A cab heater is beneﬁcial in very cold weather. The When Group 2 diesel fuels are used the following feed from the engine and the return lines from the components provide a means of minimizing problems cab should be insulated in order to reduce heat loss in cold weather: to the outside air.
Page 160 SEBU7833-03 Operation Section Cold Weather Operation i01903588 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially ﬁlled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.
Page 161 SEBU7833-03 Maintenance Section Reﬁll Capacities Maintenance Section Cooling System To maintain the cooling system, the Total Cooling System capacity must be known. The approximate Reﬁll Capacities capacity for the engine cooling system is listed below. External System capacities will vary among applications.
Page 162 SEBU7833-03 Maintenance Section Reﬁll Capacities 1103 Engine API Oils Table 9 The Engine Oil Licensing and Certiﬁcation System by the American Petroleum Institute (API) is recognized 1103 Naturally Aspirated Engine without an oil cooler by Perkins. For detailed information about this Compartment or System Liters Quarts...
Page 163 SEBU7833-03 Maintenance Section Reﬁll Capacities Engine Oil DHD-1 oils are recommended for use in extended oil change interval programs that optimize the life of the oil. These oil change interval programs are based Commercial Oils on oil analysis. DHD-1 oils are recommended for conditions that demand a premium oil.
Page 164 SEBU7833-03 Maintenance Section Reﬁll Capacities Table 12 NOTICE Percentage of Sulfur in Oil change interval Failure to follow these oil recommendations can cause the fuel shortened engine service life due to deposits and/or Lower than 0.5 Normal excessive wear. 0.5 to 1.0 0.75 of normal Total Base Number (TBN) and Fuel Sulfur Greater than 1.0...
Page 165 SEBU7833-03 Maintenance Section Reﬁll Capacities Some synthetic base oils have performance characteristics that enhance the service life of the NOTICE oil. Perkins does not recommend the automatic Shortened engine service life could result if second extending of the oil change intervals for any type of choice oils are used.
Page 166 SEBU7833-03 Maintenance Section Reﬁll Capacities • The Wear Rate Analysis monitors the wear of the High sulfur content of the fuel is not normally found engine’s metals. The amount of wear metal and in Europe, North America or Australasia. This can type of wear metal that is in the oil is analyzed.
Page 167 SEBU7833-03 Maintenance Section Reﬁll Capacities “ASTM D975 - 91 Class 1D” The preferred fuels provide maximum engine service life and performance. The preferred fuels are distillate “JP7, Mil T38219” fuels. These fuels are commonly called diesel fuel or gas oil. “NATO F63”...
Page 168 SEBU7833-03 Maintenance Section Reﬁll Capacities (Table 14, contd) NOTICE Copper Strip No. 3 maximum “D130” Operating with fuels that do not meet the Perkins rec- Corrosion ommendations can cause the following effects: Start- 10% at 282 °C ing difﬁculty, poor combustion, deposits in the fuel in- (540 °F) jectors, reduced service life of the fuel system, de- maximum...
Page 169 SEBU7833-03 Maintenance Section Reﬁll Capacities Cooling System Speciﬁcations DO NOT use the following types of water in cooling systems: Hard water, softened water that has been conditioned with salt, and sea water. General Coolant Information If distilled water or deionized water is not available, NOTICE use water with the properties that are listed in Table Never add coolant to an overheated engine.
Page 170 SEBU7833-03 Maintenance Section Reﬁll Capacities Glycol Acceptable – A commercial heavy-duty coolant/antifreeze that meets “ASTM D4985” Glycol in the coolant helps to provide protection speciﬁcations against the following conditions: NOTICE • Boiling Do not use a commercial coolant/antifreeze that on- ly meets the ASTM D3306 speciﬁcation.
Page 171 SEBU7833-03 Maintenance Section Reﬁll Capacities • Heavy-duty diesel engines NOTICE • Automotive applications Do not use a conventional coolant to top-off a cooling system that is ﬁlled with Extended Life Coolant (ELC). The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants.
Page 172 SEBU7833-03 Maintenance Section Reﬁll Capacities ELC Cooling System Cleaning NOTICE Note: If the cooling system is already using ELC, Incorrect or incomplete ﬂushing of the cooling system cleaning agents are not required to be used at can result in damage to copper and other metal com- the speciﬁed coolant change interval.
Page 173 SEBU7833-03 Maintenance Section Reﬁll Capacities Commercial Heavy-Duty Coolant/ Table 24 is an example for using the equation that is in Table 23. Antifreeze and SCA Table 24 NOTICE Example Of The Equation For Adding The SCA To Commercial Heavy-Duty Coolant which contains The Heavy-Duty Coolant At The Initial Fill Amine as part of the corrision protection system must not be used.
Page 174 SEBU7833-03 Maintenance Section Reﬁll Capacities Cleaning the System of Heavy-Duty Coolant/Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge. •...
Page 175 SEBU7833-03 Maintenance Section Maintenance Interval Schedule Every 2 Years i03302982 Maintenance Interval Schedule Cooling System Coolant - Change ....... 58 Every 3000 Service Hours Fuel Injector - Test/Change ........68 When Required Battery - Replace ..........54 Every 3000 Service Hours or 2 Years Battery or Battery Cable - Disconnect ....
Page 176 SEBU7833-03 Maintenance Section Aftercooler Core - Clean/Test i02322260 Aftercooler Core - Clean/Test Personal injury can result from air pressure. Personal injury can result without following prop- er procedure. When using pressure air, wear a pro- 1. Remove the core. Refer to the OEM information tective face shield and protective clothing.
Page 177 SEBU7833-03 Maintenance Section Alternator - Inspect After cleaning, start the engine and accelerate the For applications that require multiple drive belts, engine to high idle rpm. This will help in the removal replace the belts in matched sets. Replacing only of debris and drying of the core.
Page 178 SEBU7833-03 Maintenance Section Battery - Replace 2. Move the alternator in order to increase or 5. Remove the used battery. decrease the belt tension. Tighten the alternator pivot bolt and the link bolt to 22 N·m (16 lb ft).(1). 6. Install the new battery. Note: Before the cables are connected, ensure that Replacement the engine start switch is OFF.
Page 179 SEBU7833-03 Maintenance Section Battery or Battery Cable - Disconnect i02323088 i02203590 Battery or Battery Cable - Cooling System Coolant Disconnect (Commercial Heavy-Duty) - Change NOTICE The battery cables or the batteries should not be Care must be taken to ensure that ﬂuids are contained removed with the battery cover in place.
Page 180 SEBU7833-03 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change 1. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool. Loosen the cooling system ﬁller cap slowly in Loosen the cooling system ﬁller cap slowly in order to relieve any pressure.
Page 181 SEBU7833-03 Maintenance Section Cooling System Coolant (ELC) - Change 1. Stop the engine and allow the engine to cool. i02203595 Loosen the cooling system ﬁller cap slowly in Cooling System Coolant (ELC) order to relieve any pressure. Remove the cooling - Change system ﬁller cap.
Page 182 SEBU7833-03 Maintenance Section Cooling System Coolant - Change 5. Stop the engine and allow the engine to cool. i01929799 Loosen the cooling system ﬁller cap slowly in Cooling System Coolant - order to relieve any pressure. Remove the cooling Change system ﬁller cap.
Page 183 SEBU7833-03 Maintenance Section Cooling System Coolant Extender (ELC) - Add 1. Observe the coolant level in the coolant recovery i02335364 tank. Maintain the coolant level to “COLD FULL” Cooling System Coolant mark on the coolant recovery tank. Extender (ELC) - Add Pressurized System: Hot coolant can cause seri- The Perkins Extended Life Coolant (ELC) does not ous burns.
Page 184 SEBU7833-03 Maintenance Section Driven Equipment - Check • Lubrication • Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM. i01930350 Engine - Clean g00285520 Illustration 32 Personal injury or death can result from high volt- Cooling system ﬁller cap age.
Page 185 SEBU7833-03 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Dual Element Air Cleaners i01915869 Engine Air Cleaner Element The dual element air cleaner contains a primary air (Dual Element) - Clean/Replace cleaner element and a secondary air cleaner element. The primary air cleaner element can be used up to six times if the element is properly cleaned and properly inspected.
Page 186 SEBU7833-03 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Cleaning the Primary Air Cleaner Elements NOTICE Observe the following guidelines if you attempt to clean the ﬁlter element: Do not tap or strike the ﬁlter element in order to re- move dust.
Page 187 SEBU7833-03 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Inspect the clean, dry primary air cleaner element. Some engines are equipped with a differential gauge Use a 60 watt blue light in a dark room or in a similar for inlet air pressure.
Page 188 SEBU7833-03 Maintenance Section Engine Ground - Inspect/Clean i01941505 Engine Ground - Inspect/Clean Inspect the wiring harness for good connections. Perkins use the starter motor in order to ground the engine. Check the connection on the starter motor at every oil change. Ground wires and straps should be combined at engine grounds.
