User and Maintenance Manual For Generating Sets: Translation of The Original Instructions

User and maintenance manual
for generating sets
Translation of the original instructions

R33C3
33504023701NE_2_1
CONTENTS
1. Preface .................................................................................................................................................................................................. 4
1.1. General recommendations ....................................................................................................................................................... 4
1.2. Warnings .................................................................................................................................................................................. 4
1.3. Pictograms and their meanings................................................................................................................................................ 5
1.4. Safety instructions .................................................................................................................................................................... 8
1.4.1 General guidelines .................................................................................................................................................................... 8
1.4.2 Electrical safety precautions ................................................................................................................................................... 10
1.4.3 Safety precautions in case of electrical shock ........................................................................................................................ 11
1.4.4 Safety precautions relating to fire, burns and explosions ....................................................................................................... 11
1.4.5 Toxic risk safety precautions .................................................................................................................................................. 13
1.4.6 Precautions for risks relating to handling phases ................................................................................................................... 14
1.4.7 Precautions for risks relating to noise ..................................................................................................................................... 14
2. General description.............................................................................................................................................................................. 15
2.1. Description ............................................................................................................................................................................. 15
2.2. Technical specifications ......................................................................................................................................................... 18
2.3. Identifying sets ....................................................................................................................................................................... 20
2.4. Fluid retention ........................................................................................................................................................................ 21
2.5. Fuels, lubricants and coolants................................................................................................................................................ 22
2.5.1 Fuel specifications .................................................................................................................................................................. 22
2.5.2 Lubricant specifications .......................................................................................................................................................... 24
2.5.3 Coolant specifications ............................................................................................................................................................. 25
3. Transporting the equipment ................................................................................................................................................................. 27
3.1. Warnings concerning transport .............................................................................................................................................. 27
3.2. Preparing for transport ........................................................................................................................................................... 27
3.3. Road transport ....................................................................................................................................................................... 27
3.3.1 Generating sets with and without an enclosure ...................................................................................................................... 27
3.3.2 Generating sets on trailers...................................................................................................................................................... 28
3.3.2.1. Hitching and unhitching the trailer ............................................................................................................................. 28
3.3.2.2. Check before towing ................................................................................................................................................. 32
3.3.2.3. Operation .................................................................................................................................................................. 32
3.4. Rail transport.......................................................................................................................................................................... 33
3.5. Shipping ................................................................................................................................................................................. 34
3.6. Air transport ........................................................................................................................................................................... 34
4. Installation - Connections .................................................................................................................................................................... 35
4.1. Unloading the generating set ................................................................................................................................................. 35
4.1.1 Choosing the location ............................................................................................................................................................. 35
4.1.2 Safety during unloading .......................................................................................................................................................... 36
4.1.3 Unloading the generating set .................................................................................................................................................. 36
4.1.3.1. Slings ........................................................................................................................................................................ 36
4.1.3.2. Fork lift truck ............................................................................................................................................................. 37
4.1.4 Moving the generating set ...................................................................................................................................................... 37
4.2. Connecting the generating set ............................................................................................................................................... 38
4.2.1 Connection summary .............................................................................................................................................................. 38
4.2.2 Protecting people and equipment ........................................................................................................................................... 39
4.2.2.1. Earthing system principle .......................................................................................................................................... 39
4.2.2.2. TT system ................................................................................................................................................................. 39
4.2.2.3. Installing the differential protection ........................................................................................................................... 40
4.2.2.4. Setting the generating set differential protection ....................................................................................................... 41
4.2.2.5. Earthing the generating set ....................................................................................................................................... 43
4.2.3 Making the connections .......................................................................................................................................................... 44
4.2.3.1. Connections - general information ............................................................................................................................ 44
4.2.3.2. Selecting the power cables ....................................................................................................................................... 45
4.2.3.3. Connecting the generating set to the installation ...................................................................................................... 46
4.2.3.4. Connecting the battery or batteries to the generating set ......................................................................................... 48
4.2.4 Overvoltage ............................................................................................................................................................................ 48
5. Installation............................................................................................................................................................................................ 48
5.1. Warnings concerning commissioning ..................................................................................................................................... 48
5.2. Checking the generating set installation ................................................................................................................................ 48
5.3. Preparing for operation of the generating set ......................................................................................................................... 49
5.4. Checking the generating set before startup ........................................................................................................................... 49
5.5. Checking the generating set after startup .............................................................................................................................. 49
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6. Using the generator set ....................................................................................................................................................................... 50
6.1. Pre-Start Inspection ............................................................................................................................................................... 50
6.2. Generator set with NEXYS control panel ............................................................................................................................... 53
6.2.1 Control panel presentation ..................................................................................................................................................... 53
6.2.1.1. Introduction to pictograms......................................................................................................................................... 54
6.2.2 Manual starting ....................................................................................................................................................................... 55
6.2.3 Switching off ........................................................................................................................................................................... 56
6.2.4 Alarms and faults .................................................................................................................................................................... 56
6.2.5 Faults and alarms - Details ..................................................................................................................................................... 56
6.2.6 MURPHY diagnostic module .................................................................................................................................................. 58
6.3. Generator set with TELYS control panel ................................................................................................................................ 64
6.3.1 Control panel presentation ..................................................................................................................................................... 64
6.3.1.1. View of the front panel .............................................................................................................................................. 64
6.3.1.2. Description of the screen .......................................................................................................................................... 66
6.3.1.3. Description of the pictograms in zone 1 .................................................................................................................... 67
6.3.1.6. Display of messages in zone 4 ................................................................................................................................. 71
6.3.2 Starting ................................................................................................................................................................................... 76
6.3.3 Switching off ........................................................................................................................................................................... 77
6.3.4 Alarms and faults .................................................................................................................................................................... 77
6.3.4.1. Viewing alarms and faults ......................................................................................................................................... 77
6.3.4.2. Activation of an alarm or fault ................................................................................................................................... 78
6.3.4.3. Activation of an alarm and a fault .............................................................................................................................. 79
6.3.4.4. Engine fault codes display ........................................................................................................................................ 80
6.3.4.5. Horn reset ................................................................................................................................................................. 81
7. Maintenance schedule ......................................................................................................................................................................... 81
7.1. Reminder of use..................................................................................................................................................................... 81
7.2. Maintenance safety instructions ............................................................................................................................................. 81
7.3. Table of maintenance operations ........................................................................................................................................... 82
7.4. Cover maintenance ................................................................................................................................................................ 83
7.5. Trailer maintenance ............................................................................................................................................................... 83
7.6. Fault finding ........................................................................................................................................................................... 84
7.7. No load and under load tests ................................................................................................................................................. 84
8. Starter batteries ................................................................................................................................................................................... 85
8.1. Checking the electrolyte level ................................................................................................................................................ 85
8.2. Checking the voltage/acid density.......................................................................................................................................... 85
8.3. Charging the battery .............................................................................................................................................................. 86
8.4. Cleaning the battery ............................................................................................................................................................... 86
8.5. Fault finding ........................................................................................................................................................................... 87
9. Options ................................................................................................................................................................................................ 88
9.1. Dual frequency ....................................................................................................................................................................... 88
9.2. Neutral system ....................................................................................................................................................................... 91
9.3. Fuel supply valve ................................................................................................................................................................... 91
10. Appendix ............................................................................................................................................................................................ 93
10.1. Appendix A – Engine user and maintenance manual ............................................................................................................ 93
10.2. Appendix B - Alternator user and maintenance manual ........................................................................................................191
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TABLE OF ILLUSTRATIONS
Figure 1 : Warning pictograms .................................................................................................................................................................. 5

Figure 2 : Pictograms indicating prohibited activities ................................................................................................................................. 5
Figure 3 : Pictograms indicating compulsory operations ........................................................................................................................... 6
Figure 4 : Information pictograms .............................................................................................................................................................. 6
Figure 5 : Specific pictograms ................................................................................................................................................................... 7
Figure 6 : Pictograms relating to battery operations .................................................................................................................................. 7
Figure 7 : General description of the generating set ................................................................................................................................ 15
Figure 8 : General description of the generating set (Continuation) ........................................................................................................ 16
Figure 9 : General description of the generating set (control).................................................................................................................. 17
Figure 10 : Example of a generating set identification plate .................................................................................................................... 20
Figure 11 : Fluid retention container ........................................................................................................................................................ 21
Figure 12 : Example of French signalling ................................................................................................................................................ 33
Figure 13 : Examples of problems that may be encountered .................................................................................................................. 35
Figure 14 : Points used for lifting and moving.......................................................................................................................................... 37
Figure 15 : TT earthing system................................................................................................................................................................ 39
Figure 16 : View of the front side ............................................................................................................................................................. 53
Figure 17 : Description of the LEDs ......................................................................................................................................................... 54
Figure 18 : View of pictograms ................................................................................................................................................................ 54
Figure 19 : View of the front panel ........................................................................................................................................................... 64
Figure 20 : Description of the LEDs ......................................................................................................................................................... 65
Figure 21 : Close-up of USB ports ........................................................................................................................................................... 65
Figure 22 : Description of the screen (example) ...................................................................................................................................... 66
Figure 23 : Trailer lubrication/greasing points.......................................................................................................................................... 83
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1. Preface
1.1. General recommendations

The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually
improving the quality of our products, this information may be amended without warning.
Read the safety instructions attentively in order to prevent any accident, incident or damage. These instructions must be adhered to
constantly.
In order to obtain optimum efficiency and the longest possible service life for the generating sets, maintenance operations must be
carried out according to the periods indicated in the attached maintenance tables. If the generating set is used under dusty or
unfavourable conditions, some of these periods will be shorter.
Ensure that all adjustments and repairs are carried out by personnel who have received appropriate training. Our agents possess this
qualification, and can answer all of your questions. They can also supply you with spare parts and other services and they have
qualified staff to carry out preventive and corrective maintenance or even total reconditioning of generating sets.
The left and right sides can be seen from the back of the generating set (the radiator is at the front).
Note: some user and maintenance manuals for engines fitted to generating sets cover control units and include the start-up and shut
down procedures for the engines.
As our generating sets are fitted with control units that are specific to the generating sets; only the information that appears in the
documentation for the generating set control units should be taken into consideration.
In addition, depending on the manufacturing criteria of the generating sets, some engines may be fitted with specific electrical wiring
different to that described in the engine documentation.
1.2. Warnings
In this manual, the warning messages are used as follows:
Immediate danger.
Indicates an imminent danger which may result in death or serious injury. Failure to follow the instruction
shown may pose serious risks to the health and life of those concerned.
DANGER
Potential danger.
Indicates a dangerous situation if the warning is not heeded. Failure to follow the instruction indicated may
cause minor injuries to those concerned or damage to equipment.
IMPORTANT
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1.3. Pictograms and their meanings
The aim of the pictograms is as follows:
- To draw the attention of the operator or maintenance technician to the potential dangers.
- To explain how to act in the interest of personal safety and to avoid damaging the equipment.
The safety pictograms present on the equipment are explained below.
Important, Important,
Warning: danger
Electrical risk risk of explosion
Important,
Important, Important,
rotating or moving
toxic materials pressurised fluids
parts
Important, Important, Danger: automatic

high temperature corrosive product start-up
Figure 1 : Warning pictograms
Entry prohibited to
Jet washing
unauthorised
prohibited
persons
Figure 2 : Pictograms indicating prohibited activities
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Reading the Wearing suitable
Wearing suitable
manual for the protective goggles
protective clothing
equipment is and ear defenders
is compulsory
compulsory is compulsory
Lifting point Forklift required for Battery charge

required lifting must be checked
Periodic
maintenance
compulsory
Figure 3 : Pictograms indicating compulsory operations
Battery isolating External fuel

Earth
switch connections
Diesel fuel Drain the fuel Inspection flap
Mains supply
connection
Fill the coolant Drain the coolant
prohibited before
filling with water
Fill the oil Drain the oil
Retention container Drain the retention

high level container
Figure 4 : Information pictograms
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Flammable product, Reading the manual for the equipment is
Do not smoke or create sparks or flames compulsory
Fuel supply
Securing straps routing point
- Selection valve -
Figure 5 : Specific pictograms
Rinse any splashes of acid on the skin or

in the eyes using clean water.
Wearing suitable protective clothing and
Consult a doctor immediately.
goggles is compulsory
Wash contaminated clothing with water.
Figure 6 : Pictograms relating to battery operations
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1.4. Safety instructions
RETAIN THIS MANUAL
This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set
and batteries.
IMPORTANT - SAFETY ADVICE
If any parts of this manual are not understood, or in case of doubt, contact your nearest agent in order to receive an explanation or
demonstration to allow the equipment to be used correctly. The guidelines listed below must always be respected to ensure the safety
of personnel and equipment. In addition to this information, it is essential to refer to the local and national regulations applicable
according to the jurisdiction.
1.4.1 General guidelines

Installing the equipment
The installer of the equipment must create a document describing any modifications made to the equipment during installation.
Using the equipment
- Before starting any operations on the equipment:

Nominate an operations manager.
The role of the operations manager is to monitor, either directly or indirectly, any operations performed on the equipment
and to ensure that the safety and operating instructions are respected.
The operations manager should read and understand all the documentation supplied with the equipment.
- Information for personnel:

Regularly reiterate the safety and operating instructions to the operating personnel.
Contact your dealer if you have any questions regarding the equipment and any training requests for personnel.
Make the manufacturer's instructions available to the users (if possible on site).
- Protection for individuals and equipment:

Wear suitable clothing.
Move away from equipment in operation.
Ensure that persons who are not authorised to intervene as well as animals are kept away from the equipment. Observe
this guideline regardless of whether the equipment is in operation or stopped.
Protect the equipment from any fluid splashes and bad weather.
Before starting the equipment, refit the enclosures and close all the access doors.
Before starting the engine, check that the air filter is present and the correct extraction circuit for the exhaust gas.
Respect the current regulations relating to fuel use.
Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit.
Adjust the equipment according to the manufacturer's prescriptions.
Check that the equipment operates correctly.
Engage the parking brake when the equipment is installed on the operating site on its trailer. When chocking the trailer on
a slope, ensure that there is nobody in the path of the trailer.
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Maintaining the equipment
- Personnel skills:
Ensure that the maintenance operations are performed on the equipment by appropriately trained personnel.
- Personnel protection:
Wear suitable clothing and protective goggles.
Remove any personal belongings that may hinder the operation: watch, bracelet, etc.
Fit a panel over the controls of the equipment to prevent any attempt to start.
Disconnect the battery (and pneumatic starter if fitted) before beginning any maintenance operation.
Handle the equipment according to best practices, using techniques which do not endanger the personnel.
It is essential to wear gloves when detecting leaks.
Regularly check that the safety devices are operating correctly.
- Equipment protection:
Use tools in good condition and suited to the work to be done. Ensure you have understood the instructions before
beginning any operation.
Respect the maintenance table and its recommendations. In dusty or unfavourable conditions, certain maintenance
intervals will need to be reduced.
Check that the spare parts fitted on the equipment are supplied only by the dealer.
Handle the equipment according to best practices, using techniques which do not risk damaging the equipment.
Replace any safety pictograms that are missing or illegible on the equipment.
Note: the mounting bolts on the protective devices of the rotating parts are captive bolts equipped with retaining washers.
Also, in order to ensure the integrity of this assembly, it is prohibited to use electric or pneumatic screwdrivers to undo these
mounting bolts.
- Cleaning the equipment:

Clean off any trace of oil, fuel or coolant using a clean cloth.
Use only approved cleaning solvents.
Cleaning products and methods that are strictly prohibited:
• petrol or other flammable substances;
• soapy solution containing chlorine or ammonia;
• high pressure cleaner.
- Additional instruction:
If necessary, contact the dealer for the following reasons:
• answers to any questions relating to the equipment;
• training requests for personnel;
• supplying the relevant documentation for maintenance operations;
• supplying spare parts;
• corrective or preventive maintenance operations.
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Operating site
- Maintenance:
Clean the entire operating site regularly with suitable cleaning materials.
The presence of dangerous or combustible materials inside premises must be limited to the operating requirements.
- Access:
Prohibit free access to persons who are not part of the establishment, except for those designated by the user.
- Respecting the environment:

Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil).
Burning of waste in the open air is prohibited.
Remove waste water, sludge and other waste in a specialised processing centre.
1.4.2 Electrical safety precautions
ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS
DANGER
- Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check
that these values match the installation being supplied.
- The electrical connections must be made in accordance with current standards and regulations in the country of use and the
neutral system sold.
- Ask a qualified electrician to intervene when there are specific cases requiring equipment to be connected to an existing
electrical network.
- Disconnect the power to the equipment (equipment voltage, battery voltage and network voltage) before any installation or
maintenance operation is performed.
- Connect the equipment wires by respecting the wiring diagram supplied by the manufacturer.
- Always handle the equipment with dry hands and feet.
- Take all the necessary precautions to avoid touching stripped cables or disconnected connectors.
- Use and maintain the cables in good condition, well insulated and connected correctly and securely.
- Only replace equipment that provides protection against electric shock with identical equipment (specifications and nominal
values).
- Only use flexible durable cables with a rubber covering, which conform to ECI 245-4, or equivalent cables.
- Refit the protective plates (blanking covers) after each maintenance operation.
Note: The electrical equipment supplied with the equipment complies with standard NF C15.100 (France), or with the standards of the
countries in question.
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1.4.3 Safety precautions in case of electrical shock
In the event of an electric shock, observe the following instructions:
1. Avoid direct contact both with the live conductor and the victim's body.
2. Shut off the power immediately and activate the emergency stop for the
equipment concerned. Note: the live wire may be cut with an axe. Take extreme
care to avoid the electric arc that will be generated by this.
3. If it is impossible to access the equipment: move the victim away from the live
conductor using a dry piece of wood, dry clothing or other non-conducting
material.
4. Move the victim away from any situations where there is a danger of death.
5. Contact the emergency services.
6. If breathing has stopped, begin artificial respiration at once.
7. In the event of cardiac arrest, carry out cardiac massage.
1.4.4 Safety precautions relating to fire, burns and explosions
DANGER
FUELS / FLAMMABLE PRODUCTS / PRESSURISED FLUID
- RISK OF BURNS -
- RISK OF FIRE -
- RISK OF EXPLOSION -
1. Before starting the equipment, move any flammable or explosive products away (petrol, oil, cloth, etc.).
2. It is prohibited to put combustible materials on the hot parts of the equipment (for example: exhaust pipe).
3. Avoid any contact with the hot parts of the equipment (for example: exhaust pipe).
4. Use appropriate ventilation to allow the equipment to cool correctly.
5. Wait for the engine to stop and cool down completely before removing the radiator cap.
6. Wait for the equipment to stop and cool down completely before covering the equipment (if necessary).
7. Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components.
8. Ensure that the equipment in operation is fixed (in a stationary position).
When installing the equipment on a vehicle or other mobile equipment, a study must be conducted
beforehand in order to take into account the various specific uses of the generating set.
IMPORTANT
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Fuels
- Respect current local regulations regarding the equipment and fuel used
(petrol, diesel and gas).
- Top up the engine with fuel when the engine has stopped (except for
equipment with an automatic filling system).
- Smoking, using a flame or producing sparks are forbidden while the fuel
tank is being filled.
- Use protection suitable against fires and explosions.
- Pipes must be replaced as soon as their condition demands it.
Oils
1. Check that the system is no longer pressurised before carrying out any procedures.
2. Avoid contact with hot oil.
3. Wait for the engine to stop and cool down completely before topping up the oil.
4. Before starting the engine, refit the oil filler cap.
5. It is prohibited to cover the generating set with a fine layer of oil for anti-rust protection.
Battery
- Smoking, using a flame or producing sparks are forbidden close to batteries (particularly when the batteries are being
charged).
Supply gas (concerns generating sets running on gas)
- Request the user technical notes and LPG or NG safety data sheets from your gas supplier.
- For any operation on a gas installation, ask a recognised specialist to intervene.
- Gas supply procedures must be carried out in the open air (outside) in accordance with local regulations, in an area well away
from fires, people or animals.
- Check the sealing of the gas supply circuit using soapy water with the circuit pressurised, or using a leak detector.
- It is forbidden to smoke, bring flames near or create sparks when the tank is being filled, and near to the generating set.
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1.4.5 Toxic risk safety precautions
DANGER
EXHAUST GAS - TOXIC PRODUCTS
- TOXIC RISK -
Exhaust gas
- Use suitable ventilation to release the exhaust gas outside and prevent it from
accumulating.
- Respect current local regulations regarding the equipment and fuel used (petrol, diesel
and gas).
- Periodically examine the burnt gas exhaust.
- Pipes must be replaced as soon as their condition demands it.
Note: the carbon monoxide present in the exhaust gas may lead to death by inhalation if the concentration levels in the atmosphere are
too high.
Corrosion inhibitor in the coolant (contains alkali)
- Read the instructions on the packaging.

- Keep the product out of the reach of children.
- Do not swallow it.
- Avoid prolonged or repeated contact with the skin.
- Never allow contact with the eyes.
In the event of contact with the eyes:
1. Rinse immediately with plenty of water for at least 15 minutes.

2. Consult a doctor immediately.
In the event of contact with the skin:
1. Wash thoroughly with water and soap.

Fuels and oils
- Do not swallow it.

- Ensure proper ventilation.
- Use a suitable protective mask.
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Battery electrolyte
- Avoid all contact with the skin and eyes.
- Wear suitable protective goggles and clothing and strong alkali-resistant
gloves for handling the electrolyte .
If splashes get into the eyes:
1. Rinse immediately with running water and/or a 10% diluted boric acid solution.
1.4.6 Precautions for risks relating to handling phases
DANGER
HANDLING PHASES - RISK OF DROPPING
1. Select the appropriate handling equipment and apparatus according to the type of equipment being handled. Check that there
is sufficient handling capacity.
2. Check that the handling equipment and apparatus are in good operating condition.
3. Respect the handling instructions described in the present documentation and the pictograms displayed on the equipment to
be handled.
4. Be sure never to stand under the load being handled.
Note: the lifting rings provided on the equipment are designed to handle the generating set alone. If additional equipment is fitted to the
generating set, a study should be conducted in order to define the centre of gravity of the assembly and to check the correct
mechanical performance of the structure and its lifting rings.
1.4.7 Precautions for risks relating to noise
HIGH SOUND LEVEL - RISK OF HEARING LOSS
DANGER
- Always use suitable ear defenders when working in close proximity to a generating set which is in operation.
Note: for generating sets used inside, for which the ambient noise levels are dependent upon the installation conditions, it is not
possible to specify these ambient noise levels in the operating instructions. As prolonged exposure to high sound pressure levels can
cause permanent damage to hearing, it is necessary to measure the acoustics after installation in order to determine the sound
pressure level and, if necessary, to implement the appropriate preventive measures.
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2. General description
2.1. Description
Overview
6
3
Figure 7 : General description of the generating set
1 Acces to maintenance area 4 Acces to control unit

2 Lifting ring 5 Acces to power connections
3 Forklift grooves 6 Drawbar
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1 6
2 4
Figure 8 : General description of the generating set (Continuation)
1 Protective grille 4 Alternator

External fuel supply combined tap
2 Battery isolating switch 5
(optional)
3 Starter battery 6 Charging alternator
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Control
4
1
Figure 9 : General description of the generating set (control)

6
1 Control unit 4 Working hours counter

2 Emergency stop 5 Power circuit breaker
3 Socket control panel 6 Connection terminal block
Note : Photo presented with the Nexys control unit.
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2.2. Technical specifications
Range / Generating set type RENTAL POWER / R33C3
Weights and Dimensions
Dimensions with high autonomy tank
Dimensions l x w x h
2200 mm x 1000 mm x 1528 mm
Weight:
1100 kg à vide / 1300 kg en ordre de marche
Hood:
M3127
Sound pressure level at 1 m : 72 dB(A)
Measurement uncertainty : 0.66
Output
Emergency
1 Prime power 2
Voltage Hz Phase Load factor Max current (A) power
kW / kVA
kW / kVA
400/230 50 3 0.8 48 26.4 / 33 24 / 30
(1) ESP: Stand-by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528-1, no overload available
under these service conditions.
(2) PRP: Main output available continuously under variable load for an unlimited time period per year as per ISO 8528-1, an overload of 10%
one hour every 12 hours is available, as per ISO 3046-1.
Term of use :
Standard reference conditions ESP/PRP 40° / 40°, Air Intlet Temp, 1000m / 1000m mA.S.L. 60 % relative humidity.
Engine data
Manufacturer / model MITSUBISHI S4S-Z361SD
Type 4 Cycles Naturally aspirated
Cylinder configuration 4 XL
Cubic capacity 3.33 L
Rotation speed 1500 Rpm
Max emergency/prime power at nominal speed 31.3 / 28.3 kW
Adjustment type Mechanical
Fuel consumption
100 % main power 8.60 L/h
Fuel
Fuel type Diesel
High autonomy fuel tank 220 L
Lubrication
Oil capacity 10 L
Min. Oil pressure 1 bar
Nominal oil pressure 3.9 bar
Oil consumption (100 % load) 0.08 L/h
Oil sump capacity 9L
Type of lubricant Genlub
Cooling
Engine capacity with radiator 8.5 L
Max coolant temperature 105 °C
Fan power 0.8 kW
Refrigerant type Gencool
Thermostat 76.5 – 90 °C
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Alternator data
● Compliant with NEMA MG21 standards, UTE NF C51 111, ● The alternator is protected against short circuits
VDE 0530, BS 4999, IEC 34.1, CSA ● Vacuum impregnation, epoxy winding, IP23 protection rating
Type LEROY SOMER LSA42.2L9
Number of phases 3
Power factor (cos Phi) 0.8
Number of poles 4
Excitation type AREP
Regulation R438
Number of bearings 1
Coupling Direct
Control unit(s)
NEXYS
Standard specifications:
Frequency meter, Voltmeter, Ammeter
Alarms and faults:
Oil pressure, Coolant temperature, Fail to start, Overspeed,
Alternator min/max, Fuel level low, Emergency shutdown
Engine parameters:
Working hours counter, Engine speed, Battery voltage, Fuel
Level, Air Preheating
TELYS
Standard specifications:
Voltmeter, Ammeter, Frequency meter
Alarms and faults:
Oil pressure, Water temperature, Start failure, Overspeed,
Alternator min/max, Battery voltage min/max, Emergency stop
Engine parameters:
Timer, Oil pressure, Water temperature, Fuel level, Engine
speed, Battery voltage
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2.3. Identifying sets
Generating sets and their components are identified by means of identification plates.
The precise rules for identifying each major component (engine, alternator, etc.) are set out in each manufacturer's documentation
contained in the appendices of this manual.
1 - Generating set 9 - Maximum ambient temperature for the rated

power (°C)
2 - Manufacturer name
10 - Rated frequency (Hz)
3 - Model
11 - Generating set rotation speed (RPM)
4 - Serial number
12- Rated voltage (V)
5 - Year of manufacture
13 - Rated current (A)
6 - Rated output (kVA and kW) according to the ISO
8528-1 standard 14 - Weight (kg)
PRP: main power 15 - CE marking
ESP: emergency power 16 - Non CE standard marking
(e.g.: GOSSTANDART)
7 - Rated power factor
17 - Sound pressure
8 - Maximum altitude of the site above sea level (m)
for the rated power 18 - Sound power
Figure 10 : Example of a generating set identification plate
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2.4. Fluid retention
Any outflow of the fluids contained in the generating sets (fuel, oil and coolant, or rainwater or condensation) will be collected in a
retention container.
The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected.
Figure 11 : Fluid retention container
The generating sets are fitted with a visual alarm warning when the upper limit of the retention container has been reached.
In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or
condensation). If necessary, drain the containers via the drain port.
Note: Never allow these fluids to drain onto the ground; ensure they are collected in a designated container.
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2.5. Fuels, lubricants and coolants
All specifications (product features) are given in the engine and alternator maintenance manuals attached to this manual.
In addition to these, we recommend the fuels, lubricants and coolants mentioned in the "Specifications" section.
2.5.1 Fuel specifications

General quality requirements
The quality of the fuel is essential for engine performance. It affects the technical performances such as the service life, power supplied
and fuel consumption as well as the ability to respect the requirements issued by authorities relating to pollutant emissions. Only fuels
which conform to the current legal requirements and national and international standards should be used. Consult the local
fuel distributor to find out the characteristics of the diesel fuel available in the area.
Examples of standards and requirements:
European standard (CEN) for vehicle fuel - fuels for diesel engines (diesel fuel) -
EN 590
requirements and test methods
American Society for Testing and Materials: basic requirement in the United States and
ASTM D 975 1-D and 2-D
Canada
JIS KK 2204 Japanese Industrial Standards: Japanese industrial standards
Respecting pollutant emissions
The certification measures confirming that the legal emission value limits are respected are performed with certified fuels which
conform to the standards and requirements stated above.
Resistance to low temperatures
When the external temperature is low, the fluidity of diesel fuel may no longer be sufficient due to paraffin deposits. Also, in the winter
in order to avoid malfunctions (for example, clogged filters), use diesel fuels which are fluid enough in cold weather.
The requirements to respect for the various geographical regions and various seasons (winter/summer) are specified in the standards
and/or national regulations. Petrol companies should always supply fuels with the correct flow properties regardless of the time of year.
In general, diesel fuel is treated with additives so that the fuel can be used at low temperatures in the region where it is marketed.
Treating fuel with additives must respect the engine manufacturer's recommendations and maintain a suitable lubricity for the injection
systems. It is recommended to favour fuels whose additives have been added in a refinery over those modified in the storage tank.
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General specifications for diesel fuel
The fuel used must have the following characteristics (non-exhaustive list):
The sulphur content must meet the current emissions regulations in the region where the
generating set is used.
For the United States and countries respecting the EPA regulation
Only use Ultra Low Sulphur Diesel (ULSD) fuel with a maximum sulphur content of 15 mg/kg
for Interim Tier 4 and Tier 4 certified engines.
Sulphur content For the European Union
Directive 2009/30/CE whose aim is to limit atmospheric pollution, imposes the use of a diesel
fuel with a very low sulphur content of 10 mg/kg, for non road mobile machinery.
In France, this obligation has resulted in the development of a diesel fuel called "off road diesel
fuel" or "GNR". The maximum admissible sulphur content is 10 mg/kg. However, member
states allow these diesel fuels to contain up to 20 mg/kg of sulphur when they are distributed
to the final users. It is recommendable to avoid storing off road diesel fuel for long periods of
time (over 6 months).
The viscosity and density directly affect the performance (power and fuel consumption),
emissions and service life of the engine. A low level of viscosity and density reduces engine
power and increases fuel consumption. Too high a level of viscosity and density seriously
Viscosity and reduces the service life and operation of the fuel injection system.
density
In order to maintain adequate technical and environmental performance, the viscosity and
density must conform to the specifications indicated in the manufacturer's instructions for the
engines fitted to our generating sets.
Lubricity (or
In order to protect the fuel injection system against excessive wear, the fuel must have
capacity for
satisfactory lubricity (refer to the manufacturer's instructions for the engines fitted to our
lubrication or
generating sets).
oiliness)
The ignition behaviour of diesel fuels is described by the cetane index. The cetane index is
Cetane index important for emissions, the ability to start in cold weather and engine noises. The minimum
technical requirements are 45.
The fuel and tank must not contain any water. Water causes the engine parts to corrode and
wear more rapidly, particularly the injection system parts. In addition, water promotes the
Water and growth of bacteria and fungi in the tank, which can clog the fuel filter. The fuel must not contain
contaminants any type of residue. Organic contaminants (bacteria, fungi, etc.) can block the fuel filters;
inorganic material in the fuel (dust, sand) can cause serious damage to the injection
equipment.
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2.5.2 Lubricant specifications
Essential for the correct operation of the engine. The oil should be selected according to its use. Besides the lubrication function, oil
should also:
- cool certain parts;

- protect metal parts against corrosion;
- improve the sealing, in particular between pistons, piston rings and cylinders;
- remove impurities (to the filter).
It is recommendable to use a top of the range lubricant for diesel engines. The table below lists the oils recommended for each engine
manufacturer.
Engine
Make Type Make Type
Cummins All GenPARTS GENLUB TDX 15W40
John Deere John Deere PLUS-50
John Deere All
GenPARTS GENLUB TDX 15W40
MTU All GenPARTS GENLUB TDX 15W40
Mitsubishi All GenPARTS GENLUB TDX 15W40

Fuel GenPARTS GENLUB TDX 15W40
Perkins
Gas MOBIL PEGASUS 705
Volvo All GenPARTS GENLUB TDX 15W40
Doosan All GenPARTS GENLUB TDX 15W40
Lombardini GenPARTS GENLUB TDX 15W40 or Kohler 5W40,
All
Kohler or Kohler according to the model of the engine
Viscosity
Viscosity is a measure of the flow resistance of a fluid. The viscosity of an engine oil is expressed by 2 SAE (Society of Automotive
Engineers) grades. One grade for cold weather and one grade for hot weather. The grade for cold weather appears before the letter W.
The 1st grade represents dynamic viscosity in cold weather, namely the ability to start the engine and to prime the oil pump (and
therefore to lubricate the various components quickly). The lower the number, the more fluid the oil.
The 2nd grade represents the kinematic viscosity in hot weather. The higher the number, the thicker the film of oil when hot (which aids
protection and sealing). The lower the number, the less friction there will be in hot weather (it helps to save fuel).
In order to ensure immediate protection when starting the engine, the choice of viscosity grade when cold is essential. More fluid oil is
quicker to flow when oil begins to circulate through the engine. It should be selected according to the ambient temperature. See the
table below.
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Characteristics of GENLUB TDX 15W40 oil
Performance
GENLUB TDX oil is a 15W40 multigrade mineral oil which meets the following specifications: ACEA E3 and API CG-4.
ACEA E3: oil with superior viscosity stability, suited to extended oil change intervals and severe conditions of use.
API CG-4: oil particularly effective to meet the emissions requirements.
ACEA = European Automobile Manufacturers' Association
API = American Petroleum Institute
Specifications
Specifications Units Grade SAE 15W-40
Density at 15°C kg/m3 883
Kinematic viscosity at 100°C mm2/s (cSt) 14
Viscosity index – 130
Flow point °C - 27°
Flash point °C >200
TBN* mgKOH/g 9.7
Typical values given for information purposes
* TBN (Total Base Number – degree of alkalinity): a measure of a lubricant's reserve alkalinity according to standard ASTMD 2896.
This check makes it possible to assess the ability of the product to remain in service and to check the ’capacity of the lubricant to
neutralise the acidity contained in the oil, which may corrode the metallic elements of the lubricated component.
2.5.3 Coolant specifications

The engine's internal cooling system allows the engine to operate at a precise temperature.
The table below lists the coolants recommended for each engine manufacturer.
Engine
Make Type Make Type
Mitsubishi LLC
Mitsubishi All
GenPARTS GENCOOL PC -26
MTU All GenPARTS GENCOOL PC -26
John Deere All GenPARTS GENCOOL PC -26
Volvo All GenPARTS GENCOOL PC -26
Doosan All GenPARTS GENCOOL PC -26
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Specifications of GENCOOL PC -26 coolant
Performance
GENCOOL PC -26 coolant is a ready-to-use cooling fluid which provides a high level of protection and is produced from an antifreeze
approved by the majority of manufacturers (Power Cooling concentrated antifreeze).
It offers the following:
- Improved anticorrosion: improves the effectiveness and service life of the cooling system.
- High temperature feature: promotes heat exchange.
- Long-term protection: against overheating and corrosion under extreme conditions of use.
- Compatible with the original fluid (however, it is recommended to drain the entire cooling system when replacing the fluid).
Specifications
Specifications Units Characteristics
Density at 20°C kg/m3 1053 ± 3
pH pH 7.5 to 8.5
Alkalinity reserve ML ≥ 10
Boiling temperature °C 105 ± 2
Freezing temperature °C -26 ± 2
Typical values given for information purposes
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3. Transporting the equipment
3.1. Warnings concerning transport
It is prohibited to operate generating sets whilst they are being transported.
IMPORTANT
3.2. Preparing for transport

Before the equipment is transported, perform the following operations:
1. Close the tap on the oil top up tank outlet.