Page 189 SEBU7833-03 Maintenance Section Engine Oil and Filter - Change Perkins recommends using a sampling valve in order i01929323 to obtain oil samples. The quality and the consistency Engine Oil and Filter - Change of the samples are better when a sampling valve is used.
Page 190 SEBU7833-03 Maintenance Section Engine Oil and Filter - Change After the oil has drained, the oil drain plugs should be cleaned and installed. If necessary, renew the O ring seal on the drain plug. Some types of oil pans have oil drain plugs that are on both sides of the oil pan, because of the shape of the pan.
Page 191 SEBU7833-03 Maintenance Section Engine Valve Lash - Inspect/Adjust 2. Locate a suitable wrench into the square hole (2) in order to remove the ﬁlter bowl (3). NOTICE To prevent crankshaft bearing damage, crank the en- 3. Remove the ﬁlter bowl (3) and remove the element gine with the fuel OFF.
Page 192 SEBU7833-03 Maintenance Section Fuel Injector - Test/Change Ensure that the engine can not be started while this maintenance is being performed. To help pre- vent possible injury, do not use the starting motor to turn the ﬂywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before mea- suring/adjusting valve lash clearance.
Page 193 SEBU7833-03 Maintenance Section Fuel System - Prime Removal and Installation of the Use the following procedure in order to remove air from the fuel system: Fuel Injectors 1. Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly. 2.
Page 194 SEBU7833-03 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 2. Place a suitable container under the water i02206563 separator. Clean the outside of the water Fuel System Primary Filter separator. (Water Separator) Element - 3. Open the drain (5). Allow the ﬂuid to drain into Replace the container.
Page 195 SEBU7833-03 Maintenance Section Fuel System Secondary Filter - Replace NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over discon- nected fuel system component. Element ﬁlter Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance.
Page 196 SEBU7833-03 Maintenance Section Fuel System Secondary Filter - Replace g01010595 Illustration 48 (3) O ring seal (4) Element (5) Filter head 3. Remove the ﬁlter bowl (2) from the ﬁlter head (5). Press on the element (4). Rotate the element g01121396 counterclockwise in order to release the element Illustration 49...
Page 197 SEBU7833-03 Maintenance Section Fuel Tank Water and Sediment - Drain Water can be introduced into the fuel tank when the fuel tank is being ﬁlled. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank.
Page 198 SEBU7833-03 Maintenance Section Hoses and Clamps - Inspect/Replace • Anticipated expansion and contraction of the hose i02813964 Hoses and Clamps - • Anticipated expansion and contraction of the Inspect/Replace ﬁttings Replace the Hoses and the Clamps Inspect all hoses for leaks that are caused by the Refer to the OEM information for further information following conditions: on removing and replacing fuel hoses (if equipped).
Page 199 SEBU7833-03 Maintenance Section Radiator - Clean Inspect the ﬁns for damage. Bent ﬁns may be opened i02335774 with a “comb”. Inspect these items for good condition: Radiator - Clean Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary. The radiator is not usually supplied by Perkins.
Page 200 SEBU7833-03 Maintenance Section Starting Motor - Inspect Environmental Factors Check the starting motor for correct operation. Check the electrical connections and clean the electrical Ambient temperatures – The engine may be connections. Refer to the Systems Operation, Testing exposed to extended operation in extremely and Adjusting Manual, “Electric Starting System - cold environments or hot environments.
Page 201 SEBU7833-03 Maintenance Section Walk-Around Inspection • For options regarding the removal, installation, and The guards must be in the correct place. Repair replacement, consult your Perkins dealer or your damaged guards or replace missing guards. Perkins distributor. Refer to the Disassembly and •...
Page 202 SEBU7833-03 Maintenance Section Water Pump - Inspect Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.
Page 203 SEBU7833-03 Warranty Section Warranty Information Warranty Section Warranty Information i01903596 Emissions Warranty Information This engine may be certiﬁed to comply with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture, and this engine may be covered by an Emissions Warranty.
Page 204 SEBU7833-03 Index Section Index Electrical System ............ 11 After Starting Engine ..........30 After Stopping Engine..........32 Grounding Practices .......... 12 Aftercooler Core - Clean/Test ........ 52 Emergency Stopping ..........32 Aftercooler Core - Inspect........52 Emissions Certiﬁcation Film ........20 Alternator - Inspect ..........
Page 205 SEBU7833-03 Index Section Fluid Recommendations........38 Cooling System Speciﬁcations......45 ELC Cooling System Maintenance ....47 Maintenance Interval Schedule ......51 Engine Oil ............39 Maintenance Section ..........37 Fuel Speciﬁcations..........42 Model View Illustrations......... 13 General Lubricant Information ......38 1103 Engine Model Views........
Page 206 SEBU7833-03 Index Section Walk-Around Inspection ........77 Inspect the Engine for Leaks and for Loose Connections ............. 77 Warranty Information ..........79 Warranty Section ........... 79 Water Pump - Inspect..........78 This document is printed from SPI². Not for Resale.
Page 207 Product and Dealer Information Note: For product identiﬁcation plate locations, see the section “Product Identiﬁcation Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identiﬁcation Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...
Page 208 Copyright © 2008 Perkins Engines Company Limited Printed in U.K. All Rights Reserved This document is printed from SPI². Not for Resale.
Page 209 Proposal for the supply of DPX Catalysed Soot Filters for ………… Quotation No.: ……… Customer: Date: …………. Manufacturer Application Engineering & Distribution Engelhard Technologies Ltd. Krone GmbH Crucible Close Herbert-Ludwig-Str.14 Coleford, GL 16 8RD D-28832 Achim Tel.:+(49)04202-9769-20 Fax:+49(0)4202-9769-11 e-mail: info@krone-filter.de official representation of: DPX01-Standard Vorlage Englisch.doc Seite 1 von 8...
Page 210 cope of Supply This proposal applies to the supply of the DPX™ Catalysed Soot Filter for use on …………………. (Euro ……) Engines powered by Diesel Fuel with a maximum content of 350 ppm Sulphur level. The target is to reach EURO 3 standards in terms of Particulate Matter (PM), CO &...
Page 211 The catalyst coating on the Filter element effectively lowers the ,,Light Off" temperature at which soot particles will combust. Therefore it promotes continuous and automatic regeneration of the soot particles that have been collected within the filter element. The DPX Catalysed Soot Filter System does not require the use of fuel additives, burners or additional power sources and has no moving parts.
Page 212 Cleaning and Maintenance The cleaning procedure for DPX units must be followed to ensure proper operation and durability. Failure to follow this procedure may void the warranty. The DPX unit must be cleaned annually, every 1000 hours, according to the following procedure.
Page 213 Pricing & Delivery Prices given below are based upon the following Filter Sizing: Catalysed Wall Flow Filter : ∅ ….” x ……” Calculated Exhaust Back Pressure (as fresh) : < …..mbar (…..” w.c.) Dimensions : see page 8 Terms: Prices given are in EURO, FOB Achim, excluding freight, taxes, duties, insurance or any other additional cost.
Page 214 Product References Engelhard is the world wide leading company for automotive catalysts. In the field of industrial exhaust abatement Engelhard’s PTX™ Catalyst made it’s name in the industry with more than 500.000 catalysts sold. Gaining from this experience the innovative and patented coating technology of the DPX Catalysed Soot Filter is State of the Art for particulate traps at the moment and is permanently improved.
Page 215 PM Conversions: > 90% Exhaust Temperature 200 - 400° C Emission-Reduction Emission Reduction in the US Transient Cycle official representation of: DPX01-Standard Vorlage Englisch.doc Seite 7 von 8...
Page 216 Dimensions DPX Model Monolith-Dim. Ø A Ø B DPX 9056 Ø 5.66“ x 6.0“ 76.2 mm 162 mm 356 mm DPX 8939 Ø 7.5“ x 8.0“ 76.2 mm 223 mm 440 mm DPX 8944 Ø 7.5“ x 12.0“ 76.2 mm 223 mm 540 mm DPX 8945...
Page 217 FG Wilson WARRANTY Statement This is a warranty which applies to Electric The User’s Responsibilities The costs and risks for transport/shipping Power Generation Products sold by FG Wilson and other charges associated with the (herein after referred to as “the Company”). The User is responsible for: replacement of the repair parts.
Page 218 www.FGWilson.com P110-2 Image for illustration purposes only. Output Ratings Ratings and Performance Data Generating Set Model Prime* Standby* Engine Make & Model: Perkins 1104C-44TAG2 Alternator manufactured for 380-415V,50Hz 100.0 kVA 80.0 kW 110.0 kVA 88.0 kW Leroy Somer FG Wilson by: 480V, 60 Hz 113.0 kVA 90.4 kW...
Page 219 Engine Technical Data Air Systems 50 Hz 60 Hz No. of Cylinders / Alignment: 4 / In Line Air Filter Type: Replaceable Element Combustion Air Flow: Cycle: 4 Stroke m³ min (cfm) Bore / Stroke: 105.0 (4.1)/127.0 (5.0) - Prime 6.0 (212) 7.8 (274) mm (in)
Page 220 Alternator Physical Data Alternator Operating Data Manufactured for FG Wilson by: Leroy Somer Overspeed: 2250 Model: LL3014B Voltage Reguation: +/- 0.5 (Steady state) No. of Bearings: Wave Form NEMA = TIF: Insulation Class: Wave Form IEC = THF: 2.0% Winding Pitch Code: 2/3 - 6 Total Harmonic content LL/LN: 4.0%...
Page 221 General Information Documentation A full set of operation and maintenance manuals and circuit wiring diagrams. Generating Set Standards The equipment meets the following standards: BS5000, ISO 8528, ISO 3046, IEC 60034, NEMA MG-1.22. FG Wilson is a fully accredited ISO 9001 company. EU Stage II Emissions Compliant.
Page 222 Generator set oPerator and Maintenance instruction ManuaL This manual has been designed as a guide to operators to aid in starting, stopping and otherwise operating the generator set. Issue Number: 06/12 Part Number: 356-5901 Language: English Revision ORIGINAL INSTRUCTIONS...
Page 223 356-5901(GB)
Page 224 CONTeNTS INTRODUCTION SAFeTY General ....................................7 2.1.1 Emergency Stop Button ...............................7 Personal Protective Equipment ............................7 General Hazard Information .............................8 2.3.1 Pressurized Air and Water ............................8 2.3.2 Containing Fluid Spillage ............................8 2.3.3 Lines, Tubes and Hoses ..............................8 2.3.4 Disposal of Waste................................9 Fire and Explosion ................................9 2.4.1 Fire Extinguisher ................................9 Exhaust Gases ..................................10 Mechanical ....................................10...
Page 225 CONTROL SYSTeM DeSCRIPTION AND TROUBLe SHOOTING Control System Description ............................26 1002T and LCP1002 (Quickstart) ............................26 5.2.1 Control Panel Instrumentation ..........................26 5.2.2 General Information1002T / LCP1002 Control Systems ................28 5.2.3 Pre-Start Checks ................................28 5.2.4 Normal Startup / Shutdown – Key Start Panel (1002T / LCP1002 ) ............29 5.2.5 Control System Fault Finding / Trouble Shooting Guide 1002T / LCP1002 ...........
Page 226 Control System Options and Upgrades ........................55 5.6.1 Battery Trickle / Switch-Mode Chargers ......................55 5.6.2 Heaters ................................... 55 5.6.3 Electric Fuel Transfer Pumps ............................ 55 5.6.4 Meters / Gauges ................................56 5.6.5 Speed / Voltage Control ......................................... 56 5.6.6 Alarm Signalling ................................56 5.6.7 Automatic Preheat Control ............................
Page 227 1. introduction Thank you for choosing our company to supply your electrical power needs. In line with our policy of continuous product improvement, we reserve the right to change the information contained within this manual without notice. This Operator Instruction Manual has been designed to help you operate and maintain your electrical generator set correctly. We recommend that the operator should take the time to read this manual.
Page 228 2. saFetY 2.1 General The generator set is designed to be safe when used in the correct manner. Responsibility for safety, however, rests with the personnel who use the set. Before performing any procedure or operating technique, it is the user’s responsibility to ensure that it is safe to do so.
Page 229 • Ensure that all protective guards and all covers are secured in place on the engine. • Never put maintenance fluids into glass containers. Glass containers can break. • Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: •...
Page 230 2.3.4 Disposal of Waste Improper disposal of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. 2.4 Fire and explosion All fuels, most lubricants, and some coolant mixtures are flammable.
Page 231 2.5 exhaust Gases Always start and operate the engine in a well-ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside. Warning engine exhaust contains products of combustion which may be harmful to your health. 2.6 Mechanical The generator set is designed with guards for protection from moving parts.
Page 232 2.8 Noise Sound levels will vary depending on the configuration of the generator set and the final installation of the generator set. Refer to the following for factors that influence the level of exposure: • The characteristics of the area around the generator set •...
Page 233 IF NO BReATHING BUT PULSe IS PReSeNT: Pinch the victim’s nose firmly. Take a deep breath and seal your lips around the victim’s lips. Blow slowly into the mouth watching for the chest to rise. Let the chest fall completely. Give breaths at a rate of 10 per minute.
Page 234 2.11 HAZARD LABeL LeGeND - (6.8 – 275 kVA range) Ensure that all of the safety messages are legible. Clean the safety messages or replace them if the words cannot be read or if the illustrations are not visible. Use a cloth, water and soap to clean the safety messages. Do not use solvents, gasoline, or other harsh chemicals as these could loosen the adhesive that secures the safety messages.
Page 235 HAZARD LABeL LeGeND - (350 – 2500 kVA range) Use Fan Guards Electric Shock Hazard Low Overhead Objects Hot Exhaust Gas Do Not Tamper With Unless You Have Read The Instruction Manual Rated Speed Diesel Fuel Line Supply No Naked Flames Emergency / Panic Exit Wear Ear Protection Diesel Fuel Warning...
Page 236 3. GeneraL descriPtion This generator set has been designed as a complete package to provide superior performance and reliability. Each generator set is provided with a Rating Plate generally affixed to the alternator housing / panel enclosure. This label contains the information needed to identify the generator set and its operating characteristics. This information includes, but is not limited to, the model and serial numbers, output characteristics such as voltage, phase and frequency, output rating in kVA and kW and rating type (basis of the rating).
Page 237 3.2 Generator set Description 356-5901(GB)
Page 238 3.3 Generator set Description (26 – 200 kVA Range) 356-5901(GB)
Page 239 4. instaLLation, HandLinG and storaGe 4.1 General This section discusses factors important in the effective and safe installation of the generator set. Selecting a location for the generator set can be the most important part of any installation procedure. The following factors are important in determining the location: •...
Page 240 4.2 Outdoor Installation Installation and handling is greatly simplified when the generator set has been equipped with an enclosure. Two basic types may be fitted. The first type is a close fitting canopy enclosure. This will be both weatherproof and sound attenuated. The other enclosure type is a walk-in type container, similar to a shipping container.
Page 241 4.2.1 Positioning of Walk-in Containers Proper installation of the container is required if successful generation of power is to be achieved. The following information must be considered in the selection of the operating site for the container. The containerised generator set must be placed on a flat surface in order to maintain proper alignment.
Page 242 1 - Forklift Pockets 2 - Oil FIeld Skid Figure 4e – Typical generator set with Oil Field Skid base option If the generator set will be regularly moved, it should be fitted with the optional Oil Field Skid which provides forklift pockets in the base frame along with eyes for pulling.
Page 243 1 - Two Point Lift (455 – 625 kVA Product) Figure 4g – Two Point lift Warning Centre of gravity decal is located on the base / canopy of the generator set. The centre of gravity may not always be located at the centre of the generator set. Do not attempt to lift in high winds.
Page 244 4.3.1 Approved Lifting Methods for ISO Walk in Containers Containers are manufactured to ISO dimensions, ISO 1496–4:1994(E) and ISO 668:1995(E). To ensure the safety of all personnel involved with the handling of containers, it is important that the correct lifting and handling procedures are employed. The procedures detailed below are derived from ISO 3874:1997(E) and must be followed at all times.
Page 245 4.4 Foundations and Vibration Isolation The generator set is supplied on a rigid base frame that precisely aligns the alternator and engine and needs only be bolted down to a suitably prepared surface. 1. Vibration Isolators 2. Flexible Exhaust Coupling 3.
Page 246 4.5 Storage Long term storage can have detrimental effects on both the engine and alternator. These effects can be minimised by properly preparing and storing the generator set. 4.5.1 engine Storage The engine should be put through an engine “preservation” procedure that includes cleaning the engine and replacing all the fluids with new or preserving fluids.
Page 247 5. controL sYsteM descriPtion and trouBLe sHootinG 5.1 Control System Description An electronic control system has been designed and installed to control and monitor the generator set. Depending on the requirements of the generator set, one of several different standard control systems may be fitted. Other more specialised systems may be fitted for specific installations in which case separate documentation is provided.
Page 248 AC VOLTMETER – indicates the AC voltage generated at the alternator output terminals. The reading indicated on the voltmeter will vary depending on the position of the voltmeter selector switch (item 2). It should not, however, vary while the generator set is operating. If the meter gives no reading while the generator set is running, ensure that the AC voltmeter selector switch is not in the OFF position.