2. Fill up the oil top up tank with oil.
3. Fill up the crankcase with oil.
4. Fill up the on-board tank with fuel.
5. Check that the batteries are fitted and filled with electrolyte.
3.3. Road transport
3.3.1 Generating sets with and without an enclosure

Generating sets must be transported by road in accordance with the regulations of the countries concerned.
When transporting generating sets in containers by road, the following steps must be observed:
1. Put a plastic cover over non-enclosed generating sets during transportation.

2. Select transport equipment (trailer, semi-trailer, etc.) suitable for this usage and having all the safety guarantees in terms of
load bearing capacity and of the securing devices.
3. Chock and fix the generating sets to the floor of the transport equipment.
4. Strap the generating sets to the transport equipment.
5. Select a transport route which makes it possible to travel on roads suitable for vehicles, and whose quality will not damage the
on-board generating sets.
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3.3.2 Generating sets on trailers
3.3.2.1. Hitching and unhitching the trailer
Jockey wheel for

M3128
Jockey wheel for
and M3129
M3126
type trailers
and M3127
type trailers
Before hitching the trailer, check the hitching system on the towing vehicle; this must be perfectly compatible with the trailer.
Towing a trailer with a non-compliant device (bar, cables, lashing, etc.) runs the risk of serious accidents.
Also check:
- That there are no incipient ruptures or significant wear on the hitching system.
- That the locking system is working properly.
IMPORTANT
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Hitching a trailer fitted with a hitching ring
1. Drive the towing vehicle or bring the trailer up to the hitching point, then:
- With the jockey wheel touching the ground, place the stabiliser (1) in the top position: 2
Loosen the jaw of the stabiliser (2) with its lever;
Raise the stabiliser fully;
Tighten the jaw of the stabiliser (2) with its lever. 1
- Remove the wheel chocks if necessary and store them.

2. Position the trailer parallel to the ground using the guide wheel handle (jockey wheel).
3. Place the hitching ring above the towing vehicle's hitching system:
After this adjustment, the trailer must remain parallel to the ground.
Make any necessary height adjustments to the towbar using the jockey wheel to enable hitching.
IMPORTANT
4
- Remove the safety pin from the towbar (3);
3
- Undo the nut with the lever (4);
- Use the adjustable towbar handle to place the ring above the hitching system;
- Tighten the nut to lock the towbar; 5
- Fit the towbar safety pin.
4. Attach the ring to the hitching system:
- Lower the trailer by moving the jockey wheel away from the ground using
its handle (5).
5. Lock the jockey wheel in the towing position:
When in the towing position, the jockey wheel must not:

- obstruct the unlocking cable's movement;
- trap any electrical cables.
IMPORTANT
M3126/M3127 type trailers M3128/M3129 type trailers

- Position the jockey wheel at the rear. - Remove the safety pin from the position lock (8).
- Raise the jockey wheel with its handle (5) into the - Remove the position lock (8).
notches on its tube (6).
- Place the jockey wheel in the towing position.
- Loosen the jaw of the tube (7) with its lever.
- Fit the position lock (8).
- Raise the tube fully.
- Fit the safety pin in the position lock (8).
- Tighten the jaw of the tube (7) with its lever.
- Raise the jockey wheel with its handle fully and at right
angles to the towbar.
5
6
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6. Attach the unlocking cable to the hitching plate on the towing vehicle.
Examples of how to attach the hitching cable
If the hitching ring is not correctly connected to the hitching hook, the trailer will become separated from the
towing vehicle. In this case the unlocking cable actuates the parking brake (which then becomes an emergency
brake).
To ensure that the device fulfils its function correctly, the unlocking cable:
- MUST NOT be wound around the jockey wheel, as this will disable emergency braking;
IMPORTANT - MUST NOT be taut or obstructed, as this could activate emergency braking during towing;
- MUST be routed as straight as possible and not be obstructed at any point;
- MUST be sufficiently long to allow cornering.
7. Connect the electrical cable plug controlling the lamps, indicators, etc. to the socket on the towing vehicle.
8. Remove the parking brake:
- Remove the wheel chocks if necessary and store them;
- Perform the following operations simultaneously on the parking brake:
Press the unlocking button (9);
Lower the handle (10) fully. 9
10
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Unhitching a trailer fitted with a hitching ring
1. Immobilise the trailer:
- Chock the wheels;
- Apply the parking brake:
Raise the parking brake lever (10) fully.
2. Disconnect the electrical cable plug controlling the lights, indicators, etc. from the socket on the towing vehicle.
3. Remove the unlocking cable on the towing vehicle.
4. Release the hitching ring:
M3126/M3127 type trailers M3128/M3129 type trailers
- Disengage the jockey wheel from the notches in the - Remove the safety pin from the position lock (8) on the
tube (6) with its handle (5). jockey wheel.
- Loosen the jaw of the tube (7) with its lever. - Remove the position lock (8).
- Lower the tube until the jockey wheel touches the - Place the jockey wheel in the bottom position.
ground.
- Fit the position lock (8).
- Tighten the jaw of the tube (7) with its lever.
- Fit the position lock pin.
- Lower the jockey wheel to the ground with its handle.
5
6
7
8
- Support the load on the jockey wheel:

Lower the jockey wheel with its handle;
When you are sure that the wheel can bear the load (the towbar rises), unhitch the trailer from the vehicle.
5. Fit the stabiliser (1):
- Loosen the jaw of the stabiliser (2) with its lever;
1
- Place the stabiliser in contact with the ground;
- Tighten the jaw of the stabiliser (2) with its lever.
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3.3.2.2. Check before towing
Before first use, it is essential to check the tightness of the wheel bolts.
IMPORTANT
Before towing, check the following:
- Wheel tightness.
- Hitching hook locked.
- Tyre pressure.
- Signalling lights working.
- Enclosure doors closed.
- Parking brake released.
- Guide wheels (jockey wheels) and stands lifted and locked.
- Safety cable fitted.
INFLATION PRESSURE (BAR)

145R13 2.2 185R14C 4.5
155 / 70R13 2.5 195R14C 4.5
185 / 70R13 2.5 215R14C 4.5
175R14C 4.5 215 / 75R14C 4.5
TIGHTENING TORQUE WHEELS

Axis of 10 60 Nm
Axis of 14 and 16 120 Nm
3.3.2.3. Operation
The driving speed must be suited to the condition of the road and the handling of the trailer.
Maximal speed on road: 140km/h.
Driving at high speed causes the tyres to heat; it is therefore important to stop from time to time and check them. Excessive heating
may cause a puncture, and therefore a serious accident. For reversing manoeuvres, remember to lock the inertia brake.
Particular attention must be paid to the tightness of the wheels on new vehicles.
In the first few miles' driving, heating of the brake hubs and drums will actually reduce the wheel tightness. It
is therefore essential to check the tightness every 6 miles (10 kilometres) until no further loosening is noted.
IMPORTANT The tightness check must nonetheless be carried out whenever you have towed the trailer.
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Lights / signalling
Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use.
Front reflective devices (white)

Red rear lights
+ direction indicators
+ stop lights
Rear reflective devices

(red triangle)
Side reflective devices (orange)
Figure 12 : Example of French signalling
3.4. Rail transport

Generating sets must be transported by rail in accordance with the specific rules governing rail transport.
When transporting generating sets in containers by rail, the following steps must be observed:
1. Put a plastic cover over non-enclosed generating sets during transportation.

2. Choose transport equipment appropriate for this usage, and having all the safety guarantees both in terms of load-bearing
capacity and securing devices.
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3.5. Shipping

Transportation must be carried out in accordance with the rules of shipping. Generating sets must be transported in a shipping
container.
When shipping generating sets in containers, the following steps must be observed:
2. In the case of a grouped load container, SEI cases must be used for packing.
3.6. Air transport

Containers must be transported by air in accordance with the specific rules governing air transport.
The UN has classified generating sets as "dangerous goods" listed under UN code 3166 - class 9 - "Engine, internal combustion
(flammable liquid powered)".
Any air shipment of generating sets must be subject to prior declaration to the air freight company, in accordance with form MOD3909.
For air transport, observe the following steps:
2. For control boxes, packing in an SEI 4 C case (solid case with waterproof cover) is obligatory.
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4. Installation - Connections
4.1. Unloading the generating set
4.1.1 Choosing the location

When choosing where to site the generating set, bear in mind the:
- proximity to the electrical distribution panel;

- nuisance caused by the noise;
- fuel supply;
- burnt gas evacuation;
- direction of these gases and the noise generated.
1 m min.
Incorrect ventilation and exhaust Building or terrain too rough

Generating set incorrectly seated
Impossible to open enclosure doors Impossible to fill with fuel
Figure 13 : Examples of problems that may be encountered
35/242
4.1.2 Safety during unloading
Always follow the safety instructions before unloading

IMPORTANT
- The lifting machinery or equipment is suitable for the work required and the weight of the generating set. This is indicated on the
generating set's identification plate.
- The sling is correctly positioned in the central lifting eye or the lifting arms are correctly positioned in the fork-lift pockets intended
for this purpose.
- The ground is able to bear the load of the generating set and its lifting machinery without stress (otherwise lay down stabilising
beams of sufficient strength).
- The generating set is put down as close as possible to its place of use or transport, in a clear space with free access.
Example of equipment to be used:
crane;
slings;
lifting beam;
safety hook;
shackles;
Forklift truck.
4.1.3 Unloading the generating set
Before unloading or moving generating set, check that the handling equipment used is able to bear the weight of
the generating set (shown on the generating set's identification plate.
IMPORTANT
4.1.3.1. Slings
1. Attach the sling on the lifting equipment to the ring on the generating set (no. 1) provided for this purpose. Tension the slings
slightly.
2. Check that the sling is correctly attached and the equipment is steady.
3. Lift the generating set carefully.
4. Direct the generating set towards the chosen location and stabilise it.
5. Carefully set down the equipment while continuing to position it.
6. Release the sling, then detach it.
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4.1.3.2. Fork lift truck
1. Position the arms of the forklift truck in the forklift pockets (no. 2).
2. Lift the equipment, handling it gently.
3. Set down the generating set in its unloading position.
1
3
2
Figure 14 : Points used for lifting and moving
4.1.4 Moving the generating set

Whenever moving the generating set, ensure suitable equipment is used (e.g. sling, forklift, etc.) and identify those parts on the
generating set which can be used to move it:
- lifting eye (no.1);
- forklift grooves (no.2);
- tow bar (no.3).
37/242
4.2. Connecting the generating set
4.2.1 Connection summary
This diagram can be used to retrace the different steps enabling the generating set to be correctly connected.
TT earthing system
"EDF application" option (France

TT only)
Identify the type of differential protection

fitted on the generating set
Fixed differential protection Adjustable differential protection
Set the differential protection

of the generating set
30 mA 300 mA 30 mA 300 mA
No operation required: Add differential protection No operation required: Add differential protection
terminal circuits protected set to 30 mA to the terminal terminal circuits protected set to 30 mA to the terminal
circuit output(s) circuit output(s)
Earth the generating set
Connect the generating set to the installation
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4.2.2 Protecting people and equipment
4.2.2.1. Earthing system principle

The Earthing system, or SLT (formerly Neutral system) of the electrical installation defines the situation of the generating set neutral
in relation to earth and the grounds of the electrical installation at the user end.
Our generating sets are designed to operate with the TT system (or EDF application depending on the option, for France only).
4.2.2.2. TT system
In the TT earthing system, automatic power cut-off via a Residual Current Device (RCD) is obligatory at the upstream part of the
installation, to ensure that personnel are protected (additionally, a maximum 30 mA device must be installed on outlet circuits).
R R
Ph 1 Ph 1
Ph 2 Ph 2
id
Ph 3 Ph 3
N N
PE PE
id
R
Neutral connected
R
Ground connected
to earth to earth
T T
id
Neutral earth Ground earth
Equipment
Figure 15 : TT earthing system
The alternator neutral is earthed, the grounds of the user equipment have their own earth connection.
39/242
4.2.2.3. Installing the differential protection
The generating set is equipped with a residual current device in order to guarantee individuals are protected from electric shocks with
the TT system. This may be fixed ("vigi" unit) or adjustable (Resys) depending on the option chosen.
• If the generating set's residual current device is fixed and the activation threshold is set to 30 mA, it is guaranteed to protect people.
• If the generating set's residual current device is fixed and the activation threshold has been set at 300 mA, a 30mA residual current
device must be added to each of the circuit outlets in use.
• If the generating set's residual current device is adjustable, (located upstream) this must be above those devices located
downstream (terminal circuits); this means that continuity on clean circuits will be maintained in the event of a fault on one of the
terminal circuits (see the following point on setting the residual current device).
Example:
Generating set
0.3A Generating set's residual

(300mA) current device
Residual current device Residual current device Residual current device

0.03A Terminal circuit 1 0.03A Terminal circuit 2 0.03A Terminal circuit 3
30mA 30mA 30mA
Risk of electric shock.

The generating set's differential relay is factory-set with a current threshold of 0.03 A (30 mA) and with an
automatic time delay (0 s).
Any change to the setting on the residual current device could pose a risk to personal safety. The user will be held
liable - any changes must only be made by trained, qualified engineers.
If the setting is modified, it is essential to restore the original settings after use.
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4.2.2.4. Setting the generating set differential protection
The setting of the generating set's residual current device is guaranteed by a differential relay fitted near the control unit (type A / AC or
B depending on the generating sets). As a result, two parameters relating to the downstream device (terminal circuit) must be set:
- Current threshold: the generating set's differential relay must be three times more sensitive than that of the terminal circuit.
- Time delay: the cut-off of the generating set's differential relay must be longer than that of the terminal circuit.
- Type A / AC differential relay:

Use:
Differential relay for which operation is guaranteed:
• for residual sinusoidal alternating currents;
• for continuous pulsed residual currents;
• for continuous pulsed residual currents with a continuous component of 0.006 A with or without phase check,
independent of the polarity.
Setting:
1. Use a screwdriver to set the current

threshold potentiometer (1) to 0.03 A (30
mA).
2. Use a screwdriver to set the time delay Test Button

potentiometer (2) to 0s (automatic). (3)
3. Test the residual current device using the Time setting potentiometer
"Test" button on the relay (3). (2)
Current threshold potentiometer
(1)
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- Type B differential relay:
Use:
Differential relay for which operation is guaranteed:
• as in the case of type A;
• for residual sinusoidal currents up to 1000 Hz;
• for residual sinusoidal currents superimposed on a pure continuous current;
• for continuous pulsed currents superimposed on a pure continuous current;
• for residual currents which could come from rectifier circuits i.e.:- three phase half-wave rectifier or a three-phase full-
wave bridge rectifier, full-wave bridge rectifier between phases, with or without phase angle check, independent of
the polarity.
Setting:
1. Use a screwdriver to adjust the current

threshold using the setting potentiometer
(1) and the micro-switches (4)
to 0.03 A (30 mA).
2. Use a screwdriver to adjust the time delay

using the setting potentiometer (2) and the
micro-switches (4) to 0s (automatic).
3. Test the residual current device using the

"Test" button on the relay.
Test Button
(3)
Sensitive area (4)

(white = position of micro-
switches)
Time setting
potentiometer (2)
Current threshold potentiometer

(1)

The generating set's differential relay is factory-set with a current threshold of 0.03 A (30 mA) and with an
automatic time delay (0 s).
Any change to the setting on the residual current device could pose a risk to personal safety. The user will be held
liable - any changes must only be made by trained, qualified engineers.
DANGER If the setting is modified, it is essential to restore the original settings after use.
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4.2.2.5. Earthing the generating set

Before use, the generating set must always be earthed. Protection against electric shocks is only effective
once the earthing connection has been made.
Disconnect the battery leads, starting with the negative lead (-), or use the battery isolating switch before
DANGER carrying out any operations on the generating set.
1. Open the door to the power section (no.1) then the access
door to the cable router flap and to the connection terminal
box (no.2). 1
2
2. Connect the earth cable (supplied) to the terminal (rep.3)

on the generating set located on the connection terminal
box.
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Length of earthing
Nature of ground
rod (in metres)
3. Check the length of the earthing rod depending on the
nature of the ground and adapt if necessary. Thick arable land, damp
1
compact backfill
The equipment supplied is not suitable for Thin arable land, gravel, rough
1
bare stony soils, dry sand or impermeable backfill
rock.
IMPORTANT
Bare stony soils, dry sand,
4 or 4 x 1
impermeable rock
4. Plant the earthing rod in the ground and connect it to the

earth cable.
Earth cable
ground
1 meter
Note: For the United States (National Electrical Code ref. NFPA-70), use a copper wire with a minimum cross-section of 13.3 mm² (or
AWG 6 at most) connected to the generating set's earth connection and a galvanised steel earthing rod completely buried in the ground
in an upright position. This earthing rod must be at least 2.5 m long (of which at least 1 m must be in the ground).
4.2.3 Making the connections
4.2.3.1. Connections - general information

When connecting, always comply with standard NFC 15-100 and the application guide NFC 15-401 (in France) or follow standards
based on the international standard IEC 60364 (countries outside France).
The cable cross-section and number of connection cables should be determined according to the type of connection cable and the
current standards to be observed in the country of installation. The choice of connection cables must comply with international standard
IEC 60364-5-52.
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4.2.3.2. Selecting the power cables
The calculation rules used to choose the power connection cable size are defined below:
- Identify the current shown on the generating set's identification plate.
- From the table below, select the circuit breaker rating directly above the current shown on the generating set's identification
plate.
- Choose the corresponding cable size.
.
Three-phase
Permitted drop in voltage = 5% / Multi-core conductors or connected single-core conductors where rating = 4X…(1) / Cable type
PVC 70°C (e.g. H07RNF) / Ambient temperature = 30°C.
Circuit breaker Cable sizes
rating 0 - 50m 51 - 100m 101 - 150m
(A) mm²/AWG* mm²/AWG* mm²/AWG*
10 1.5 / 14 2.5 / 12 4 / 10
16 2.5 / 12 4 / 10 6/9
20 2.5 / 12 4 / 10 6/9
25 4 / 10 6/9 10 / 7
32 6/9 6/9 10 / 7
40 10 / 7 10 / 7 16 / 5
50 10 / 7 10 / 7 16 / 5
63 16 / 5 16 / 5 25 / 3
80 25 / 3 25 / 3 35 / 2
100 35 / 2 35 / 2 4X(1X50) / 0
125 (1) 4X(1X50) / 0 4X(1X50) / 0 4X(1X70) / 2/0
160 (1) 4X(1X70) / 2/0 4X(1X70) / 2/0 4X(1X95) / 4/0
250 (1) 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X150) / 2350MCM
400 (1) 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM 4X(1X185) / 0400MCM
630 (1) 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM 4X(2X1X150) / 2x 2350MCM
Single phase
Permitted drop in voltage = 5% / Multi-core conductors / Cable type PVC 70°C (e.g. H07RNF) / Ambient temperature =30°C.
Cable sizes
Circuit breaker
0 - 50m 51 - 100m 101 - 150m
rating (A)
mm²/AWG* mm²/AWG* mm²/AWG*
10 4 / 10 10 / 7 10 / 7
16 6/9 10 / 7 16 / 5
20 10 / 7 16 / 5 25 / 3
25 10 / 7 16 / 5 25 / 3
32 10 / 7 25 / 3 35 / 2
40 16 / 5 35 / 2 50 / 0
50 16 / 5 35 / 2 50 / 0
63 25 / 3 50 / 0 70 / 2/0
80 35 / 2 50 / 0 95 / 4/0
100 35 / 2 70 / 2/0 95 / 4/0
125 50 / 0 95 / 4/0 120 / 2250MCM
* : AWG. American Wire Gauge, American standard for electrical cables.
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4.2.3.3. Connecting the generating set to the installation