Page 249 5.2.2 General Information1002T / LCP1002 Control Systems Figure 5c – 1002T & LCP1002 Control Systems Controller version is dictated by product configuration, a 1002T or LCP1002 panel may be fitted. Both control systems provide for manual starting and stopping of the generator set and provide protection for the engine against critical failures. 5.2.3 Pre-Start Checks Warning The following checks detailed below are the only tasks that an operator should undertake.
Page 250 Warning Before tightening the fan belts, disconnect the battery negative (–) lead to ensure the engine cannot be accidentally started. Check the condition and tension of the fan and engine alternator belts – tighten as necessary. Check all hoses for loose connections or deterioration – tighten or replace as necessary. Check the battery terminals for corrosion –...
Page 251 Note: • Load can now be applied to the generator set. However, the maximum step load that can be accepted in any one step is dependent on the operating temperature of the generator set. SHUTDOWN: To shut the generator set down, turn off the load by switching the Alternator Output Circuit Breaker to “OFF” (handle down). Allow the generator set to run without load for a few minutes to cool.
Page 252 5.3 PowerWizard 1.0 & 2.0 (Quickstart) 5.3.1 General Information Figure 5d – PowerWizard Control System Panel The controller is available in two versions, PowerWizard 1.0 and PowerWizard 2.0. These two versions are based on different features. This guide is intended to cover the PowerWizard generator set control and its application in generator set systems. 5.3.2 PowerWizard Control Module Description 1 - display screen 2 - AC overview hot key...
Page 253 Pre-Start Checks (applicable to all control systems) Warning The following checks detailed below are the only tasks that an operator should undertake. The following checks should be performed prior to starting the generator set: A visual inspection should take only a few minutes and can prevent costly repairs and accidents – for maximum generator set life, visually inspect the generator set before starting.
Page 254 Visually check the entire generator set for signs of leaks from the fuel system, cooling system or lubrication seals. Periodically drain exhaust system condensate traps, if equipped. Ensure the Alternator Output Circuit Breaker is in the “OFF” (handle down) position. 5.3.4 Basic Operation START Mode Press Start key...
Page 255 5.3.5 Fault / Alarm Reset Process 2. Fault / Alarm Reset 1. Fault / Alarm Reset Process If either of these indication lamps are flashing Press STOP or solid there is a warning or shurdown 4. Fault / Alarm Reset Process. The display will show: 3.
Page 256 AUTO – Pressing the Auto key will cause the engine to enter the auto mode. STOP – Pressing the Stop key will cause the engine to enter stop mode. Menu Navigators: Scroll Up – The Scroll Up key is used to navigate up through the various menus or monitoring screens. The Scroll Up key is also used during setpoint entry.
Page 257 Display Preferences for PowerWizard Panels: To change the display preferences, from the main menu scroll down to the “Preferences” item (last in the menu). Press the “Enter” Key. Scroll down through the preferences menu until the desired display preference is highlighted. Press “Enter” to adjust this preference.
Page 258 5.3.8 Security There are three levels of password protection on the PowerWizard control panel. All of the adjustable setpoints are associated with a specific level of security required to make an adjustment to the parameter. The passwords only affect changing setpoints within the control panel.
Page 259 5.3.10 Fuel Priming – engines with electric Fuel Lift Pump Certain engines fitted with an electric fuel pump do not have a manual priming feature on the engine. In these circumstances the PowerWizard can be used to energise the fuel lift pump in order to prime the engine. In order to prime the generator set: MAIN MENU >...
Page 260 5.4 PowerWizard 1.1, 1.1+ & 2.1 (Quickstart) 5.4.1 General Information Figure 5j – PowerWizard Control System Panel The controller is available in three versions, PowerWizard 1.1, 1.1+ and 2.1. These three versions are based on different features. This guide is intended to cover the PowerWizard generator set Control and its application in generator set systems. 5.4.2 PowerWizard Control Module Description Display screen AC overview key...
Page 261 5.4.3 Pre-Start Checks (applicable to all control systems) Warning The following checks detailed below are the only tasks that an operator should undertake. The following checks should be performed prior to starting the generator set: A visual inspection should take only a few minutes and can prevent costly repairs and accidents – For maximum generator set life, visually inspect the generator set before starting.
Page 262 Check the battery electrolyte level – fill with distilled water as necessary. Check the control panel and the generator set for heavy accumulation of dust and dirt – clean as necessary. These can pose an electrical hazard or give rise to cooling problems. Check the air filter restriction indicator, if fitted –...
Page 263 5.4.4 Basic Operation START Mode Press START Key Figure 5l – Basic Operation Start Key STOP Mode Press STOP Key Figure 5m – Basic Operation Stop Key AUTO Mode Press AUTO Key Figure 5n – Basic Operation Auto Key Note: •...
Page 264 5.4.5 Fault / Alarm Reset Process 1. Fault / Alarm Reset Process 2. Fault / Alarm Reset If either of these indication lamps are flashing or Press STOP Key solid there is a warning or shurdown 3. Fault / Alarm Reset 4.
Page 265 Control Keys: RUN – Pressing the Run key will cause the engine to enter the run mode. AUTO – Pressing the Auto key will cause the engine to enter the auto mode. STOP – Pressing the Stop key will cause the engine to enter stop mode. Navigation Keys: Scroll Up –...
Page 266 Event Log Key – Pressing the Event Log key will navigate to the “Active Events” menu. In order to scroll through the events, use the up and down keys. After highlighting an event, press the “OK” key to see information about the event such as the SPN and the FMI.
Page 267 Shut Down Resetting A flashing red shutdown light indicates there is an unacknowledged shutdown event. The red shutdown light will change from flashing red to solid red when the Alarm Acknowledged key is pressed. Once a fault has been checked and the cause rectified, use the following procedure in order to reset the event: Press the “Stop”...
Page 268 5.4.9 Real Time Clock Programming (PowerWizard 2.1) The real time clock provides information for the time and date of an automatic time based start/stop control. It also provides a mechanism for time stamps in the event log. The real time clock is not calibrated and is for information only. The date and time are set by the user.
Page 269 5.4.12 Trouble Shooting Guide for PowerWizard Fault Symptom Remedy 1. Check All Emergency Stop Push Buttons Are Released Engine Does Not Crank When Start Signal 2. Check The Stop Button Light Is Not On Engine Fails To Start Is Given, Either Manually Via Run Key Or 3.
Page 270 5.5 DCP-10 & DCP-20 5.5.1 General Information Figure 5p – DCP-10 and DCP-20 Control Panels Illustrated above are the Automatic Start Control Modules (DCP-10 & DCP-20) designed to automatically start and stop the generator set. The modules also monitor and protect the engine, indicating operational status, fault conditions and metering on the front panel LCD and LED’s.
Page 271 5.5.3 Pre-Start Checks (applicable to all control systems) Warning The following checks detailed below are the only tasks that an operator should undertake. The following checks should be performed prior to starting the generator set: A visual inspection should take only a few minutes and can prevent costly repairs and accidents – for maximum generator set life, visually inspect the generator set before starting.
Page 272 Visually check the entire generator set for signs of leaks from the fuel system, cooling system or lubrication seals. Periodically drain exhaust system condensate traps, if equipped. Ensure the Alternator Output Circuit Breaker is in the “OFF” (handle down) position. 5.5.4 Basic Operation START Mode Press START Key...
Page 273 5.5.5 Fault / Alarm Reset Process - DCP-10 Alarm / Shutdown Whenever a warning occurs the LED indicator will flash, but the generator set will not shut down. Once the issue is resolvedthe Warning LED will automatically turn off. Whenever a shutdown occurs the LED indicator illuminates.. The system is immediately locked out and the generator set stops.
Page 274 Navigation Keys – DCP-20 When in parameter setting mode this button is used to increase value/scroll down menu. When in parameter setting mode this button is used to decrease value/scroll up menu. When in parameter setting mode this button is used to enter into submenu/confirm modification. When in parameter setting mode this button is used to return to the upper menu.
Page 275 Display Preferences for DCP-20 Panel Each page can display multi-row information simultaneously. Pressing will allow the user to scroll to the next page. The display can also be configured to scroll automatically. When an alarm occurs, the alarm is displayed on the LCD immediately. When the Generator set is running the LCD scrolls through the screens showing the following data –...
Page 276 5.6 Control System Options and Upgrades A large variety of options may be fitted to customise the control system to a specific installation. The following sections cover the use and operation of some of these options. 5.6.1 Battery Trickle / Switch-Mode Chargers Both battery chargers are designed to ensure that the starter batteries maintain their charge even if the generator set is not operated for long periods.
Page 277 5.6.4 Meters / Gauges The following additional meters or gauges may be fitted to the control panel: • Three ammeters mounted on the panel instead of one ammeter and a selector switch. This allows a continuous indication of the current flowing in each phase, not applicable for PowerWizard as this module will display all phase currents. (Not applicable to 26 –...
Page 278 6. oPeration 6.1 Priming Procedure for 1100 Series Warning: Please wear appropriate Personal Protective equipment (Section 2.2) before carrying out any of the following procedures as the operator will be in direct contact with diesel fuel. There will also be a risk of spillage. Note: •...
Page 279 6.1.2 Products fitted with the Racor Pre-Filter / Water Separator (Option) 1 - T Handle 2 - Racor Lid 3 - Racor Filter Figure 6b – Example of a Racor With Fuel Supply from the Base Tank Following Racor element change or if the Racor unit is drained for any reason, then repriming of the unit, as specified by Racor, will be required: •...
Page 280 6.1.3 Troubleshooting Having completed the designated priming procedure, if the engine does not start, there may be air in the Pressure Regulator Valve (PRV) return loop hose. Figure 6c – Tooling (Not supplied) & Pressure Regulator Valve (PRV) return loop hose Close the PRV return loop hose (B).
Page 281 Ensure that the main power switch is in the OFF position before jump start cables are attached to the engine that is being started. Turn the start switch on the stalled engine to the OFF position. Turn off all accessories. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery.
Page 282 7. Load transFer PaneLs When the generator set is required to automatically provide switching to standby power in the event of mains failure, an optional load transfer panel is required. These transfer panels are designed to sense when the mains have failed, signal the generator set to start, switch the load from the failed mains to the generator set and then switch it back after the mains supply is re-established.
Page 283 7.1 engine Interface Module Description (where fitted) The Engine Interface Module is a sealed, engine mounted module that provides switching relays for the Starter Motor Solenoid, Glow Plug and Fuel Solenoid. Each of these circuits is protected with individual fuses mounted in the module. Individual LED’s illuminate when each circuit is energised.
Page 284 8. eLectronic enGine FauLt detection FLasH codes Perkins 1306–E87 electronic engines automatically record engine faults in the Electronic Control Module (ECM) to assist the engineer in troubleshooting. The fault codes can be read using the red and amber lamps situated on the top of the relay box, as shown in the picture below.
Page 285 9. Maintenance Warning: The following procedures should only be carried out by a qualified technician. A good maintenance programme is the key to long generator set life. Maintenance and service should only be carried out by qualified technicians. Records of this work should be kept to aid in developing an efficient maintenance programme. In general, the generator set should be kept clean.
Page 286 9.2 Preventative Maintenance Depending on the application of the generator set, requirement for preventative maintenance will vary. The preventative maintenance requirements associated with the engine are detailed in the Engine Manual, which should be reviewed in conjunction with this section. Maintenance intervals for the engine may be more frequent than those shown in this section.
Page 287 NOTeS 356-5901(GB)
Page 288  InteliNano NT Operator Guide Copyright © 2011 ComAp s.r.o. ComAp, spol. s r.o. Kundratka 17, 180 00 Praha 8, Czech Republic Tel: +420 246 012 111, Fax: +420 266 316 647 E-mail: info@comap.cz, www.comap.cz...
Page 289 ABLE OF CONTENTS Operator Interface AMF and MRS ....................3 Display Screens Structure ........................ 5 AMF main screens structure ...................... 5 MRS main screens structure ...................... 6 Alarms, Events and History ......................7 Events ............................8 Warnings ............................ 9 Shutdowns ..........................9 ECU Messages .........................
Page 290 1 Operator Interface AMF and MRS Figure 1.1 GEN-SET CONTROL BUTTONS Position Button Description Start (Start) button. Works in Manual mode only. Press this button to initiate the start sequence of the engine - in Manual operating mode only. This button is also used to confirm changes in setup mode.
Page 291 GEN-SET OPERATION INDICATORS Position Indicator Description Engine operation. Green LED is blinking, if engine is starting, cooling or stopping. When LED is on the engine is running and is loaded or ready to load. Operating mode. When the green LED is on, the controller is in Auto operating mode. When is off the controller is in Manual mode.
Page 292 2 Display Screens Structure The displayed information is structured into "screens". Use button to switch over the ▲ ▼ screens. 2.1 AMF main screens structure Figure 2.1 First screen contain basic information about voltage and frequency measurement on mains and generator side.
Page 293 2.2 MRS main screens structure Figure 2.2 First screen contains basic information about generator voltage and frequency measurement Also there is displayed position (status) of GCB (only when is configured) and running hours counter. When any alarm occur the general warning symbol will be displayed on the LCD’s upper right corner Second screen contain detail voltage and frequency information.
Page 294 3 Alarms, Events and History Following alarms and records are available:  Event  Warnings  Shutdowns  ECU Messages Four records can be displayed simultaneously on the LCD screen. Total capacity is 10 records the Figure 3.1 is an example of how the history is organized. The last screen in this example is showing the four latest events.
Page 295 Figure 3.2 3.1 Events Every event listed in table below is saved in history with running hours stamp see Figure 3.3. Figure 3.3 – P EVENT OWER InteliNano-NT Operator guide, ©ComAp – February 2012 IN-NT - Operator Guide.pdf...
Page 296 3.2 Warnings 3.2.1 Active warning When a warning occurs, output will close and the red LED above button will blink. O04 Alarm Stop Warning symbol will blink in the upper-right corner of the LCD and the proper warning symbol will be displayed in the history with running hours stamp.
Page 297 3.3.3 Active confirmed shutdown When an active shutdown is confirmed the red LED above the button stops blinking. The record Stop in history stays negative with confirmation symbol at the end. output is open. O04 Alarm Figure 3.7 – E ACTIVE CONFIRMED SHUTDOWN MERGENCY 3.3.4 Inactive unconfirmed shutdown...
Page 298 Complete list of text diagnostic messages for each ECU can be found in ComAp Electronic Engines Support manual. InteliNano-NT Operator guide, ©ComAp – February 2012 IN-NT - Operator Guide.pdf...
Page 299 4 Start and Stop engine 4.1 AMF in MANUAL mode Green LED above Auto button is off (controller is in MANUAL mode). When there is no any active shut down alarm you can start the engine by pressing button. Green LED above button will blink. LED Start is blinking during starting, cooling or stopping procedure.
Page 300 Engine can be started or stopped via binary input Load. For Remote Start/stop Remote Start And more detail see IN-NT AMF Reference guide. InteliNano-NT Operator guide, ©ComAp – February 2012 IN-NT - Operator Guide.pdf...
Page 301 HTC GRINDER HTC2500 GENSET 110kVA REFERENTIE LEVERANCIER : 501219939 REFERENTIE KLANT : KEMPER EN VAN TWIST DIESEL B.V. HTC SWEDEN KEERWEER 62 KLEVVAGEN 7 POSTBUS 156 61492 SODERKOPIG 3316 KA DORDRECHT TEL : +31 (0)78-6326600 TEL: +46 (0)121-29400 FAX :...
Page 302 CABINE AND ENGINE WIRING 3 4-11-2012 arjan NEW DISTRIBUTION PANEL, MAIN CIRCUIT 4-11-2012 arjan NEW DISTRIBUTION PANEL, AUXILIARY CIRCUIT 4-11-2012 arjan HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status...
Page 303 MAIN CURRENT (NEUTRAL) 0 Vac BLUE 1,0mm² MEASUREMENT (m)A GREY 1,0 / 2,5mm² AUXILIARY CURRENT 24 Vdc WHITE 1,0 / 2,5mm² +CAB/6 HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status...
Page 304 ALTERNATOR GLOW PLUG ENGINE OIL PRESSURE COOLANT TEMP. OIL PRESSURE CONTROLLER TOO LOW TOO HIGH MEASUREMENT +COM/3 HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status AS BUILT CABINE AND ENGINE WIRING 1...
Page 305 START OPERATION ENGINE SPARE COOLANT TEMP. STOP IN FUEL OIL PRESSURE MEASUREMENT CABIN TOO LOW HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status AS BUILT CABINE AND ENGINE WIRING 2...
Page 306 /6.5 GENERATOR VOLTAGE FROM DISTIBUTION PANEL +DP/6 HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status AS BUILT CABINE AND ENGINE WIRING 3 Revisie Datum Aanmaakdatum 5-11-2012 Uitgave : Aantal pagina's :...
Page 307 SOCKET 32A 5P SOCKET 16A 5P SOCKET 16A 3P SOCKET 16A 3P GENERATOR MAIN BREAKER IN VOLTAGE MAIN CONTROL CABINET TO CONTROLLER +CAB/8 HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status...
Page 308 /6.3 /6.2 /6.3 24Vdc START START - CONTROL START - CONTROL SUPPLY VAC1 AND VAC2 VAC MOTOR1 VAC MOTOR2 HTC GRINDER HTC2500 Tekeningnummer : Bladzijde : Getekend A.J. van Veldhoven GENSET 110kVA Gecontroleerd 501219939 HTC GRINDER HTC2500 Status AS BUILT...
Page 309 ALTERNATORS 3608 en - 04.2006 / c PART NUMBER 277 - 800 LL 2000 - 3000 ALTERNATORS Installation and maintenance...