Before use, the generating set must always be earthed. Protection against electric shocks is only effective
once the earthing connection has been made.
Disconnect the battery leads, starting with the negative lead (-), or use the battery isolating switch before
DANGER carrying out any operations on the generating set.
1. Open the door to the power section (no.1) then the

access door to the power connection cable router flap
and to the connection terminal box (no.2). 2
1
2. Loosen the two knobs (no.3) of the power connection

cable router flap then slide the flap (no 4) towards the
outside of the generating set.
3
3
3. Feed the power connection cables through the cable

router flap.
Power cables
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4. Connect the power connection cables onto the bars
(N/L0-L1-L2-L3 or N2-R2-S2-T2) using the terminals (no.5) or
clamps (no.6).
5 6
5. Slide the cable router flap towards the inside of the generating
set until it makes contact with the power connection cables then 3
retighten the two knobs; close the access door to the power
section back up again.
3
6. Connect the power connection cables to the installation to be

powered ensuring the live and neutral wires are correctly
connected.
Our generating sets are factory-set with a

conventional direction of phase rotation. A
phase converter (not supplied) can be used to
ensure correspondence of phases between
IMPORTANT the generating set and the installation..
N/L0 L1 L2 L3
ou ou ou ou
N2 R2 S2 T2
Installation to be powered
(e.g.: cabinet, distribution
box, installation etc.)
To limit the risk of falls caused by obstacles on the floor, it is recommended to suspend cables and ventilation
ducts. As necessary, ensure that cables which remain on the floor are protected by burying or covering them.
IMPORTANT
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4.2.3.4. Connecting the battery or batteries to the generating set
Always ensure that the polarities of the battery and starter motor correspond. Never swap the positive and
negative battery terminals when connecting them. This could cause severe damage to the electrical equipment.
IMPORTANT
To connect the battery:

1. Connect the red connecting cable (+) to the positive battery terminal.
2. Then connect the black cable (-) to the negative battery terminal.
To disconnect the battery:

1. First disconnect the black cable (-)
2. Then disconnect the red cable (+).
4.2.4 Overvoltage
Generating sets are not equipped with devices that protect against voltage surges from atmospheric discharges or due to handling
operations.
The company disclaims all liability for any accidents caused by these phenomena.
However, it is possible to install surge protectors considering that this assembly does not provide complete protection.
5. Installation
5.1. Warnings concerning commissioning

The inspections referred to in this section enable the electrical generator set to operate.
Specific skills are required to carry out these operations.
They must only be entrusted to personnel with the necessary skills.

IMPORTANT
Failure to follow these instructions in any way could result in malfunction or very serious accidents.
5.2. Checking the generating set installation
- Check the position of the generating set (stability, mounting, available space, ventilation, exhaust, etc.).
- Check the electrical connections :
earthing;
electrical control connections;
electrical power connections;
starter battery charging system (rating and voltage) if fitted to the generating set.
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5.3. Preparing for operation of the generating set
- Become familiar with the controls useful to operate the generating set.
- Read and understand the "user" menus of the control unit.
- Become familiar with the maintenance plans for the generating set .
- Become familiar with the operation of the generating set at no load or under load.
- Become familiar with the fluid specifications (fuel, lubricant and coolant).
5.4. Checking the generating set before startup

- Check that the plugs, blanking covers and protective adhesive strips have been removed.
- Ensure that the anti-humidity bags have been removed from the electrical sections (cabinet or control console, alternator, etc.).
- Check the insulation of the alternator see the alternator's maintenance manual.
- Check the levels see the engine's maintenance manual:
coolant;
oil;
fuel.
- Open the oil filler tap (if fitted to the generating set).
- Check the starter battery or batteries (connecting and charge) see the paragraph entitled "Starter batteries".
- Check the starter battery charging system (if fitted to the generating set).
5.5. Checking the generating set after startup

Off-load tests
- Carry out the safety checks (emergency shutdown, oil pressure, coolant temperature, etc.).
- Check the mechanical parameters:
engine parameters (oil pressure, coolant temperature);
absence of abnormal vibrations;
absence of abnormal noises;
absence of leaks.
- Check the electrical parameters:
voltage, frequency, current;
rotating field.
On-load tests
- Check the mechanical parameters:

engine parameters (oil pressure, coolant temperature);
absence of abnormal vibrations;
absence of abnormal noises;
absence of leaks.
- Check the electrical parameters:
voltage, frequency, current;
rotating field.
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6. Using the generator set
6.1. Pre-Start Inspection

Inspecting the engine compartment
Make sure there is no combustible material near the engine or battery. Also, check to
make sure that the engine and battery are clean. If combustible materials or dust are
found near the engine or battery, remove them.
Check the electrical wiring for such components as the starter and alternator for
looseness
Check the entire engine for fuel leakage, engine oil or coolant. If leakages are found,
repair.
Make sure the following valves, plugs and cocks are open or closed (tightened) properly:
Fuel feed valve: Open
Coolant drain cock (plug): Closed (Tightened)
Oil drain valve: Closed
Checking the engine oil level
- Do not top up the oil if the oil level is not below the low level marker.
Important
Pull out the oil level gauge and wipe it clean using a waste cloth.
Insert the oil level gauge fully into the oil level gauge guide, then pull out the gauge again.
The proper oil level is between the high and low marks on the oil level gauge. If the oil level is low, add engine oil of the specified
type.
Install the oil filler cap after refilling.
Check the oil pan and other area for oil leakage.
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Checking the coolant level
Remove the radiator filler cap only after the engine has cooled to room temperature. Place a waste cloth
over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release
internal pressure. Never open the radiator filler cap while the engine is hot, otherwise the steam or hot
Warning coolant spurts out and you may be scald with it.
Open the radiator filler cap and check the coolant level.
If the coolant level is low, add coolant to the speci-fied level.
Check for leaks in the cooling circuit.
Checking the air filter
A clogged filter element limits the engine's air intake and a reduced air supply to the engine.
Important
If the air filter is fitted with a dust control valve (A), press the tip
of the valve to evacuate any accumulated dust particles. B
Check the air filter clogging indicator (B). If the indicator is red,
clean the air filter.
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Checking the fuel pre-filter
The fuel is highly flammable and its vapours are combustible.

The fuel pre-filter must only be bled when the engine is stopped and cold.
Danger
Check that there is no water or sediment at the bottom of the pre-filter.

If necessary, drain the pre-filter using the following procedure:
Place a suitable container under the drain plug prefilter

Undo the drain plug (A) at the bottom of the pre-filter by two or three turns.
Collect the water and/or sediment in the container.
When fuel starts to flow out, tighten the drain plug.
Check that there are no leaks. A
If necessary, reprime the fuel circuit.
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6.2. Generator set with NEXYS control panel
6.2.1 Control panel presentation

7 9
9 1
10
8
6
9 5 9
4
Figure 16 : View of the front side
Emergency stop button for switching off the generating set in the event of a fault which could endanger personnel or damage
equipment
Key switch for starting up/shutting down the module and RESET function
Electronic card protection fuse
Screen-scroll button, press successively to access the various screens which are available
STOP button, press to switch off the generating set
START button, press to switch on the generating set
Normal operation LEDs and alarm and fault warning LEDs
Slot reserved for panel fascia options
Mounting bolt.
LCD for displaying alarms and faults, operating states, electrical and mechanical quantities
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1 2 3 4 5
Figure 17 : Description of the LEDs
A lit LED indicates:
Module being supplied (green, lights up and remains lit)

Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit)
Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to
generate (green, lights up and remains lit)
General alarm (orange, flashing)
General fault (red, flashing).
6.2.1.1. Introduction to pictograms
The pictograms are as follows:
Operating temperature
Fuel
Symbols for electric and
mechanical sizes
Overspeed
Non-starting fault
Battery
Starting on external command
Preheating
Air intake
Delay
Oil pressure
Figure 18 : View of pictograms
The "fuel level" pictogram is used to display the fault, the alarm and the fuel level.
The "operating temperature" and "oil pressure" pictograms are used to display the fault and analog value
The "overspeed" and "non-starting fault" pictograms are used to display the fault.
The "battery" pictogram is used to display the "alternator charge" fault and to indicate the battery voltage.
54/242
6.2.2 Manual starting
Check that the generating set circuit breaker has triggered.

Danger
connect the generating set battery.

turn the key switch to the ON position (without forcing it)
All of the LEDs light up for 2 seconds, to confirm that they are operating correctly.
If the LEDs do not light up, check the protection fuse and replace it if necessary.
All the items on the screen are displayed for 2 seconds.
Only the "ON" LED remains lit to indicate that the module is powered up.
The following screen appears.
The first line displays the motor speed in RPM.

The second line displays the battery voltage in
volts (V).
Check the battery voltage (min. 12 V)
Press (once briefly) the green "START" button.

If the motor is equipped with an air preheating system, there is a 10-second delay before the motor starts (preheating
activation period).
The following screen appears
The third line displays the air preheating time

remaining (with pictograms representing a
resistor and an hourglass).
If the motor is not fitted with an air preheating system or once the preheating delay has elapsed, the engine starts up
(start of a cycle comprising 3 attempts to start up the engine).
The following screen appears.
The number of successive and automatic starting attempts is limited to 3.

Warning
Note: the LED flashes as soon as the START button is pressed and continues to flash until the frequency stabilises if
a "measurements" card has not been inserted and until the frequency and voltage stabilise if a "measurements" card has been
inserted.
Following stabilisation, the LED light comes on

continuously.
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6.2.3 Switching off
trigger the circuit breaker located at the base of the centre console
Let the motor run under no load for 1 to 2 minutes to allow it to cool.
press the "STOP" button to stop the generating set.
switch off the MICS Nexys module by switching the key to "OFF" (without forcing it).
6.2.4 Alarms and faults
The appearance of a fault or an alarm causes the following

screen to be displayed (one or more pictograms or a fault
code along with the SOS message are displayed).
The user can access the following screens by pressing the key
The fault or alarm screen will disappear once the fault or alarm has been removed.
Only one fault is displayed on this screen (the fault which caused the generating set to stop).
If one or more faults have appeared after the first fault, they can only be displayed after the first fault has been reset
(press "Reset" as many times as the number of faults present).
Note: an alarm can appear at the same time as a fault.
6.2.5 Faults and alarms - Details

List of faults which will cause the generating set to stop and generate a pictogram
Associated pictogram
Oil pressure fault: Indicates that the oil pressure is incorrect
Engine temperature fault: Indicates that the engine

temperature is too high.
Non-starting fault: Indicates that there have been three

consecutive unsuccessful starting attempts.
Overspeed fault: Indicates an excessive generating set

running speed.
Low fuel level fault: Indicates the need to top up the fuel.
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List of faults which will cause the generating set to stop and generate a fault code
Associated message
Low coolant level fault: indicates that the level of coolant is
low in the radiator (linked to a two second time delay).
Or
Overload or short-circuit fault (optional): with the circuit
breaker SD contact closing (overload or short-circuit), the
generating set switches off immediately also causing the
main circuit breaker to be triggered.
Additional fault linked to message opposite: is displayed in

the following two cases: Associated message
Differential fault (1)
insulation fault (2)
(1) Differential fault (optional): with a differential fault
causing the activation of the differential relay, the
generating set stops immediately also causing the
main circuit breaker to be tripped.
(2) Insulation fault (optional): with an insulation fault
causing the activation of the control unit performing
insulation, the generating set stops immediately.
Associated message
Underspeed fault: indicates an incorrect rotation speed

(below 1000 rpm).
Associated message
Emergency stop or external emergency stop fault
Associated message
"STOP" fault activated if the "STOP" button is pressed

whilst the "AUT" LED is flashing to indicate that the
generating set is operating in automatic mode.
List of alarms associated with a pictogram

Low fuel level alarm: Indicates the need to fill up with fuel.
"Alternator charging fault" alarm indicates a problem

affecting the alternator charging rate.
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6.2.6 MURPHY diagnostic module
The fault finding module (MDDM) is an indicator for analysis and fault finding designed and manufactured for reading information
available on the J1939 CAN Bus. The fault finding module is easy to use and will enable you to view the values of the various engine
parameters and engine operating status codes.
It shows two lines, each of 8 characters, on a backlit LCD display. Two scroll buttons enable you to navigate in the menus and
parameters. Two LEDs, one red and one orange, indicate the fault or alarm status of the engine or ECU.
LED
DISPLAY
SCROLL BUTTONS
A- Machine Parameters
The following parameters are available on the Murphy fault finding module:
- working hours counter
- engine speed
- battery voltage
- engine speed
- coolant temperature
- oil pressure
- fuel economy
- air manifold temperature
- actual consumption
- active status codes
- status codes recorded coming from the engine
- MDDM20 parameter configuration for display
- display of the engine configuration parameters
-etc. depending on the type of engine.
B-Use
The Murphy module (MDDM) offers simple menu navigation:
1.To browse the list of parameters, press the Up and Down buttons.
2.To enter or exit a sub-menu, press both arrows simultaneously.
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The following diagram shows the structure of the main menu and how to go to each parameter:
59/242
The Parameter menu: to navigate in this menu simply use the arrow buttons separately.
The sub-menus: The sub-menus are available at the end of the parameter menu. To go to these sub-menus, scroll through the
parameters using the ▲ and ▼ buttons until you reach the required sub-menu.
C- The Sub-menus.
The sub-menus enable certain aspects of the fault finding module display to be modified.
Changing the unit of measurement:

There are two display modes available for units: English or metric. To change your units of measurement, use the ▲ and ▼ scroll
buttons until you get to the sub-menu:
Press the ▲ and ▼ arrows simultaneously if you want to retain the current designation.
Press one of the scroll buttons to show the second mode for displaying units. If you want to retain the second display mode, confirm
this by pressing the ▲ and ▼ buttons simultaneously.
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D-Displaying the active service codes:
The fault finding module enables the machine faults and alarms to be displayed in real time. When a fault appears, the display shows
the message "SrvcCode" every five seconds between displaying the current parameters.
The orange LED will light up when an alarm code is displayed (engine does not stop), the red LED will light up when a fault code is
displayed.
SPN and FMI codes are used in standard J1939 to identify faulty equipment
SPN: Suspect Parameter Number.
FMI: Failure Mode Indicator.
In the event that there are no active fault codes, the following screen will appear:
Depending on the SPN/FMI code, refer to the attached "List of engine fault codes" and "Engine user and maintenance manual" for help
on fault finding and maintenance.
Note that the manufacturer documents do not always stipulate the SPN used, for example:
-Volvo uses a set of codes called PID (Parameter Identifier) or SID (System Identifier); these two names relate to standards J1587 or
J1979, but in the case of VOLVO engines they relate to standard J1587. These two codes find their equivalent in standard J1939
(SPN). The attached "List of engine fault codes" indicates the SPN equivalent to Volvo's SID and PID.
- John DEERE complies with standard J1939 and uses SPN codes.
61/242
E-display of machine codes programmed:
The MDDM can display the codes of services programmed in the ECU memory. These programmed service codes are useful for
generating set fault finding and maintenance.
To display the programmed codes, scroll through the parameters until you reach the following sub-menus:
In the event that there are no programmed codes to display, the following screen will appear:
The purpose of programmed codes is to create a fault log, which is used to determine recurrent faults and thereby carry out effective
corrective and preventive maintenance on the engine; also it not desirable to delete these when the generating set is in operation
onsite. Note that at the test bench outlets the EEPROM memory, in which the programmed codes are stored, is reset to zero.
The following diagram shows the structure of the STORCODE (programmed code) menu and how to go to each parameter:
62/242
F)-Fault finding module internal errors.
Like any equipment using internal memory and a program, the fault finding module generates fault codes. Two types of code can be
recognised:
- Address Claim Procedure Errors
- Run Time Bus Errors.
Address Claim Procedure Errors (ACP-Err):

The following fault codes relate to the switching on of the fault finding module.
Error Code 1:
When switched on, the fault finding module must issue a request to the ECU for the network addresses used in order to exploit them;
this screen appears when:
- an address cannot be used.
- the fault finding module cannot find the default addresses.
- an address cannot be found in the correct register.
Error Code 2:
Passive Bus Error: this code appears when:

- the fault finding module cannot detect the ECU: in this case the CAN Bus is open.
- the CAN_hi and CAN_lo run time bus connection is reversed between the source (ECU) and the fault finding module.
Error Code 3:
This code is the result of the following problems:

- the CAN_Hi or CAN_lo bus, or both, are connected to an electrical ground or an external source of current.
- data is being not transmitted at a standard baud rate.
This type of fault generally requires repairs to be carried out on the CAN BUS connection and therefore involves work on the engine
wiring harness, i.e. on the fault finding module extension.
Run Time Bus Errors:

Fault codes can only be active if the fault finding module has been able to obtain the network addresses when it was switched on, see
Address Claim Procedure Errors (ACP-err).
Error Code 1:
EP=Passive Error, this screen appears when the fault finding module loses contact with the ECU, there may be two causes of this:
- one connector on the bus connection is disconnected.
- the CAN Bus is open.
Error Code 2:
BO=Bus Off, in this case, the case is identical to Error code 3 of the ACP.
Error Code 3:
BR=Bus Reset, this error code is similar to Error code 3 of the ACP, as are its causes. In this case the fault finding module has
encountered problems on the CAN Bus and it tries to automatically re-establish the network connection.
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6.3. Generator set with TELYS control panel
6.3.1 Control panel presentation
6.3.1.1. View of the front panel

9 1 13 7 6 9
12
2
9
8 10 11 4 9
Figure 19 : View of the front panel
1 Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage
equipment.
2 Key switch for switching the module on/off.
3 Electronic board protection fuse.
4 Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel.
5 STOP button, press to switch off the generating set.
6 START button, press to switch on the generating set.
7 Power ON LEDs and alarm/fault warning LEDs.
8 Location of USB ports.
9 Mounting bolt.
10 LCD for displaying alarms and faults, operating statuses, electrical and mechanical quantities.
11 ESC button: for returning to the previous selection and for default RESET function.
12 MENU button for accessing the menus.
13 Lighting for the emergency stop button.
64/242
1 2 3
Figure 20 : Description of the LEDs
A lit LED indicates:

1 Alarm activated (flashing yellow).
2 Fault found (flashing red).
3 Module on (green, on continuously).
Figure 21 : Close-up of USB ports
1 USB key connection (HOST): file transfer between USB key and TELYS and vice versa.
2 Connection for microcomputer (DEVICE):
file transfer between PC and TELYS and vice versa,
main module power supply.
3 Protective cover.
65/242
6.3.1.2. Description of the screen
The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.
SERIAL No.: 08030010000

SOFTWARE: 5.3.5
NOMINAL VOLTAGE: 400V
FREQUENCY: 50Hz
NOMINAL KW: 320kW
EARTH SYSTEM: TNS
Figure 22 : Description of the screen (example)
Zone 1: in this zone, the status of the generating set is displayed

Zone 2: in this zone, pictograms relating to dimensions measured are displayed, as well as Alarm and Fault pictograms
Zone 3: in this zone, the measured values corresponding to the measured dimensions are displayed with the corresponding units
of measurement
Zone 4: in this zone, messages relating to the control of the generating set and the menus are displayed.
Note: the information displayed on measurements, alarms and faults as well as messages and menus relating to control of the
generating set will depend on the equipment level of each generating set. Certain screens may therefore not be present.
66/242
6.3.1.3. Description of the pictograms in zone 1
Zone 1 pictograms
Pictograms Display Activation conditions

Fixed TELYS in manual mode (MAN)
For 5 seconds when switching from
Flashing
"MAN" mode AUTO to MAN mode
Fixed TELYS in automatic mode (AUTO)
For 5 seconds when switching from
Flashing
MAN to AUTO mode
"AUTO" mode
Flashing Genset starting
Fixed Genset started
Genset stabilised (voltage and

Fixed
frequency)
Flashing (impression of constant

The genset is generating and in use
movement from left to right)
Fixed Usage supplied
Not used
Fixed
Synchronisation
Flashing
Fixed Genset synchronised or coupled
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Alarm and fault pictograms in zone 2
All the pictograms in this zone are activated when TELYS is initialised.
Data displayed
Fuel level indicator
Alarm / Fault Alarm / Fault

low fuel level high fuel level
Coolant level / temperature indicator

Alarm
Alarm High No preheating
High
Low level level fault fault
temperature
fault alarm alarm
fault
Battery
Min battery Battery charge

Max battery
voltage indicator
voltage (flashing)
(flashing) (flashing bars)
Oil pressure / temperature indicator

High or low oil
High or low oil
Oil pressure level
temperature
Alarm / Fault Alarm /
Alarm / Fault
Fault
Emergency stop
Emergency stop fault
Overload or short circuit
Tripping of circuit breaker following an overload

or short circuit
Engine speed
Underspeed fault Overspeed fault Non-starting fault
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Zone 3 pictograms
All the pictograms for these zones are activated when the TELYS is initialised. The pictograms below are shown for information only.
Generating set stopped
Screen No. Pictograms Data displayed

Fuel Level Indication
High-temperature (HT) coolant temperature

indication (units as per settings menu)
P1
Battery Voltage indication
Oil Temperature Indication (units as per settings

menu)
Genset start-up or genset started or genset stoppage in progress

Engine Speed Indication
High-temperature (HT) coolant temperature

indication (units as per settings menu)
P2
Oil Pressure Indication (units as per settings menu)
Oil Temperature Indication (units as per settings

menu)
Genset started
P3 Alternator Compound Voltage Indication

Operation
default
screen Total Active Power Indication
Alternator Frequency Indication
Alternator U12 compound Voltage Indication

P4
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Alternator V1 single Voltage Indication

P5

P6

P7
Alternator phase 1 Current Indication

P8
Alternator Neutral Current Indication
Total Active Power Indication
Total Reactive Power Indication

P9
Total Apparent Power Indication
Total Output Factor Indication (inductive or

capacitive)
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P10
Battery Voltage indication
Battery Ammeter Indication
Total Reactive Power Indication

P11
Total Active Power Indication
Order of appearance of screens based on the type of network with the genset started.
Type of line
Order of appearance 3P+N 3P 2P+N 1P+N
P3 if genset started P3 if genset P3 if genset started P3 if genset started
P11 if genset started P11 if genset P11 if genset
1
coupled P11 if genset coupled coupled
coupled
2 P4 P4 P6 P7
3 P5 P8 P8 P9
4 P8 P9 P9 P2
5 P9 P2 P2 P10
6 P2 P10 P10
7 P10
The screen is changed using the scrolling and validation wheel.

When the wheel is turned clockwise, the screens scroll upwards and backwards.
The screens scroll in a loop.
Example: in a 3P+N network after screen 7, then screen 1 and in reverse.
6.3.1.6. Display of messages in zone 4

The graphic zone (zone 4) is used to display messages relating to the generating set's operation. These messages are as follows:
Initialisation of the TELYS
Screen No. Screen Data displayed
Initialisation of the TELYS when switching on and/or

G1
when loading a configuration
SERIAL No.: 08030010000

SOFTWARE: 6.1.0 Generating set serial number
NOMINAL VOLTAGE: 400V TELYS software version
FREQUENCY: 50Hz Alternator nominal voltage
G2 NOMINAL KW: 320kW Alternator nominal frequency
EARTH SYSTEM: TNS Nominal active power
Neutral speed
Bar graph indicating the screen display time
71/242
Generating set stopped
Screen
Screen Data displayed
No.
MANUAL
OPERATION
Press START Operation mode - genset in MAN mode ready to

G3 start
to start
Date and time (depending on settings)
24/08/2005 13:12
AUTOMATIC
OPERATION
IMPORTANT Operation mode - genset in AUTO mode ready to

G4 start
IMMEDIATE START-UP
POSSIBLE
24/08/2005 13:12
Screen
No.
IMPORTANT
Operation mode - genset in AUTO mode with
AUTOMATIC starting programmed start
G5 Countdown of micro disconnection delay OR EJP
19min30
(for France only)
24/08/2005 13:12
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Generating set start-up
Screen
No.
STARTING Operating phase - genset starting

G6
IN PROGRESS Date and time (depending on settings)
24/08/2005 13:12
AIR PREHEATING Operating phase - air preheating prior to genset

starting
G7
Countdown of the air preheating delay
10sec Date and time (depending on settings)
24/08/2005 13:12
Generating set started
Screen Screen
Data displayed
No.
AVAILABLE POWER
Operating phase – genset operating – stable voltage
G8 75% and frequency
Default
Available power
screen
24/08/2005 13:12
AUTOMATIC STOP Operation mode - operation in AUTO mode

IN PROGRESS Power supply device opens (motorised circuit
breaker or changeover switch controlled by the
G9 TELYS)
LOAD SUPPRESSION
Countdown of the Mains Return delay OR Test on
1min30 load delay
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Screen Screen
Data displayed
No.
AUTOMATIC STOP Operation mode - operation in AUTO mode

IN PROGRESS Genset cooling in progress
Countdown of the Engine Stop delay (cooling) OR
G 10 Gradual Stop delay (Water temperature) OR
COOLING
Overload Gradual Stop delay OR No Load Test
1min30 delay
24/08/2005 13:14
COUPLING Operation mode - operation in AUTO mode

IN PROGRESS Synchronisation of the genset with the grid or
G-10/1
another genset
24/08/2005 13:14
POWER TRANSFER
Grid Generating set Operation mode - operation in AUTO mode
G-10/2 Transfer of power from the generating set to the grid
24/08/2005 13:16
POWER TRANSFER
Grid Generating set Operation mode - operation in AUTO mode
G-10/3 Transfer of power from the grid to the generating set
24/08/2005 13:16
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Generating set stoppage
Screen Screen
Data displayed
No.
STOPPAGE Genset stoppage

G 11
IN PROGRESS Date and time (depending on settings)
24/08/2005 13:16
Change of operation mode (switch from MAN mode to AUTO mode when an automatic start demand is issued)
Screen Screen
Data displayed
No.
AUTOMATIC
start demand
Do you want to switch
to AUTO mode? Operation mode - operation in MAN mode
G 12
IMPORTANT AUTOMATIC start demand
Immediate start
OK Esc
Generating set stop demand if a fault occurs or if STOP is pressed in AUTO mode
Screen Screen
Data displayed
No.
MAN mode
activated
Operation mode - operation in AUTO mode (genset
Do you want to switch running)
G 13
to AUTOMATIC mode? Warning message for switch to MAN mode if STOP
is pressed or if a fault occurs
OK Esc
The "51 Hz" offset

must be applied to Operating phase – genset operating – stable voltage
all of the power plant's and frequency
G 13/1
gensets Warning message for setting offset on all of the
power plant's generating sets
Esc
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6.3.2 Starting
Check that the generating set circuit breaker has triggered.

Danger
Connect the generating set battery

Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not
light up, check and replace the fuse if necessary)
Test the Alarm and Fault LEDs (menu 15 – TEST LAMPS)

1 ACTIONS
1/5
11 MANUAL <> AUTO
12 CONTROL LOAD
13 TEST GENERATING SET
14 PROGRAMS
15 TEST LAMPS
12 OK Esc
Press "Esc" several times to return to the following home menu

OPERATION
MANUAL
Press START
to start
24/08/2005 13:12
Check the battery voltage

Press START:
AVAILABLE POWER
AIR PREHEATING
START-UP 100.0%
IN PROGRESS
10 seconds
24/08/2005 13:12 24/08/2005 13:12

24/08/2005 13:12
The following pictogram is displayed
If the engine is equipped with an Warning: the number of successive
air preheating system, there is a and automatic starting attempts is
delay (adjustable) before the limited to 3.
engine starts (preheating
activation period). The following pictogram will flash The following information is displayed
If the motor is not fitted with an
air preheating system or once the Speed of rotation
preheating delay has elapsed,
the engine starts up (start of a
cycle comprising 3 attempts to Coolant temperature
Options
start up the engine).

Oil pressure
Oil Temperature
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6.3.3 Switching off
Open the circuit breaker
manually OR by selecting menu 12 "CONTROL LOAD"
The following display will disappear (supply stopped)
Press the STOP button
The following screen is displayed and the generating set will stop
OFF
IN PROGRESS
24/08/2005 13:12
Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position).
6.3.4 Alarms and faults
6.3.4.1. Viewing alarms and faults
Alarms and faults are displayed as follows:
Alarms
All alarms will cause:
the yellow LED to flash "General alarm".
In conjunction with this LED:

a flashing pictogram appears on the LCD screen message on graphic display (example)
representing the circuit affected by the alarm and the
associated indicator, if present FAULT
(example)
ALARM
Low Fuel Level
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OK=HELP
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Faults
All faults will cause:

the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit)
the red LED to flash "General fault".
In conjunction with this LED:

a flashing pictogram appears on the LCD screen message on graphic display (example)
representing the circuit affected by the fault and the
associated indicator, if present FAULT
(example)
FAULT
Oil Pressure
25/12/05 15:30
OK=HELP
Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the oldest).
6.3.4.2. Activation of an alarm or fault
The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below)
FAULT FAULT
ALARM FAULT
Low coolant Level Emergency Stop
06/10/06 10:30 06/10/06 15:30
OK=HELP Esc=RESET OK=HELP

Press OK (on the scrolling and selection wheel) to access the help message if it is available (example below)
HELP
Check the level

fuel
Esc=EXIT
If the alarm is no longer active, it is reset automatically (cause disappears).
Press Esc to reset a fault:
- reset acknowledged if the cause of the fault has been removed
- reset not performed if the cause of the fault is still present.
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6.3.4.3. Activation of an alarm and a fault
The appearance of an alarm and a fault causes:

The yellow and red LEDs to flash
the related screen to be displayed (example below)
FAULTS 1/2
FAULT
Emergency Stop If several faults are present, the number of faults is
25/12/05 15:30 displayed at the top of the screen.
Esc=RESET OK=LIST
The faults list can be accessed by pressing OK (of the scrolling and selection wheel) (examples below)
FAULTS
1/2
Press Esc to return to the previous screen.
FAULT 25/12/05 15:30 Press OK to go to the HELP screen (help on the
highlighted fault)
Emergency Stop
Use the scrolling and selection wheel to scroll through
ALARM 25/12/05 15:30 the list of faults.
Low Fuel Level
12 OK=HELP Esc
HELP
Check:
- Emerg. Stop Pos.
- Connector(s)
Esc
If the alarm is no longer active, it is reset automatically (cause disappears).

Press Esc to reset a fault:
- reset acknowledged if the cause of the fault has been removed
- reset not performed if the cause of the fault is still present.
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6.3.4.4. Engine fault codes display
Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587
standards.
Terminology used by the SAE CAN J1939 standard
SPN: Suspect Parameter This represents the system or component at fault, for example: SPN 100,
Number indicates an oil pressure problem or a problem with the oil pressure sensor.
This represents the type of fault that has occurred. This may be an electrical,
FMI: Failure Mode identifier
mechanical or equipment fault.
Terminology used by VOLVO
This term, used in the J1587 standard, has an equivalent in the J1939 standard
(SPN).
SID: System Identifier
However, this term corresponds, more particularly, to an assembly of
components, for example, the injection system.
(SPN).
PID: Parameter Identifier
However, this term corresponds, more particularly, to a specific component, for
example, a sensor.
PPID: Parameter Identifier (SPN).
PPID corresponds to PID, but is only used by VOLVO.
FMI: Failure Mode identifier mechanical or equipment fault. VOLVO uses a SID-FMI or PID-FMI or PPID-FMI
combination.
Terminology used by JOHN DEERE
SPN: Suspect Parameter This represents the system or component at fault, for example: SPN 100,
Number indicates an oil pressure problem or a problem with the oil pressure sensor.
FMI: Failure Mode identifier
mechanical or equipment fault.
80/242
In the event of a fault, the screen will display the following message:
FAULT
Engine fault code.
ALARM Pressing OK will display fault finding information.
ENGINE GENERAL 110 18 In addition, appendix D indicate the meaning of the
code. The checking and maintenance operations to
25/12/2005 15:30
carry out in order to solve the fault are included in the
user and maintenance manuals of the engines
supplied with the generating set documentation.
OK=HELP
For JOHN DEERE (JD) and VOLVO (VO) engines, the codes displayed are SPN and FMI codes.
6.3.4.5. Horn reset

Depending on the settings made (menu 363 - HORN), the activation of an alarm and/or a fault leads to the horn
sounding and the following screen appearing:
HORN STOP
PRESS OK This screen will display first any messages relating to
the alarms and faults that appear as soon as OK is
pressed.
25/12/2005 15:30
7. Maintenance schedule
7.1. Reminder of use

The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline.
N.B. the environment in which the generating set is operating determines this schedule.
If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed
These maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given in
this manual.
7.2. Maintenance safety instructions

Before each operation, please observe the following maintenance safety instructions:
read the safety instructions carefully (chapter 1),
refer systematically to the maintenance instructions,
the battery isolating switch must be in the open position,
no operations must be carried out while the motor is running,
wear protective equipment (gloves, goggles, safety shoes etc.),
before operating on a pressurised circuit, ensure that the circuit pressure has been reduced (atmospheric pressure),
after the operations, ensure that the equipment is clean, or clean it if necessary.
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7.3. Table of maintenance operations
10 h 20 000 h
OPERATIONS 250 h 500 h 1000 h 1500 h 3000 h 2 years
Daily 3 years
Generator set
• Check the general condition ●
• Check the tightening torques ●
• Check the absence of leaks ●
• Check the condition of battery charge ●
• Clean the battery terminals ●
• Check condition and connections of
●
electrical equipment
• Clean with compressed air the relays and
●
contactors
Engine
• Check engine oil and coolant level ●
• Check fuel filter / Water bowl ●
• Check air cleaner ●
• Replace engine oil and oil filtera ●
• Inspect belt and adjust and belt tension ●
• Check and Clean radiator fins ●
• Add grease to link joints, etc. ●
• Replace fuel filter (in-line type fuel injection
●
pump)
• Inspect valve clearance ●
• Check glow plug ●
• Inspect starter ●
• Inspect alternator ●
• Retighten bolts and nuts on the enginea ●
• Clean nozzle tip ●
• Check and Clean fuel injection nozzle ●
• Inspect turbocharger ●
• Change coolant ●
Alternator
• Check the tightening torques
• Check the general condition
After the first 20 hours
• Check the various electrical connections of
the installation
• Grease the bearings ●
a
After the first 50 service hours for a new or overhauled engine
82/242
7.4. Cover maintenance
The sealing between the cover and the frame and between the frame and the retention tank
is ensured by a gasket. It is essential to replace the gasket if the cover has been removed.
IMPORTANT
Users must maintain the enclosures and base frames to ensure that the paintwork retains all its protective properties.
7.5. Trailer maintenance
Frequency When commissioning

Every 6 months Every year
Operations and before towing
General condition of the

vehicle
Tyre pressure
Tighten the wheel nuts
Efficiency of the automatic
brake
Efficiency of the parking
Check brake
Braking adjustment and
distribution across all wheels
Wear on brake linings and
drums
No play in the hubs
Play in the clamping tube
Play in the ball socket or ring
Braking control hinges and
Lubricate joints
Stabilising
Lubricate or grease the moving parts on the coupling device (see lubrication point examples in the Figure 23).
Recommended lubricant: general purpose grease compliant with DIN 51825 KTA 3KA.
Figure 23 : Trailer lubrication/greasing points
83/242
7.6. Fault finding
Refer to the user manual and engine and alternator maintenance manuals appended.
Additionally, in the event of an abnormal rise in engine temperature, check that the radiator is clean.
7.7. No load and under load tests