Page 310 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 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 of alternators, this range benefits from the...
Page 311 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS RECEIPT 1 - RECEIPT 1.3 - Identification The alternator is identified by means of a nameplate glued to 1.1 - Standards and safety measures the frame. Make sure that the nameplate on the machine conforms to Our alternators comply with most international standards and your order.
Page 312 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS TECHNICAL CHARACTERISTICS 2 - TECHNICAL 2.2 - Mechanical characteristics CHARACTERISTICS - Steel frame - Cast iron end shields 2.1 - Electrical characteristics - Protected ball bearings, greased for life - Mounting arrangements: 2000 - 3000 alternators are machines without sliprings or IM 1201 (MD 35) foot and flange mounted, single-bearing...
Page 313 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS INSTALLATION 3 - INSTALLATION 3.1.2.2 - Two-bearing alternator - Semi-flexible coupling 3.1 - Assembly Careful alignment of the machines is recommended, checking that the concentricity and parallelism of both parts of the coupling does not exceed 0.1 mm.
Page 314 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS INSTALLATION 3.2.2 - Mechanical checks 3.3 - Terminal connection diagrams Before starting the machine for the first time, check that: To modify the connection, change the position of the terminal - the fixing bolts on the feet are tight cables.
Page 315 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS INSTALLATION Connection codes Factory connec tion L.L voltage 50 H z 60 H z Winding Connection not recommended 220 - 240 220 - 240 1 PH 250 - 260 220 - 240 R 230 voltage det ection :...
Page 316 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS INSTALLATION 3.3.2 - Option connection diagram Voltage pot e ntiometer R 791 T int erferenc e suppression k it (standard f o r CE mar king) Connections B F/F G Bl a ck...
Page 317 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE 4 - SERVICING / MAINTENANCE - Ciclohexare (non toxic); inflammable 4.1 - Safety measures Cleaning of the stator, rotor, exciter and diode bridge The insulating components and the impregnation system are not at risk of damage from solvents (see the list of authorized products).
Page 318 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE 4.4 - Mechanical defects Fault Action Excessive overheating of one or both - If the bearing has turned blue or if the grease has turned black, change the Bearing bearings (temperature >...
Page 319 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE 4.5.1 - Checking the winding Assembly A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode on both exciter You can check the winding insulation by performing a high field wires (5+) and (6-).
Page 320 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE 4.6 - Dismantling, reassembly 4.6.3 - Access to connections and the (see sections regulation system 5.4.1/5.4.2) The terminals are accessed directly by removing the terminal CAUTION CAUTION box lid [48].
Page 321 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE - Refit the air intake grille [51]. - Rest the rotor on one of its poles, then slide it out. Use the - Replace the terminal box lid [48]. tube as a lever arm to assist dismantling.
Page 322 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE 4.7 - Installation and maintenance Electrical characteristics of the PMG Stator phase/phase resistance 20 °C: 0.7 Ω of the PMG No-load voltage : 73 V For the 2000 - 3000, the PMG reference is PMG 1.
Page 323 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SERVICING / MAINTENANCE 4.8 - Electrical characteristics table SHUNT 2000 Dedicated single phase : field excitation current i exc (A) - 240 V - 60 Hz - Winding M1 Alternator - 4 pole - 50/60 Hz - No.
Page 324 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SPARE PARTS 5 - SPARE PARTS 5.2 - Technical support service 5.1 - First maintenance parts Our technical support service will be happy to provide any information you require.
Page 325 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SPARE PARTS 5.4 - Exploded views, parts list 5.4.1 - Single-bearing 2000 J - 3000 N° Description N° Description Stator assembly Terminal block support (AREP) Rotor assembly Terminal block Voltage regulator (AVR) Fixing screws (3000 only)
Page 326 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS SPARE PARTS 5.4.2 - Two-bearing 3000 P.M .G N° Description N° Description Stator assembly Exciter field Rotor assembly Exciter field fixing screw Exciter armature Fixing screws (3000) Diode crescent support Earth terminal Terminal block support (AREP)
Page 327 INSTALLATION AND MAINTENANCE 3608 en - 04.2006 / c LL 2000 - 3000 ALTERNATORS NOTES...
Page 330 Bäste kund, Tack för att Ni valt HTC Sweden som leverantör. Vi önskar Er lycka till med Er nya stoftsugare av modell HTC 55D/75D och 86D och hoppas att den motsvarar Era förväntningar. Vi har valt Pullman-Ermator AB som tillverkar av stoftsugare. Pullman-Ermator har sedan 1967 producerat produkter för professionell stofthantering och har genom åren erhållit en...
Page 331 Uppackning Var noga med att kontrollera att stoftsugaren är oskadad att inga synliga märken finns på sladden, slangar och tillbehör. Säkerhetsföreskrifter Handhavande Varning • En elkabel som har klämskador eller torrsprickor kan vara farlig att använda och skall omedelbart bytas ut. Risk för personskada. Varning •...
Page 332 Handhavande Maskinen är avsedd för uppsugning och avskiljning av torrt icke brännbart damm med explosionsgränsvärde > 0.1mg/m Med start knappen startas sidokanalfläkten. Därvid sugs stoftblandad luft med stor hastighet, via sugslang, genom inloppet. I cyklonen dämpas hastigheten varvid det grövre stoftet avskiljs, dels genom centrifugalkraft och dels genom sin egenvikt.
Page 333 Absolutfilter Vrid undan cyklontoppen enligt ovan. Lossa de tre hänkena och lyft av filterlocket, lyft därefter varsamt ur mikrofilterpatronerna och placerade den i lämplig plastpåse, som omedelbart förslutes. Sätt i två nya patroner. Montera tillbaka filterlocket. Vid filterbyte skall även packningar bytas, dessa kommer med filterna. •...
Page 334 Felsökning HTC 55D, HTC 75D och HTC 86D är konstruerade och anpassade för en krävande miljö och uppgift, men användaren bör dock beakta att aggregaten innehåller precisionstillverkade komponenter som bör skyddas mot hårda slag och stötar. Filter, tätningar, infästningar och anslutningar är omsorgsfullt anpassade och utvalda för operatörens arbetsmiljö.
Page 335 Industrivägen 10 777 91 Smedjebacken Sverige/Sweden Produktbeteckning/ Product designation Stoftavskiljare HTC 55D, 75D samt 86D. Vacuum cleaner HTC 55D, 75D and 86D. EU-riktlinjer EU-guidelines Produkten i fråga överensstämmer med följande EU-riktlinje: The product in question conforms to the following EU-guidelines: Maskindirektivet Machinery directive………………….
Page 336 Dear Customer,. We thank you for choosing HTC Sweden AB as your supplier. We hope that the vacuume cleaner of model HTC 55D, 75D and 86D will be to your satisfaction and meet your expectations. We have chosen Pullman-Ermator AB as the manufacture of our product. They have been a manufacture of professional dust extractor since 1967 and have thru the years built up a know how in this area.
Page 337 Un packing When unpacking the machine, please check that the vacuum cleaner, hoses and accessories do not have any transportation damages. Safety Instructions Handling Warning • Cables damaged through crunching or cracking can be dangerous if used and should be replaced immediately.
Page 338 Handling The machine is for sucking and separating dry, not combustive dust with limit value of explosion >0.1mg/m The motor is started by the switch. Dust laden air is then sucked through the inlet valve at high speed via the suction hose. The air is slowed down by the cyclone and coarse dust particles are separated out, partly by centrifugal force and partly by gravity.
Page 339 Absolute filter Loosen the three latches holding the filter cover, carefully lift the filters up and into a proper plastic bag. This bag must be taken care of in a proper way. Insert new filters in reversed order. Service When cleaning and servicing the machine, You must switch off the machine and pull out the plug from the outlet.
Page 340 Problem solving HTC 55D, HTC 75D and HTC 86D are manufactured and made for a severe environment and tasks, but the user must notice that the machine contents of components which must be protected from hits and blows. Filter, sealing connections are carefully chosen for the environment of the operator.
Page 341 TEKNISKA DATA TECHNICAL PERFORMANCE HTC 55D – HTC 75D – HTC 86D HTC 55D HTC 75D HTC 86D MÄRKSPÄNNING 400 VAc, 3-fas 208 VAc, 3-fas 460 VAc, 3-fas Voltage/Spannung/Tension 50Hz 60 Hz 60Hz (3x200VAc 3fas 50/60Hz ) EFFEKTUTTAG 5500 W...
Page 343 Antal / Qty HTC55D HTC75D HTC86D Benämning / Description 200600656 Täckhuv / Top cover 200600655 Filterrens sats / Filter cleaning unit 200600658 Handtag / Handle 200600657 Tank komplett / Tank complete 200600606 Excenterlås sats / Excentric lock kit 200600596 Filter paket komplett / Filter package complete 200600652 Ventilskiva inkl.