Notes on operation at no load and under load:
When operating at no load or low load (< 30% of nominal power), the operating conditions do not allow optimum running of the engine.
The main causes are as follows:
The low volume of fuel burned in the combustion chamber leads to incomplete combustion; the resulting thermal energy means that
the optimum engine operating temperature cannot be reached.
Overheated engines have lower compression ratios (low compression ratio without turbocharging), which are defined for full load
and not suitable for good combustion at low load.
All of these factors lead to choking of the engine, in particular the piston rings and valves, which leads to:
Accelerated wear and glazing of the cylinder liners
Loss of sealing of seats, and sometimes sticking of valve stems.
Consequently, operating any turbocharged engine at low load (< 30%) can only have adverse repercussions on an engine's operation
and its service life. Maintenance intervals will have to be shortened to accompany harsh operating conditions. Shortening draining
intervals, among other things, will enable you to change the oil more frequently, which will tend to be choked with unburnt particles and
contaminated with fuel. Adding a load bench is generally used to limit low load phases, and obtain the periodic full loads necessary to
unchoke the engine.
Finally, when operating under load, we advise vigilance towards the oil breather circuit, and more particularly towards engines which
have the crankcase vent connected to the turbocharger inlet (risk of oil or oil vapour absorption and accelerated engine speed).
On load tests:
It is recommended to conduct an on load test on the generating set monthly, for a period of around 1 hour after stabilisation of the
parameters.
The load must be greater than 50% of nominal power (ideally 80%), to ensure unchoking of the engine and to obtain a decent picture of
the generating set operation.
Off load test (no load):

This test is not recommended; it must not exceed 10 minutes, and must not be repeated without a monthly on load test. This test only
allows you to check for correct engine start-up. It does not allow you to check that the generating set is working properly.
84/242
8. Starter batteries
DANGER
Risk of explosion or fire (oxygen and hydrogen present). The battery must never be
exposed to any naked flames or sparks.
Risk of sparks forming and an explosion. When fitting the battery, never invert the
polarities.
Do not short the battery terminals with a tool or other metal object.
Risk of injury. Battery electrolyte is extremely corrosive. Always protect your eyes, skin
and clothing when handling batteries. Always wear protective goggles and gloves.
In the event of contact with the skin, wash thoroughly with water and soap. If the eyes are
splashed, rinse thoroughly with water and consult a doctor immediately.
8.1. Checking the electrolyte level

The electrolyte level must be approximately 10 mm above the battery plates.
1. Top up with distilled water if necessary.

2. Pour the distilled water carefully to avoid any splashes.
Wear protective goggles and rubber gloves when handling the battery (adding water,
charging, etc.).
Note: some batteries requiring no maintenance form the subject of specific instructions
which must be respected.
After the battery has been topped up, it must be recharged for at least 30 minutes.
8.2. Checking the voltage/acid density
Every 2 months, the following checks must be performed:
1. Check the density of the acid contained in the cells (all the battery cells must have the same density; if this is not the case, the
battery must be replaced)
2. Check the voltage when idle.
Acid density Charge status Voltage when idle Observation / action

1.27 100% Above 12.60 V
1.25 80% 12.54 V
1.20 60% 12.36 V From 60% recharge
1.19 40% 12.18 V Risk of sulphation
1.13 20% Below 11.88 V Unusable
The results of the density and voltage measurements make it possible to define the charge status of the battery. If the charge status is
less than 60%, the battery must be recharged.
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8.3. Charging the battery
Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard) can no longer
regenerate or be charged in a generating set.
A discharged battery should be recharged immediately, or else it will suffer irreparable damage.
IMPORTANT
Battery charge
Example of charge:
- 12V 60 Ah battery = 6 A charging current;
- Charge status: 50% (acid density 1.19 and voltage when idle 12.30V);
- The battery is short 30 Ah, and this must be recharged.
- Charge factor: 1.2;
- 30 Ah x 1.2 = 36 Ah to be charged;
- Charging current: 6A, approximately 6 hours charging required; the charging
current must always be 1/10th of the nominal capacity of the battery.
Recharging is complete when the battery voltage and the acid density stop increasing.
The power of the charger must be suitable for the battery to be charged and the charging time available.
Note: if several batteries connected together are being recharged, the following points must be checked:
- Are the batteries connected in series?
- Is the voltage chosen exact? 1 battery x 12 V, 3 x 36V batteries.
- Adjust the charge current to the lowest battery.
- The power difference between the batteries must be as low as possible.
8.4. Cleaning the battery

Keep the batteries clean and dry. The presence of impurities and rust on the battery and
terminals may cause the current jumps, voltage drops and the battery to discharge, particularly
in humid weather.
1. Clean any signs of oxidation on the battery terminals and the cable terminals using a brass
brush.
2. Fully tighten the cable terminals and lubricate them with grease for battery terminals or
vaseline. A terminal which is not secured correctly may cause sparks and therefore lead to
an explosion.
86/242
8.5. Fault finding
Fault observed Probable origin Measures or observations
Incorrect composition Cool
The acid heats up when a new battery is
Incorrect storage Charge the battery
filled
Prolonged storage in a damp place Check the acid density
The acid escapes through the filler holes The battery is too full Reduce the battery fluid level
Battery tray not leaktight Replace the battery
Acid level too low Considerable formation of gas due to a Check the charger and repair if
very high charging voltage necessary
Insufficient charge
Acid level too low Recharge the battery
Short circuit in the power circuit
Incorrect operation from start-up Check the electrical installation
Consumption fault
Reduce the acid level and fill with
The battery has been filled with acid
Acid density too high distilled water. Repeat the operation if
instead of water
necessary
Battery empty Recharge the battery
Starting problems Battery exhausted or faulty
Starting test incorrect Capacity too low Replace the battery
Battery sulphated
Incorrect electrical connection Tighten the ends of the battery cables or
Battery terminals melted replace them if necessary and replace
Battery cabling incorrect
the battery
One or two cells release a lot of gas at
Faulty cell(s) Replace the battery
high charge
Charge status too low Check the load
Short circuit in the power circuit
The battery discharges very quickly High self-discharge (for example:
through electrolyte contamination) Replace the battery
Sulphation (storage of discharged
battery)
Incorrect battery part no Define the correct battery part no. for
the recommended use
Short service life
Repeated deep discharging It is recommended to charge the battery
Battery stored too long without charge using a regulator
Overload
High water consumption Check the charger (voltage regulator).
Charging voltage too high
Sparks after battery charging
Short circuit
The battery explodes Connection or disconnection during
Replace the battery
charging
Internal fault (for example: interruption)
and low electrolyte level
87/242
9. Options
9.1. Dual frequency

This operation must be carried out by a qualified electrician.
These operations must only be carried out when the generating set is stopped, until you are instructed
to start up the generating set.
IMPORTANT
• Close the battery isolating switch to turn on the TELYS 2.
• Turn the supply switch of the TELYS 2 to the "ON" position.
• Press the "MENU" key.
MENU
• Using the knob, select "3 SETTINGS" and press the knob to MENUS
confirm. 3/4
1 ACTIONS
2 INFORMATION
3 SETTINGS
4 COUNTRY
12 OK Esc
88/242
• As not all the settings are available, go to the "37
INSTALLER ACCESS" menu to enter the code "1966" 3 SETTINGS
4/7
using the knob to call up the desired menus.
34 50Hz <> 60Hz
35 NOMINAL VOLTAGE
36 PARAMETERS
37 INSTALLER ACCESS
12 OK Esc
INSTALLER ACCESS
Enter password
* * * *
12 OK Esc
• Using the knob, select "34 50Hz<>60Hz" and press the 3 SETTINGS
knob to confirm. 2/2
31 COMMUNICATION
32 FREQUENCY
33 VOLTAGE
34 50Hz <> 60Hz
12 OK Esc
• Select and confirm the desired frequency using the

50Hz <> 60Hz
knob to scroll and confirm (50 Hz or 60 Hz).
50Hz
12 OK Esc
• Return to the "3 SETTINGS" screen and use the knob 3 SETTINGS
to select "35 NOMINAL VOLTAGE" then press the 4/7
knob to confirm.
34 50Hz <> 60Hz
35 NOMINAL VOLTAGE
36 PARAMETERS
37 INSTALLER ACCESS
12 OK Esc
NOMINAL VOLTAGE
• Set the desired voltage then confirm using the scroll 400 Vac
and confirm knob.
Min.: 380
Max.: 480
12 OK Esc
89/242
• Select the desired configuration using the configuration
option selector located next to the TELYS 2 control
unit.
Configuration
selector
• Start up the generating set by pressing the "START"

button.
MENU
• Adjust the voltage after starting up the generating set

using the 2003R08 potentiometer.
Potentiometer
Warning: when switching to 60Hz, do not use sockets if fitted to the generating set.
IMPORTANT
90/242
9.2. Neutral system
Turn the switch to the desired neutral system.
Ф
EDF TT
Select the neutral system with the generating set switched off.
Important
9.3. Fuel supply valve

The 3-way valve is used to select between the generating set fuel tank and an external fuel supply.
Valve in vertical position (no. 1): generating set supplied by the daily service tank.
Valve in horizontal position (no. 2): generating set supplied by the external tank.
91/242
92/242
10. Appendix
10.1. Appendix A – Engine user and maintenance manual
93/242
94/242
User guide and maintenance manual
MITSUBISHI
Engine
SERIE SS
99610-29120
33522051001_3_1
01/07/2009
95/242
96/242
OPERATION &
MAINTENANCE MANUAL
199610-29120
The operator and supervisor are requested to read this Oper-

ation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work with-
out completely understanding this manual.
July 2009
Pub. No. 99610-29120
97/242
INTRODUCTION
This operation and maintenance manual contains detailed operation, inspection
and maintenance information for engines from Mitsubishi Heavy Industries, Ltd.
Please read this manual thoroughly before proceeding with operation, inspection,
and maintenance work for correct use and servicing.
Failure to follow directions in this manual may result in serious accidents.
98/242
FOREWORD
Limited warranty
Mitsubishi Heavy Industries, Ltd. will repair or replace parts returned to us when we judges that the parts are defec-
tive in material and/or workmanship after conducting inspection.
Mitsubishi Heavy Industries, Ltd.'s warranty is limited to the compensation work of repair or replacement of parts.
The warranty coverage is effective for the original purchaser only. Those to whom ownership is later transferred are
not provided with the warranty.
Mitsubishi Heavy Industries, Ltd.'s makes no warranties, either expressed or implied,

except as provided in this manual, including, but not limited to, warranties as to market-
ability, merchantability, fitness for a particular purpose or use, or against infringement of
any patent.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or consequential
damages, including, but not limited to, damages or other costs resulting from any abuse,
misuse, misapplication of the engine and devices supplied from us.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or personal injuries
resulting from any modification, without our written permission, of the engine and
devices supplied from us.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or production losses
caused by the use of fuel, engine oil and/or long life coolant (LLC) that we are not recom-
mended.
The owner of the engine is responsible for the performance of the required maintenance
listed in this operation manual.
Mitsubishi Heavy Industries, Ltd. may deny the warranty coverage if the engine or part
has failed due to inadequate or improper maintenance.
ii
99/242
FOREWORD
Emission warranty
The following warranty applies to the engines that are approved of the emission regulation of the U.S. Environ-
mental Protection Agency.
Warranty coverage
Mitsubishi Heavy Industries, Ltd. warrants to the first owner and each subsequent purchaser of a new non-road die-
sel engine that the emission control system of your engine:
is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S. Envi-
ronmental Protection Agency.If the vehicle in which the engine is installed is registered in the state of California, a
separate California emission regulation also applies.
is free from the defects in material and workmanship which will cause the engine to fail to meet these regulations
within the warranty period.
Then its warranty period is

The emission warranty period is shown below.
However, if your engine warranty period is longer than the emission warranty period, the emission warranty period
extends to same as the engine warranty period.
Below warranty period shall begin on the date the engine is delivered to the first owner.
And its maxi-

If your engine is certified as And its rated speed is Then its warranty period is
mum power is
Variable speed or constant 1,500 hours or 2 years, whichever
kW < 19 Any speed
speed comes first.
1,500 hours or 2 years, whichever
Constant speed 19 ≤ kW < 37 3800 min-1 or more comes first.
3000 hours or 5 years, whichever
Constant speed 19 ≤ kW < 37 Less than 3000 min-1 comes first.
3000 hours or 5 years, whichever
Variable speed 19 ≤ kW < 37 Any speed comes first.
Variable speed or constant 3000 hours or 5 years, whichever
kW ≥ 37 Any speed
speed comes first.
Warranted parts
Mitsubishi Heavy Industries, Ltd. warrants the parts which will increase the emission of pollutants when they
become defective.
The followings are examples.
Inlet/Exhaust manifold
Crankcase ventilation system
Fuel system
Fuel injection nozzle
LIMITED WARRANTY
Refer to "LIMITED WARRANYT".
iii
100/242
FOREWORD
California emission control warranty statement

your warranty rights and obligations
The following warranty applies to the engines that are approved of the emission regulation of the California Air
Resources Board (CARB).
The California Air Resources Board (CARB) is pleased to explain the emission control system warranty on
you 2008 or later engine.In California, new heavy-duty off-road engines must be designed, built, and equipped to
meet the State's stringent anti-smog standards.Mitsubishi Heavy Industries, Ltd. must warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel-injection system and the air induction system. Also
included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Mitsubishi Heavy Industries, Ltd. will repair your heavy-duty off-road engine
at no cost to you including diagnosis, parts, and labor.
MANUFACTURER'S WARRANTY COVERAGE:

The 2008 and later heavy-duty off-road engines are warranted for the Warranty Period. If any emission-related part
on your engine is defective, the part will be repaired or replaced by Mitsubishi Heavy Industries, Ltd.
OWNER'S WARRANTY RESPONSIBILITIES:

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in your owner's manual.Mitsubishi Heavy Industries, Ltd. recommends that you retain all receipts covering
maintenance on your heavy-duty off-road engine, but Mitsubishi Heavy Industries, Ltd. cannot deny warranty
solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the heavy-duty off-road engine owner, you should however be aware that Mitsubishi Heavy Industries, Ltd. may
deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer
operating in compliance with California's emissions requirements.
You are responsible for initiating the warranty process. The Air Rexources Board suggests that you present your
heavy-duty off-road engine to a Mitsubishi Heavy Industries, Ltd. dealer or distributor dealer as soon as problem
exists. The warranty repairs should be completed by the dealer or distributor as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact Mitsubishi
Engine North America at 1-630-268-0750.
iv
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FOREWORD
Warranty coverage
(a) The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser.
(b) Mitsubishi Heavy Industries, Ltd. warrants to the ultimate purchaser and each subsequent purchaser of the en-
gine registered in the state of California that the engine is:
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources
Board.
(2) Free from defects in materials and workmanship which cause the failure of a warranted part to be identical
in all material respects to the parts as described in Mitsubishi Heavy Industries, Ltd.'s application for certifi-
cation for a period of 5 years or 3,000 hours of operation, whichever occurs first. In the absence of a device
to measure hours of use, the engine shall be warranted for a period of 5 years. For all engines rated less
than 19kW, and for constant-speed engines rated under 37 kW with rated speeds higher than or equal to
3,000 min-1 , the period of 2 years or 1,500 hours of operation, whichever occurs first, shall apply. In the ab-
sence of a device to measure hours of use, the engine shall be warranted for a period of 2 years.
(c) The warranty on emission-related parts shall be interpreted as follows:
(1) Any warranted part which is not scheduled for replacement as required maintenance in the written instruc-
tions required by Subsection (e) shall be warranted for the warranty period defined in Subsection (b) (2). If
any such part fails during the period of warranty cove rage, it shall be repaired or replaced by Mitsubishi
Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or replaced under the war-
ranty shall be warranted for the remaining warranty period.
(2) Any warranted part which is scheduled only for regular inspection in the written instructions required by Sub-
section (e) shall be warranted for the warranty period defined in Subsection (b) (2). A statement in such writ-
ten instructions to the effect of "repair or repla ce as necessary" shall not reduce the period of warranty
coverage. Any such part repaired or replaced under the warranty shall be warranted for the remaining war-
ranty period.
(3) Any warranted part which is scheduled for replacement a s required maintenance in the written instructions
required in Subsection (e) shall be warranted for the period of time prior to the first scheduled replacement
point for that part.If the part fails prior to the first scheduled replacement, the part shall be repaired or re-
placed by Mitsubishi Heavy Industries, Ltd. accordi ng to Subsection (4) below. Any s uch part repaired or
replaced under warranty shall be warranted for the remainder of the period prior to the first scheduled re-
placement point for the part.
(4) Repair or replacement of any warranted part under the warranty provisions shall be performed at no charge
to the owner at a warranty station.
(5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs shall be provided at all
Mitsubishi Heavy Industries, Ltd. distribution centers that are franchised to service the subject engines.
(6) The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is
in fact defective, provided that such diagnostic work is performed at a warranty station.
(7) Mitsubishi Heavy Industries, Ltd. shall be liablefor damages to other engine components proximately caused
by failure under warranty of any warranted part.
(8) Throughout the engine's warranty period defined in Subsection (b) (2), Mitsubishi Heavy Industries,Ltd. shall
maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
(9) Any replacement part may be used in the performance of any maintenance or repairs and must be provided
without charge to the owner. Such use shall not reduce the warranty obligations of Mitsubishi Heavy Indus-
tries, Ltd..
102/242
FOREWORD
(10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of
any non-exempted add-on or modified p arts shall be grounds for disallowing a warranty claim. Mitsubishi
Heavy Industries, Ltd. shall not be liable to warrant failures of warranted parts caused by the use of a non-
exempted add-on or modified part.
(11) The Air Resources Board may request and, in such case, Mitsubishi Heavy Industries, Ltd. shall provide,
any documents which describe that Mitsubishi Heavy Industries, Ltd.'s warranty procedures or policies.
(d) Warranted parts list.
(1) Fuel metering system
(A) Fuel injection system.
(B) Air/fuel ratio feedback and control system.
(C) Cold start enrichment system.
(2) Air induction system
(A) Controlled hot air intake system.
(B) Intake manifold.
(C) Heat riser valve and assembly.
(D) Turbocharger/supercharger systems.
(E) Charged air cooling systems.
(3) Exhaust gas recirculation (EGR) system
(A) EGR valve body, and carburetor spacer if applicable.
(B) EGR rate feedback and control system.
(4) Air injection system
(A) Air pump or pulse valve.
(B) Valves affecting distribution of flow.
(C) Distribution manifold.
(5) Catalyst or thermal reactor system
(A) Catalytic converter.
(B) Thermal reactor.
(C) Exhaust manifold.
(6) Particulate controls
(A) Traps, filters, precipitators, and any other devices used to capture particulate emissions.
(B) Regenerators, oxidizers, fuel additive devices, and any other devic e used to regenerate or aid in the
regeneration of the particulate control device.
(C) Control device enclosures and manifolding.
(D) Smoke puff limiters.
(7) Advances oxides of nitrogen (NOx) controls
(A) NOx absorbers.
(B) Lean NOx catalysts.
(C) Selective catalyst reduction.
(D) Reductant (urea/fuel) containers/dispensing systems.
(8) Positive crankcase ventilation (PCV) system
(A) PCV valve.
(B) Oil filler cap.
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FOREWORD
(9) Miscellaneous items used in above systems

(A) Vacuum, temperature, and time sensitive valves and switches.
(B) Electronic control units, sensors, solenoids, and wiring harnesses.
(C) Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices, and mount-
ing hardware.
(D) Pulleys, belts and idlers.
(E) Emission control information labels.
(F) Any other part with the primary purpose of reducingemissions or that can increase emission during fail-
ure without significantly degrading engine performance.
(e) Mitsubishi Heavy Industries, Ltd. shall furnish with each new engine written instructions for the maintenance and
use of the engine by the owner.
LIMITED WARRANTY:
Refer to "LIMITED WARRANTY".
vii
104/242
FOREWORD
Important information
To avoid the potential hazard, accident prevention To prevent an accident, do not attempt to carry out
activities must be planned methodically and con- any operation other than those described in this man-
ducted continually by considering all aspect of ual, and do not use the engine for any unapproved
engine operation, maintenance and inspection.All purpose.
related personnel, including managers and supervi- When the ownership of the engine is transferred, be
sors, should actively participate, recognize their roles sure to provide this manual with the engine to the
and organize themselves and their work to ensure a new owner. Also inform Mitsubishi Heavy Industries,
safe environment. Ltd. of the name and address of the new owner of the
The foremost safety objective is to prevent accidents engine.
which may result in injury or death, or equipment This manual is copyrighted and all rights are
damage. reserved.No part of this manual, including illustra-
Always observe laws or regulations of the local or tions and technical references, may be photocopied,
federal/national government. translated, or reproduced in any electronic medium
Mitsubishi Heavy Industries, Ltd. cannot foresee all or machine readable form without prior written con-
potential dangers of the engine, potential danger sent from Mitsubishi Heavy Industries, Ltd.
resulting from human error and other causes, or dan- The contents in this manual are subject to change at
ger caused by a specific environment in which the any time without notice for improvement of the
engine is used. Since there are many actions that engine.
cannot be performed or must not be performed, it is Pictures or illustrations of the product in this manual
impossible to indicate every caution in this manual or may differ from those of product you have. Please
on warning labels. As such, it is extremely important note that, depending on specifications, items
to follow directions in this manual and also to take described in this manual may differ from those on
general safety measures when operating, maintain- your engine in shape, or may not be installed on your
ing and inspecting the engine. engine.
When the engine is used by individuals whose native Please contact a dealer of Mitsubishi Heavy Indus-
language is not English, the customer is requested to tries, Ltd. if you need more information or if you have
provide thorough safety guidance to the opera- any questions.
tors.Also add safety, caution and operating signs that If you lost or damaged this manual, obtain a new
describe the original warning label statements in the copy at a dealer of Mitsubishi Heavy Industries, Ltd.
native language of the operators. as soon as possible.
The engine must be operated, maintained and Mitsubishi Heavy Industries, Ltd. recommends the
inspected only by qualified persons who have thor- engine owner to install an hour meter on the engine
ough knowledge of engines and their dangers and due to monitor correct running intervals and to per-
who also have received risk avoidance training. form the maintenance at the appropriate timing.
viii
105/242
FOREWORD
Warning indication
The following means are used to call the attention of the operators and maintenance personnel to potential dangers
of the engine.
Warning statements in the manual
Warning labels affixed on the engine
Warning statements
The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine,
using the following 5 classifications to indicate the degree of potential hazard.
Failure to follow these directions could lead to serious accidents which could result in personal injury, or death in
the worst case.
Understand the directions well, and handle engines with following directions.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Note : Indicates important information or information which is useful for engine operation.
ix
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FOREWORD
Units of measurement
Measurements are based on the International System of Units (SI), and they are converted to the metric system
units in this manual using the following conversion rates.
Pressure :1 MPa = 10.197 kgf/cm2
Torque :1 N·m = 0.10197 kgf·m
Force :1 N = 0.10197 kgf
Horsepower :1 kW = 1.341 HP = 1.3596 PS
Meter of mercury :1 kPa = 0.75 cmHg
Meter of water :1 kPa = 10.197 cmH2O(cmAq)
Engine speed :1 min-1 = 1 rpm
Kinetic viscosity:1 mm2/s = 1 cSt
Abbreviations, standards and others
 API = American Petroleum Institute

 ASTM = American Society for Testing and Materials
 ISO = International Organization for Standardization
 JIS = Japanese Industrial Standards
 LLC = Long Life Coolant
 MIL = Military Specifications and Standards
 MSDS = Material Safety Data Sheet
 SAE = Society of Automotive Engineers
107/242
CONTENTS
Chapter 1 Do not add coolant immediately after a sudden
stop due to overheating.................................... 1-5
BASIC SAFETY PRECAUTIONS
Avoid immediate restart after abnormal stop.... 1-5
Fire and explosions .............................1-1
Avoid continuous engine operation at low oil
Keep flames away............................................ 1-1
pressure ........................................................... 1-5
Keep engine surrounding area tidy and clean.. 1-1
If belt breaks, stop engine immediately ............ 1-5
Care for fuel, oil and exhaust gas leakage....... 1-1
Service battery .................................... 1-6
Use explosion-proof lighting apparatus............ 1-1
Handle the battery correctly ............................. 1-6
Prevent electrical wires from short-circuiting.... 1-1
Keep fire extinguishers and a first-aid kit Other cautions..................................... 1-7
handy ............................................................... 1-1 Never modify engine ........................................ 1-7
Observe safety rules at work site ..................... 1-7
Stay clear of all rotating and moving
Work clothing and protective gear.................... 1-7
parts ....................................................1-2
Never break seals ............................................ 1-7
Install protective covers around rotating
Perform all specified pre-operation inspections
parts ................................................................. 1-2
and periodic inspections................................... 1-7
Check work area for safety .............................. 1-2
Break-in the engine .......................................... 1-7
Stay clear of moving parts while engine is
Warm up the engine before use ....................... 1-7
running ............................................................. 1-2
Never operate the engine in an overloaded
Lockout and tagout .......................................... 1-2
condition ........................................................... 1-7
Keep engine stopped during servicing ............. 1-2
Conduct cooling operation before stopping the
Always restore engine turning tools after use .. 1-2
engine .............................................................. 1-8
Changing the engine speed setting is
Protection of the engine against water entry .... 1-8
prohibited ......................................................... 1-2
Properly maintain the air cleaner and
Be careful of exhaust fume pre-cleaner ....................................................... 1-8
poisoning .............................................1-3 Use of tools optimum for each work ................. 1-8
Operate engine in a well-ventilated area.......... 1-3 Avoidance of prolonged time of starter
Be careful of falling down ....................1-3 operation .......................................................... 1-8
Lift engine carefully .......................................... 1-3 Do not turn off the battery switch during
Do not climb onto the engine ........................... 1-3 operation .......................................................... 1-8
Always prepare stable scaffold ........................ 1-3 Cautionary instructions for transporting the
Protect ears from noise .......................1-4 engine .............................................................. 1-8
Wear ear plugs................................................. 1-4
Be careful of burns ..............................1-4 Chapter 2
Do not touch the engine during or immediately
after operation .................................................. 1-4
NAME OF PARTS
Do not open the radiator filler cap when the Engine external diagrams ................... 2-1
engine is hot..................................................... 1-4 Equipment and instrument .................. 2-8
Do not touch high pressure injection fuel ......... 1-4 Starter switch ................................................... 2-8
Refill coolant only after the coolant Preheat indicator .............................................. 2-8
temperature dropped........................................ 1-4 Water temperature meter and thermo unit ....... 2-9
Be careful when handling fuel, engine Ammeter........................................................... 2-9
Hour meter ....................................................... 2-9
oil or LLC .............................................1-5
Stop solenoid ................................................. 2-10
Use only specified fuel, engine oil and LLC ..... 1-5
Handle LLC carefully........................................ 1-5 Engine protection devices................. 2-11
Proper disposal of waste oil, LLC and Oil pressure switch ......................................... 2-11
coolant ............................................................. 1-5 Thermo switch ................................................ 2-11
Air cleaner indicator ....................................... 2-11
When abnormality occurs ....................1-5
CONTENTS-1
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CONTENTS
Chapter 3 Chapter 6
OPERATION COOLANT
Preparations for operation ...................3-1 Recommended water for coolant ........ 6-1
Engine external - Inspect ................................. 3-1 Long life coolant (LLC)........................ 6-1
Battery electrolyte level - Inspect ..................... 3-1 Genuine LLC....................................... 6-1
Fuel tank oil level - Check ................................ 3-2
Other brand LLCs ............................... 6-2
Engine oil level - Check.................................... 3-2
Standard for other brand LLC ............. 6-2
Coolant level - Check ....................................... 3-3
General demands of LLC ................................. 6-2
Starting ................................................3-4
LLC specification .............................................. 6-3
Warm up operation ..............................3-4 Maintenance of LLC............................ 6-5
Checking engine oil pressure........................... 3-4
Replacement intervals of LLC .......................... 6-5
External inspection during warm up ................. 3-4
LLC concentration ............................................ 6-5
Operation.............................................3-5 Importance of LLC .............................. 6-6
Cautions when operating ................................. 3-5
Characteristics of LLC additive and
Inspection during operation.............................. 3-5
Stopping ..............................................3-6 important notes ................................... 6-6
Inspection after stopping .................................. 3-6 Examples of abnormalities caused by
LLC (amine type) ................................ 6-6
Pitting of iron parts ........................................... 6-6
Chapter 4 Corrosion of aluminum parts ............................ 6-6
FUEL Pitting and clogging of the radiator................... 6-6
Recommended fuel .............................4-1
Handling fuel........................................4-1 Chapter 7
MAINTENANCE SCHEDULE
Chapter 5 How to use the maintenance
ENGINE OIL schedule.............................................. 7-1
Recommended engine oil....................5-1 Maintenance schedule ........................ 7-2
Selection of oil viscosity.......................5-1
Handling engine oil ..............................5-1
Engine oil performance requirements..5-2
Engine oil deterioration mechanisms...5-2
Definition of properties of engine oil ....5-3
Viscosity ........................................................... 5-3
Total base number ........................................... 5-3
Total acid number ............................................ 5-3
Water content................................................... 5-3
Flash point........................................................ 5-3
Insoluble........................................................... 5-3
Service Limits of engine oil..................5-4
CONTENTS-2
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CONTENTS
Chapter 8 Chapter 10
PERIODIC INSPECTION AND TRANSPORTATION
MAINTENANCE PROCEDURES Lifting the engine............................... 10-1
Basic engine ........................................8-1
Belt and belt tension - Inspect and Adjust........ 8-1
Chapter 11
Fuel system .........................................8-2
TROUBLESHOOTING
Fuel tank - Drain water..................................... 8-2
Fuel filter - Drain water..................................... 8-3
General precautions.......................... 11-1
Contact a dealer of Mitsubishi Heavy
Fuel system (in-line type fuel injection pump)
Industries, Ltd. for repair service .................... 11-1
- Bleed air......................................................... 8-4
Considerations before work ........................... 11-1
Fuel system (distributor type fuel injection
Cautions against contamination ..................... 11-1
pump) - Bleed air.............................................. 8-5
Cautions regarding parts handling ................. 11-1
Fuel filter (in-line type fuel injection pump) -
Work safety .................................................... 11-1
Replace ............................................................ 8-6
Fuel filter (distributor type fuel injection pump) Troubleshooting ................................ 11-2
- Replace.......................................................... 8-7 The starter does not crank or cranks slowly,
Lubricating system...............................8-8 resulting in start failure ................................... 11-2
The starter cranks, but the engine does not
Engine oil and Oil filter - Replace..................... 8-8
start ................................................................ 11-2
Cooling system ..................................8-11
Output decrease............................................. 11-2
Coolant - Change ........................................... 8-11
Exhaust smoke is white or blue...................... 11-4
Radiator fins - Check and Clean .................... 8-13
Exhaust smoke is black or charcoal ............... 11-5
Inlet and exhaust systems .................8-14 Fuel consumption is high ............................... 11-6
Air cleaner - Check......................................... 8-14
Engine oil consumption is high....................... 11-7
Turbocharger - Inspect................................... 8-14
Overheating.................................................... 11-8
Pre-cleaner - Clean, Inspect and Replace ..... 8-15
Low engine oil pressure ................................. 11-8
Air cleaner element - Clean, Check and
When fuel has run out....................... 11-9
Replace .......................................................... 8-16
Electrical system................................8-17
Starter - Inspect.............................................. 8-18 Chapter 12
Alternator - Inspect......................................... 8-18 MAIN SPECIFICATIONS
Main specifications............................ 12-1
Chapter 9
LONG-TERM STORAGE
Long-term storage ...............................9-1
Storing the engine in a non-operable
condition for 3 months or more............9-1
Preparation for storage .................................... 9-1
Maintenance during storage............................. 9-1
Using the engine after storage ......................... 9-2
Storing the engine in an operable
condition for 3 months or more............9-2
Operating the engine for maintenance............. 9-2
CONTENTS-3
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CONTENTS
List of illustrations Fig. 8-6 Fuel filter - Bleed air ..............................8-4

Fig. 8-7 Fuel injection pump - Bleed air..............8-4
Fig. 2-1 Engine left view .................................... 2-1
Fig. 8-8 Fuel filter - Bleed air (1).........................8-5
Fig. 2-2 Engine right view .................................. 2-1
Fig. 8-9 Fuel filter - Bleed air (2).........................8-5
Fig. 8-10 Fuel filter - Replace ...............................8-6
Fig. 8-11 Fuel filter ...............................................8-6
Fig. 8-12 Fuel filter - Replace ...............................8-7
Fig. 8-13 Engine oil drain plug..............................8-8
Fig. 8-14 Engine oil - Refill ...................................8-9
Fig. 8-15 Oil filter - Change ................................8-10
Fig. 8-16 Oil filter ................................................8-10
Fig. 8-17 Radiator filler cap ................................8-11
Fig. 8-18 Coolant drain cock (radiator) ...............8-11
Fig. 8-19 Coolant drain plug (engine) .................8-12
Fig. 8-20 Radiator coolant level..........................8-12
Fig. 8-21 Reserve tank .......................................8-12
Fig. 2-15 Starter switch........................................ 2-8
Fig. 8-22 Radiator fins - Clean ...........................8-13
Fig. 2-16 Preheat indicator .................................. 2-8
Fig. 8-23 Air cleaner - Check..............................8-14
Fig. 2-17 Water temperature meter and thermo
Fig. 8-24 Turbocharger - Inspect ........................8-14
unit........................................................ 2-9
Fig. 8-25 Pre-cleaner - Clean .............................8-15
Fig. 2-18 Ammeter............................................... 2-9
Fig. 8-26 Air cleaner element - Remove.............8-16
Fig. 2-19 Hour meter ........................................... 2-9
Fig. 8-27 Air cleaner element - Clean and
Fig. 2-20 Stop solenoid...................................... 2-10
Check ..................................................8-16
Fig. 2-21 Oil pressure switch ............................. 2-11
Fig. 8-28 Air cleaner - Check..............................8-16
Fig. 2-22 Thermo switch .................................... 2-11
Fig. 8-29 Battery electrolyte level - Inspect ........8-17
Fig. 2-23 Air cleaner indicator............................ 2-11
Fig. 8-30 Specific gravity of battery electrolyte -
Fig. 3-1 Battery electrolyte level - Inspect ......... 3-1
Check ..................................................8-17
Fig. 3-2 Fuel tank oil level - Check .................... 3-2
Fig. 8-31 Starter - Inspect...................................8-18
Fig. 3-3 Oil filler and Oil level gauge.................. 3-2
Fig. 8-32 Alternator - Inspect ..............................8-18
Fig. 3-4 Radiator filler cap ................................. 3-3
Fig. 10-1 Hangers...............................................10-1
Fig. 3-5 Radiator coolant level........................... 3-3
Fig. 10-2 Engine's center of gravity
Fig. 3-6 Reserve tank coolant level ................... 3-3
(standard specification) .......................10-1
Fig. 4-1 Recommended fuel .............................. 4-1
Fig. 5-1 Recommended engine oil..................... 5-1
Fig. 5-2 Selection of oil viscosity ....................... 5-1
Fig. 6-1 GLASSY - LLC ..................................... 6-1
Fig. 8-1 Belt and belt tension - Inspect and
Adjust ................................................... 8-1
Fig. 8-2 Fuel tank - Drain water ......................... 8-2
Fig. 8-3 Fuel filter - Drain water (1).................... 8-3
Fig. 8-4 Fuel filter - Drain water (2).................... 8-3
Fig. 8-5 Priming pump - Handle......................... 8-4
CONTENTS-4
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CONTENTS
List of tables
Table 3-1 Standard values at rated speed.............. 3-5
Table 4-1 Recommended limit and use limit of
fuel property............................................ 4-2
Table 5-1 Engine oil properties ............................... 5-4
Table 6-1 Water quality standards .......................... 6-1
Table 6-2 LLC specification .................................... 6-3
Table 6-3 Recommended LLC concentration ......... 6-5
Table 7-1 MAINTENANCE SCHEDULE ................. 7-2
Table 8-1 Specific gravity of electrolyte ................ 8-17
Table 9-1 Recommended rust-preventive oil
and corrosion inhibitor ............................ 9-1
Table 11-1 The starter does not crank or cranks
slowly, resulting in start failure.............. 11-2
Table 11-2 The starter cranks, but the engine
does not start ........................................ 11-2
Table 11-3 Output decrease ................................... 11-3
Table 11-4 Exhaust smoke is white or blue ............ 11-4
Table 11-5 Exhaust smoke is black or charcoal ..... 11-5
Table 11-6 Fuel consumption is high ...................... 11-6
Table 11-7 Engine oil consumption is high ............. 11-7
Table 11-8 Overheating .......................................... 11-8
Table 11-9 Low engine oil pressure........................ 11-8
Table 12-1 Main specifications ............................... 12-1
Table 12-2 Main specifications ............................... 12-2
CONTENTS-5
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113/242
Chapter 1 BASIC SAFETY PRECAUTIONS
Fire and explosions
Keep flames away Use explosion-proof lighting