Page 345 ANVÄNDARHANDBOK OPERATION INSTRUCTIONS HTC 24C HTC 55C...
Page 346 Table of contents HTC 24C / 55C Manual (SV) ....................2 HTC 24C / 55C Manual (EN) ....................5 HTC 24C / 55C Teknisk data / Technical performance ............8 HTC 24C Exploded view ....................... 9 HTC 24C Spare part list .......................10 HTC 55C Assemble instruction .....................11...
Page 347 HTC 24C / 55C Manual / Spare parts list HTC 24C / 55C Manual (SV) STUDERA DENNA MANUAL NOGA FÖRE ANVÄNDNING OCH GE AKT PÅ SAMTLIGA ANVISNINGAR, SPECIELLT SÄKERHETEN. DENNA MANUAL ÄR INGEN REPARATIONSHANDBOK. . SÄKERHETSINSTRUKTION VARNING: Denna utrustning kan innehålla hälsofarligt damm. I sådant fall får tömnings- och skötselarbete, inklusive avlägsnande av dammuppsamlingsbehållare,...
Page 348 HTC 24C / 55C Manual / Spare parts list 3. SERVICE • Vid rengöring och service av maskinen får den ej var ansluten till någon sugare. • Undvik rengöring med hjälp av högtryckstvätt. Om detta är nödvändigt, se till att ej rikta strålen mot maskinens öppningar,...
Page 349 HTC 24C / 55C Manual / Spare parts list .FELSÖKNING HTC 24C och HTC 55C är konstruerade och anpassade för en krävande miljö och uppgift, men användaren bör dock beakta att aggregaten innehåller precisionstillverkade komponenter som bör skyddas mot hårda slag och stötar.
Page 350 HTC 24C / 55C Manual / Spare parts list HTC 24C / 55C Manual (EN) PLEASE READ THIS MANUAL CAREFULLY BEFORE ASSEMBLING AND FOLLOW ALL INSTRUCTIONS, ESPECIALLY SAFETY. THIS MANUAL IS NOT A REPAIR GIUDE SAFETY INSTRUCTIONS WARNING: This equipment contents hazardous dust. Only authorised persons may empty and maintanance the equipment, inclusive removing the plastic bag and filter.
Page 351 HTC 24C / 55C Manual / Spare parts list The pre-separator must be attached to a vacuum cleaner with right effect. When the vacuum cleaner is started the dust laden air is then sucked through the inlet valve at high speed via the suction hose. The air is slowed down by the cyclone and coarse dust particles are separated out, partly by centrifugal force and partly by gravity.
Page 352 6. PROBLEM SOLVING HTC 24C and HTC 55C is manufactured and made for a severe environment and tasks, but the user must notice that the machine contents of components which must be protected from hits and blows. Sealing connections are carefully chosen for the environment of the operator.
Page 353 HTC 24C / 55C Manual / Spare parts list HTC 24C / 55C Teknisk data / Technical performance HTC 24C HTC 55C 10m x ∅ 76mm SUGSLANG – HOSE 2.5m x Ø 50 mm ∅ 76mm INLOPPSRÖR - INLET Ø 50mm...
Page 354 HTC 24C / 55C Manual / Spare parts list HTC 24C Exploded view...
Page 355 HTC 24C / 55C Manual / Spare parts list HTC 24C Spare part list Description Part no 24C TOP PART DISCONTINUED SEALING STRIP TUBE FILTER 11331 CLAMP DISCONTINUED POP RIVET 310449 CYCLON DISCONTINUED LONGOPAC FIXING 10100 FLAP FOR HTC 26D...
Page 356 HTC 24C / 55C Manual / Spare parts list HTC 55C Assemble instruction...
Page 357 HTC 24C / 55C Manual / Spare parts list...
Page 358 HTC 24C / 55C Manual / Spare parts list HTC 55C Exploded view...
Page 359 HTC 24C / 55C Manual / Spare parts list HTC Spare part list Description Part no O-RING 76MM 593377401 55C TOP PART DISCONTINUED GASKET DISCONTINUED EXCENTRIC LOCK DISCONTINUED CYCLON DISCONTINUED HANDLE DISCONTINUED EXCENTRIC LOCK HOOK DISCONTINUED SEAL RING HTC 55C...
Page 360 Drift- och underhållsmanual Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual Explosion-Protected Drives Complying with Directive 94/9/EC MAS – HU MAS – ASA MAS – FUA Rak kuggväxelenhet Tappväxelenhet Parallellaxelväxelenhet Helical gear units Shaft mounted gear units Parallel shaft gear units MAS –...
Page 361 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Innehållsförteckning Sida Contents Page 1. Information 1. Information Generell information General information Säkerhets- och informationsmärkning Safety and information markings 2. Säkerhetsinformation 2.
Page 362 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 1. Information 1. Information 1.1 Generell Information 1.1 General information Denna Drift- och Skötselinstruktion (DS) är en del av den These Operating Instructions (OI) are part of the gear växelenhet som är levererad och ni måste läsa den innan unit as supplied, and you must read them before you ni startar arbetet med växel enheten.
Page 363 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 2. Säkerhetsinformation 2. Safety information 2.1 Generell säkerhetsinformation, transport 2.1 General safety information, transport Vid leverans, måste enheten kontrolleras så att inga After being delivered, the unit must be inspected for any skador uppstått...
Page 364 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Uppgifter som transport, placering i lager, uppsättning, Activities such as transport, placing in storage, setup, elektrisk anslutning, uppstart, underhåll, reparationer får electrical connection, start up, maintenance, repair may endast utföras av kvalificerad personal.
Page 365 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Information checked see chapter Inspect the shipment immediately after it has been received for any transport damages. In some cases it may not be advisable to start up the unit. Remove any transport protection before starting up.
Page 366 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 3. Växelenhetens konstruktion 3. Gear unit construction Följande typritningar visar principiellt konstruktionen för The following drawings basically show the construction of de olika serierna i teorin.
Page 367 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 3.2 Principkonstruktion – tappväxel typ ASA 3.2 Basic design principles shaft mounted gear unit Växelhus Gear case 46A-D Dubbel utgående axel Output shaft on both sides Täcklock Cover plate...
Page 368 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Principkonstruktion – tappväxel typ FUA 3.3 Basic design principles parallel shaft gear unit Växelhus Gear case 46A-V Enkel utgående axel Output shaft Växelhus Gear case 46A-D...
Page 369 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Principkonstruktion – Kuggsnäckväxel 3.4 Basic design principles helical worm typ SUA gear unit Växelhus Gear case Tätningslock Cover Utgående fläns Output flange Fotplatta Foot plate Axeltätning...
Page 370 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 3.5 Principkonstruktion – Vinkelkuggväxel 3.5 Basic design principles helical bevel gear typ KUA units Växelhus Gear case 46A-V Enkel utgående axel Output shaft Skyddsplatta Cover plate...
Page 371 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Principkonstruktion – Vinkelkuggväxel 3.6 Basic design principles angle parallel shaft "Klassisk" typ CSA gear unit Växelhus – UNIB. Gear case - UNIBLOCK 46A-V Enkel utgående axel Output shaft...
Page 372 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 3.7 Märkskylt 3.7 Nameplate, unit designation (Beispielhafte Darstellung) / (Typical appearance) Förklaringar: Legend: Utrustnikngsgrupp Instrument group Kategori Category EX - atmosfär EX Atmosphere Skyddstyp Type of ignition protection...
Page 373 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC De blanka omålade ytorna på växelenhetens utsida skall Unfinished, bare-metal parts on the outside of the unit skyddas med korrosionsskyddsmedel (kontroll var 6 are to be protected with a corrosion protection product månad är rekommendabelt).
Page 374 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Uppsättning av växelenheten 4.3 Setting up the gear unit Omgivningstemperatur: Ambient temperature: Växelenheter enligt Kategori IM2, II2G och II2D får The gear units of categories IM2, II2G, and II2D may endast användas vid omgivningstemperaturer -20°...
Page 375 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Växeldrifter utan luftplugg: Gear drives lacking a vent plug: Växelenheter i slutet (tätt) utförande levereras utan Sealed-design gear drives are supplied without a vent luftplugg.
Page 376 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Mekaniska drivelement som tillför radiell last på Mechanical drive elements that apply radial forces to the utgående axeln måste monteras så nära utgående output shaft must be installed as close as possible to the axelns lagring som möjligt! output shaft bearings!
Page 377 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 4.5.2 Demontage 4.5.1 Assembling Bild 5: Demontage av kundaxel Fig. 5: Removing the customer shaft med eller utan ansats på axeln with or without shoulder Hålaxel 1) Hollow shaft...
Page 378 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 1. Noggrann avfettning av hela hålaxeln. 1. Carefully degrease the complete hollow-shaft hole. → måste vara ABSOLUT fettfritt! → must be ABSOLUTELY free of grease! 2.
Page 379 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 4.7 Montage och Demontage av skyddskåpa 4.7 Installation and removal of protection cap Klämkopplingsversioner så väl hålaxel- The shrink disc versions as well as the hollow-shaft versioner kräver en skyddskåpa för att förebygga att versions require cover guards to prevent personnel personer ej kommer i kontakt med rörliga delar.
Page 380 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 4. Sätt ihop motor och adapter samt dra åt montage- 4. Then place the motor on the adapter and tighten the skruvarna med erforderligt åtdragningsmoment.
Page 381 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Bild 2: Monterng av IEC standard motor Fig. 2: Installing an IEC motor OBSERVERA ! ! ATTENTION ! Vid montage av pinjong (7) måste lagret (9) på In case of independent pinion assembling (7) the bearing växelsidan i IEC-adaptern fyllas med fett, enligt (9) on the gearside must to be filled with the amount of...
Page 382 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Principbild på servoadapter med kil. Principbild på servoadapter med jämn axel (utan kil) Sectional view servo adapter with key. Sectional view servo adapter with smooth shaft. Montering av motorn: Assembling of the motor: 1.
Page 383 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 4.10 Montage av momentstag 4.10 Installation of torque arms VIKTIGT! ! IMPORTANT ! Kontrollera rotationsriktningen på hålaxeln! Pay attention to the direction of rotation of the hollow Elasten (plasten) i gummibussningenheten skall belastas shaft! under sammantryckningen i huvudrotationsriktningen.
Page 384 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Vinkelkuggväxelenhet Helical bevel gear unit (*) . . . Bussningen måste ha lager på båda sidor. (*) . . . Bushing must have bearings on both sides. K..
Page 385 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Under uppstart, måste yttemperaturen mätas During start up, the surface temperature must be maximala arbetsförhållanden. maximala measured in the maximum operating condition. The max. yttemperaturen är nådd efter ca 3 timmar, och den får surface temperature is reached in about 3 hours, and it inte överstiga 90°C.
Page 386 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 6. Inspektion och Underhåll 6. Inspection and maintenance Växelenheter av modell serien H, A, F, K i storlek 40, 50, Gear units of the model range H, A, F, K, size 40, 50, 55, 55, 60, 65 är underhållsfria, ett oljebyte är ej 60, and 65 are maintenance-free, an oil change is not nödvändigt.
Page 387 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 6.2 Inspektions- och Underhållsarbeten för 6.2 Inspection and maintenance work on gear växelenheten unit Inga explosiva ämnen får användas eller finnas i No explosive atmosphere may be prevented in any närheten underhålls-...
Page 388 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 8. Tabell för åtdragningsmoment 8. Table of Tightening Torques Giltig för skruvar som uppfyller klass 8.8: Valid for screw property class 8.8 : •...
Page 389 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10. Monteringsformer och smörjmängder 10. Mounting positions and lubricant capacity 10.1 Raka kuggväxlar 10.1 Helical gear units Monteringsform MOUNTING POSITIONS B3/B5 Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE...
Page 390 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.2 1-stegs raka kuggväxlar 10.2 Single stage helical gear units MONTERINGSFORM MOUNTING POSITIONS B3/B5 Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE ENTRY (I, II, III) B7.5 B6.5...
Page 391 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.3 Tappväxlar 10.3 Shaft mounted gear units MONTERINGSFORM MOUNTING POSITIONS H3.. H4.. H1.. Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE ENTRY (I, II, III) H2..
Page 392 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.4 Parallellaxelväxlar 10.4 Parallel shaft gear units MONTERINGSFORM MOUNTING POSITIONS H3.. H4.. H1.. Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE ENTRY (I, II, III) H2..
Page 393 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.5 Vinkelkuggväxel 10.5 Helical bevel gear units MONTERINGSFORM MOUNTING POSITIONS H5.. H3.. H4.. Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE ENTRY (I, II, III) H6..
Page 394 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.6 Vinkelkuggväxel 10.6 Angle parallel shaft gear units MONTERINGSFORM MOUNTING POSITIONS H3.. H4.. Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE ENTRY (I, II, III) …...
Page 395 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.7 Kuggsnäckväxel 10.7 Helical worm gear units MONTERINGSFORM MOUNTING POSITIONS H3.. H4.. H5.. Placering av uttagslådan (A,B,C,D) samt kabelgenomföringarna (I, II, III) POSITION of TERMINAL BOX (A,B,C,D) and CABLE ENTRY (I, II, III) H6..
Page 396 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 10.8 Oljenivåkonroll på växlar med 10.8 Oil level control of gear units with oil level oljenivåplugg vid vertikala plug at vertical mounting position monteringsformer - Bryt spänningen till växelmotorn! - De-energized the geared motor!
Page 397 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 11. Konformitetsdeklaration 11. Declaration of conformity 11.1 Drifter enligt kategori I M2 - 38 WATT DRIVE GMBH A-2753 Markt Piesting Wöllersdorfer Str. 68 Tel.:+43/2633/404-0 Fax: +43/2633/404-220 www.wattdrive.com watt@wattdrive.com...
Page 398 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 11.1 Gear units of category I M2 - 39 WATT DRIVE GMBH A-2753 Markt Piesting Wöllersdorfer Str. 68 Tel.:+43/2633/404-0 Fax: +43/2633/404-220 www.wattdrive.com watt@wattdrive.com...
Page 399 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 11.2 Drifter enligt Kategori II 2G och II 2D - 40 WATT DRIVE GMBH A-2753 Markt Piesting Wöllersdorfer Str. 68 Tel.:+43/2633/404-0 Fax: +43/2633/404-220 www.wattdrive.com watt@wattdrive.com...
Page 400 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 11.2 Gear units of category II 2G and II 2D - 41 WATT DRIVE GMBH A-2753 Markt Piesting Wöllersdorfer Str. 68 Tel.:+43/2633/404-0 Fax: +43/2633/404-220 www.wattdrive.com watt@wattdrive.com...
Page 401 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 11.3 Drifter enligt Kategori II 3G och II 3D - 42 WATT DRIVE GMBH A-2753 Markt Piesting Wöllersdorfer Str. 68 Tel.:+43/2633/404-0 Fax: +43/2633/404-220 www.wattdrive.com watt@wattdrive.com...
Page 402 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 11.3 Gear units of category II 3G and II 3D - 43 WATT DRIVE GMBH A-2753 Markt Piesting Wöllersdorfer Str. 68 Tel.:+43/2633/404-0 Fax: +43/2633/404-220 www.wattdrive.com watt@wattdrive.com...
Page 403 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC 12. WATT DRIVE Partner 12. WATT DRIVE Partner Huvudkontor Austria Headquarter WATT DRIVE Antriebstechnik GmbH Wöllersdorfer Straße 68 2753 Markt Piesting Tel: +43 / 2633 / 404-0 Fax: +43 / 2633 / 404-220 E-mail:...
Page 404 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Egypt England El-Watania for Engineering & Trading Drummotors and More LTD 270 A Sudan st. 49 Cyprus Road El Mohandseen LE2 8QT Leicester Tel: +202 / 302 56 48 Tel: +44 / 0116 / 283 8344 Fax: +202 / 303 86 13...
Page 405 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Ireland Italy PRIORY MARKETING BIANCHI CUSCINETTI SpA Great Connell Transmissioni E Componenti Newbridge, Co. Kildare Via G. Zuretti, 102 20125 Milan Tel: +353 / 45 43 53 42 Fax: +353 / 45 43 55 09 Tel: +390 / 26 78 61...
Page 406 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Norway Philippines LÖNNE SCANDINAVIA AS AVESCO Marketing Corporation Liamyrane 12 810 AVESCO Building, Aurora Blvd.Corner Yale St., Cubao 5132 Nyborg Quezon City PO Box 3531 Manila Tel: +47 / 55 39 10 00 Fax: +47 / 55 39 11 00...
Page 407 Drift och underhållsmanual - Explosionsskyddade drifter enligt direktiv 94/9/EG Operating and maintenance manual- Explosion-Protected Drives Complying with Directive 94/9/EC Slovakia Slovenia WATT DRIVE Pohonné systémy, s.r.o. Branko Skribe s.p. (Watt Drive) Polovnícka 8 Bolfenška 58 03601 Martin 2000 Maribor Tel: +421 / 43 / 430 36 30 Tel: +386 / 2 / 6290304 Fax: +421 / 43 / 428 72 20 Mobil: +386 / 41 / 674 828...
Page 408 WATT Drives the World WATT DRIVE ANTRIEBSTECHNIK GMBH A-2753 Markt Piesting Wöllersdorfer Straße 68 Austria, EUROPE Tel.: +43 / 2633 / 404-0 Fax: +43 / 2633 / 404-220 Email: watt@wattdrive.com Web: www.wattdrive.com BA.MA.GT.041.004.08.08 BM.WMBA.ATEX...