Do not use flames near the engine (in apparatus
the engine room). Fuel vapor or other When inspecting fuel, engine oil, coolant, battery elec-
gas can catch fire and produce dan- trolyte, etc., use a flameproof light. An ordinary light-
gerous situations. ing apparatus may ignite gas and cause it to explode.
Wipe off spilled fuel, oil and LLC
immediately and thoroughly. Spilled fuel, oil and LLC Prevent electrical wires from
may ignite and cause a fire. short-circuiting
Store fuel and engine oil in a well-ventilated area. Avoid inspecting or servicing the electrical system with
Make sure that the caps of fuel and engine oil contain- the ground cable connected to the battery. Otherwise,
ers are tightly closed. a fire could result from short-circuiting. Be sure to dis-
connect the battery cable from the negative (-) termi-
Keep engine surrounding area nal before beginning with the work procedure.
tidy and clean Short-circuits, possibly resulting in fire, may be
Do not leave combustible or explosive materials, such caused by a loose terminal or damaged cable/wire.
as fuel, engine oil and LLC, near the engine. Such Inspect the terminals, cables and wires, and repair or
substances can cause fire or explosion. replace the faulty parts before beginning with the ser-
Remove dust, dirt and other foreign materials accu- vice procedure.
mulated on the engine and surrounding parts thor-
oughly. Such materials can cause fire or the engine to Keep fire extinguishers and a
overheat. In particular, clean the top surface of the first-aid kit handy
battery thoroughly. Dust can cause a short-circuit. Keep fire extinguishers handy, and
become familiar with their usage.
Care for fuel, oil and exhaust Keep a first-aid kit at the designated
gas leakage place where it is easily accessible by
If any fuel, oil or exhaust gas leakage is found, imme- anyone at any time.
diately take corrective measures to stop it. Establish response procedures to follow in the event
Such leakages, if left uncorrected, can cause fuel or of fire or accident. Provide an emergency evacuation
engine oil to reach hot engine surfaces or hot exhaust route and contact points and means of communication
gas to contact flammable materials, possibly leading in case of emergency.
to personal injury and/or damage to equipment.
1-1
114/242
Stay clear of all rotating and moving parts
Install protective covers around Lockout and tagout

rotating parts Be sure to lockout and tagout before starting inspec-
Make sure the protective covers of
tion and maintenance.
the engine are correctly installed.
Lockout and tagout are effective methods of cutting off
Repair any damaged or loose covers.
machines and equipment from energy sources.
Never remove the covers such as
To accomplish the lockout/tagout, remove the starter
damper cover, camshaft cover, or
switch key, set the battery switch to "OFF" position
rocker cover that enclose the revolving parts during
and attach a "Do Not Run" or similar caution tag to the
operation.
starter switch.
When the engine is coupled to driven equipment, be
The starter switch key must be kept by the person
sure to provide protective covers over the parts such
who performs inspection and maintenance during the
as the connecting belts and couplings that are
work.
exposed.
Never remove protective covers. Keep engine stopped during
servicing
Check work area for safety Be sure to stop the engine before proceeding to
Before starting the engine, make sure no one is near
inspection and service procedure. Never attempt to
the engine and tools are not left on or near the engine.
make adjustments on the engine parts while the
Verbally notify persons within the immediate area
engine is running.
when starting the engine.
Rotating parts such as belt can entangle your body
When the starter device is posted with a sign that pro-
and cause serious injuries.
hibits startup operation, do not operate the engine.
Always restore engine turning
Stay clear of moving parts while tools after use
engine is running Be sure to remove all turning tools used during main-
Do not approach rotating or sliding
tenance and inspection work. Remember also that the
parts of the engine while the engine is
turning gear must be returned to the operating condi-
running. Keep objects likely to be
tion before starting the engine.
caught by rotating parts away from
Starting the engine with the turning tools inserted or
such parts.
with the turning gear in engagement can lead to not
If any part of the clothing or outfitting is caught by a
only engine damage but also personal injuries.
rotating part, serious bodily injuries could result.
Changing the engine speed set-
ting is prohibited
Never change engine speed setting. Tampering with
the setting can cause the engine and its coupled
machine to operate at excessive speeds and result in
accidents.
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Be careful of exhaust Be careful of falling down

fume poisoning
Lift engine carefully
To lift the engine, use slings capable
Operate engine in a well-venti- of supporting the weight of the
lated area engine.
If the engine is installed in an
Attach the wire rope to the hangers
enclosed area, and the exhaust gas
provided on the engine using a cor-
is ducted outside, ensure that there is
rect sling.
no exhaust gas leakage from duct
During lifting process, keep the engine in a well-bal-
joints.
anced position by taking the center of gravity of the
When using the engine as portable generator set, do
engine into consideration.
not run it in doors such as a warehouse or tunnel, or in
Keep the angle formed by slings attached to hangers
an poorly-ventilated area near the shielding. When
within 60°. If the angle exceeds this limit, excessive
running it indoors by necessity, discharge the exhaust
load could be imposed on the hangers and this could
gas to outside and thoroughly ventilate the room.
damage the hangers and result in a serious accident.
Make sure the exhaust gas is not discharged directly
If the wire rope contacts the engine directly, place a
to surrounding buildings, plants or living passersby.
cloth or other soft padding to avoid damage to the
Exhaust gas from the engine contains carbon monox-
engine and wire rope.
ide and other harmful substances. Operating the
engine in an poorly-ventilated area can produce gas Do not climb onto the engine
poisoning. Do not climb onto the engine, nor step on any engine
parts located on the lateral sides.
To work on parts located on the upper section of
engine, use a ladder, stool, etc., that was firmly
secured.
Climbing on the engine may not only damage engine
parts but also cause falling down from the engine and
result in personal injuries.
Always prepare stable scaffold

When working on the upper part of
the engine and other hard-to-reach
places, use a stable work platform.
Standing on a decrepit stool or parts
box may result in personal injury.
Do not place any unnecessary objects on a work plat-
form.
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Protect ears from noise Be careful of burns
Wear ear plugs Do not touch the engine during

Always wear ear plugs when entering or immediately after operation
the machine room (engine room). To avoid burns, do not touch the
Combustion sound and mechanical engine during or immediately after
noise generated by the engine can operation.
cause hearing problems. A hot engine can cause burns.
To conduct maintenance and inspec-
tion work, wait until the engine has cooled sufficiently
by checking the temperature gauge.
Do not open the radiator filler

cap when the engine is hot
Never open the radiator filler cap while the engine is
running or immediately after the engine is stopped.
When opening the cap, stop the engine and allow the
coolant temperature to lower sufficiently.
When opening the radiator filler cap, open slowly to
discharge the pressure inside the tank. Also to avoid a
risk of getting scalded by steam, wear thick rubber
gloves or wrap a cloth around the cap.
When closing the cap, be sure to tighten securely.
The coolant is hot while engine is running and immedi-
ately after the engine stops. If the cap is opened when
the coolant is at operating temperature, steam and hot
coolant may blow out and result in burns.
Do not touch high pressure

injection fuel
If fuel leaks or sprays out from the high pressure injec-
tion pipe, do not touch the fuel.
Fuel in the fuel injection pipes is under high pressure
and if the fuel contact your skin, it goes into deep tis-
sues and may result gangrene.
Refill coolant only after the

coolant temperature dropped
When refilling of coolant, perform it after coolant tem-
perature drops, not immediately after the engine is
stopped. Otherwise you are scalded with hot coolant.
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Be careful when handling When abnormality occurs

fuel, engine oil or LLC
Do not add coolant immediately
Use only specified fuel, engine after a sudden stop due to over-
oil and LLC heating
Use fuel, oil and LLC specified in this manual, and If the engine stops suddenly or if you have no choice
handle them carefully. but stop the engine suddenly due to overheating, do
Use of any other fuel, oil or LLC, or improper handling not add coolant immediately.
may cause various engine problems and malfunc- Adding water while the engine is hot can damage
tions. parts such as cylinder heads due to a sudden drop of
Obtain the MSDS issued by the fuel, oil and LLC sup- temperature. Add coolant gradually after the engine
pliers, and follow the directions in the MSDSs for has completely cooled.
proper handling.
Avoid immediate restart after
Handle LLC carefully abnormal stop
When handling LLC, always wear rubber gloves and a If the engine stops abnormally, do not restart the
protective face mask. If LLC or cooling water contain- engine immediately. If the engine stops with an alarm,
ing LLC comes into contact with your skin or eyes, or if check and remedy the cause of the problem before
it is swallowed, you would suffer from inflammation, restarting. Sustained use of the engine without any
irritation or poisoning. remedy could result in serious engine problems.
Should LLC be accidentally swallowed, induce vomit-
Avoid continuous engine oper-
ing immediately and seek medical attention. Should
LLC enter your eyes, flush them immediately with
ation at low oil pressure
If an abnormal engine oil pressure drop is indicated,
plenty of water and seek medical attention. If LLC
stop the engine immediately, and inspect the lubrica-
splashes onto your skin or clothing, wash it away
tion system to locate the cause. Continuous engine
immediately with plenty of water.
operation with low oil pressure could cause bearings
Keep flames away from LLC. The LLC can catch
and other parts to seize.
flames, causing a fire. Coolant (containing LLC)
drained from the engine is toxic. Never dispose of If belt breaks, stop engine
coolant into regular sewage. Abide by the applicable immediately
law and regulations when discarding drained coolant. If the belt breaks, stop the engine immediately. Con-
tinuous engine operation with the broken belt could
Proper disposal of waste oil, cause the engine to overheat and thereby the coolant
LLC and coolant to boil into steam, which may gush out from the
Do not discharge waste engine oil, LLC and coolant
reserve tank or radiator, and you may be scalded with
into sewerage, river, lake or other similar places. Such
it.
a way of disposal is strictly prohibited by laws and reg-
ulations.
Dispose of waste oil, LLC and coolant and other envi-
ronmentally hazardous waste in accordance with the
applicable law and regulations.
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Service battery
Handle the battery correctly

Never use flames or allow sparks to
generate near the battery. The bat-
tery releases flammable hydrogen
gas and oxygen gas. Any flames or
sparks in the vicinity could cause an
explosion.
Do not use the battery when the battery electrolyte
level of which is below "LOWER LEVEL" line. Sus-
tained use of the battery could result in an explosion.
Do not short the battery terminals with a tool or other
metal object.
When removing battery, always remove the plug from
the negative (-) terminal first. When connecting bat-
tery, always connect the plug to the positive (+) termi-
nal first.
Remove all plugs, then charge the battery in a well-
ventilated area.
Make sure the cable clamps are securely installed on
the battery terminals. A loose cable clamp can cause
sparks that may result in an explosion.
Before servicing electrical components or conducting
electric welding, set the battery switch to the "Open/
OFF" position or remove the plug from the negative (-
) terminal to cut off the electrical current.
Battery electrolyte contains dilute sulfuric acid. Care-
less handling of the battery can cause the loss of sight
and/or skin burns. Also, do not consume the battery
electrolyte.
Wear protective goggles and rubber gloves when
working with the battery (when adding water, charg-
ing, etc.)
If battery electrolyte is spilled onto the skin or clothing,
immediately wash it away with lots of water. Use soap
to thoroughly clean.
The battery electrolyte can cause the loss of sight if
splashing into the eyes. If it gets into the eyes, imme-
diately flush it away with plenty of clean water, and
seek immediate medical attention.
If the battery electrolyte is accidentally consumed,
gargle with plenty of water, then drink lots of water,
and seek immediate medical attention.
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Other cautions
Never modify engine Perform all specified pre-opera-

Unauthorized modification of the engine will void our
warranty.
tion inspections and periodic
Modification of the engine may not only cause engine inspections
Conduct the pre-operation inspections and periodic
damage but also produce personal injuries.
inspections as described in this manual.
If there is a need to modify the engine, contact a
Failure to conduct the specified inspections may
dealer of Mitsubishi Heavy Industries, Ltd.
cause various engine problems, damage to parts, and
Observe safety rules at work serious accidents.
site Break-in the engine
Observe the safety rules established at your work-
To break-in new engines or overhauled engines, oper-
place when operating and maintaining the engine.
ate the engine at a speed lower than the rated speed
Do not operate the engine if you are feeling ill, inform
in a light load condition during the first 50 hours of
your supervisor of your condition. Operation of the
operation.
engine with reduced awareness may cause improper
Operating new engines or overhauled engines in a
operation that could result in accidents.
severe condition during the break-in period shortens
When working in a team for two or more people, use
the service life of the engine.
specified hand signals to communicate among work-
ers. Warm up the engine before use
After starting the engine, run the engine at low idling
Work clothing and protective speeds for 5 to 10 minutes for warm up. Start the work
gear after this operation is completed. Warm up operation
Wear a hardhat, face shield, safety shoes, dust mask,
circulates the lubricant through the engine. Therefore,
gloves and other protective gear as needed. When
individual engine parts are well lubricated before they
handling compressed air, wear safety goggles, a hard-
are subjected to heavy loads.
hat, gloves and other necessary protective gear.
Warm up operation circulates lubricants in the engine
Works without wearing proper protective gear could
and contributes to a longer service life and economi-
result in serious injuries.
cal operation.
Never break seals Do not conduct warm up operation for prolonged
To ensure proper engine operation, the fuel control period of time. Prolonged warm up operation causes
linkage is sealed to prevent accidental change of the carbon build-up in the cylinders that leads to incom-
injection volume and rotation speed settings. Operat- plete combustion.
ing the engine without these seals in place can cause
problems described below, and also invalidates the
Never operate the engine in an
warranty.
overloaded condition
If the engine shows an overloaded condition such as
 Rapid wear of sliding and rotating parts
black exhaust smoke, reduce the load immediately to
 Engine damage such as seizing of engine parts
operate the engine at an appropriate output and load.
 Considerably increased consumption of fuel and lu-
Overloading causes not only high fuel consumption
bricating oil
but also excessive carbon deposits inside the engine.
 Degradation of engine performance due to improper
Carbon deposits cause various problems and will
balance between fuel injection volume and governor
shorten the service life of the engine.
operation or overrunning of the engine which could
result in a serious accident
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Conduct cooling operation Use of tools optimum for each

before stopping the engine work
Before stopping the engine, let it idle in low gear for 5
Always keep in mind to select most appropriate tools
to 6 minutes to cool down.
for the work to be performed and use them correctly. If
Stopping the engine immediately after high-load oper-
tools are damaged, replace them with new tools.
ation will cause engine parts to heat up and shorten
the service life of the engine. Avoidance of prolonged time of
During cooling operation, check the engine for abnor- starter operation
malities. Do not use the starter for more than 10 seconds at a
time. If the engine does not start, wait for at least 1
Protection of the engine against minute before cranking again.
water entry Continuous operation of the starter will drain the bat-
Do not allow rainwater, etc. to enter the engine
tery power and cause the starter to seize.
through the air inlet or exhaust openings.
Do not wash the engine while it is operating. Cleaning Do not turn off the battery
fluid (water) can be sucked into the engine. switch during operation
Starting the engine with water inside the combustion Do not turn off the battery switch during operation.
chambers can cause the water hammer action which If the battery switch is turned OFF when the engine is
may result in internal engine damage and serious running, not only various meters will stop working but
accidents. also the alternator may have its diode and transistor
deteriorated.
Properly maintain the air
cleaner and pre-cleaner Cautionary instructions for
Maintain the engine with air cleaner or pre-cleaner transporting the engine
according to the following instructions. When transporting the engine on a truck, consider the
Do not maintain the air cleaner or pre-cleaner while engine weight, width and height to ensure safety.
the engine is running. The turbocharger may suck Abide by road traffic law, road vehicles act, vehicle
particles of foreign materials into the engine and could restriction ordinance and other pertinent laws.
result in serious accidents.
Remove the air cleaner or pre-cleaner slowly to pre-
vent foreign materials accumulated on the element
from falling off. After removing the air cleaner or pre-
cleaner, immediately cover the opening (inlet port of
air cleaner; port in body for pre-cleaner) with plastic
sheet or similar means to prevent foreign materials
from entering the engine.
Clean the pre-cleaner periodically. The pre-cleaner
clogging can cause insufficient intake air or increasing
in the exhaust temperature.
If the engine is equipped with a dust indicator, con-
duct maintenance when the clog warning sign ap-
pears.
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Chapter 2 NAME OF PARTS
Engine external diagrams
The external diagram is for the standard type of the engine. The installed equipment and shapes differ according to
the engine type.
S4S in-line type fuel injection pump left view
Governor
Fuel filter Fuel injection nozzle
Fan
Stop solenoid
Water pump Air inlet

(coolant inlet)
Front Rear
Fuel injection pump Coolant drain plug

Oil level gauge
Fuel feed pump
Oil filter
Crankshaft pulley
Fuel inlet Flywheel
Oil drain plug
Fig. 2-1 Engine left view

S4S in-line type fuel injection pump right view
Exhaust outlet Front hanger

Oil filler Coolant outlet
Thermostat case
Rear hanger
Flywheel housing Alternator
Rear Front
Belt
Starter
Oil pan
Fig. 2-2 Engine right view
2-1
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S4S-DT in-line type fuel injection pump left view
Fuel filter Governor Stop solenoid

Fuel injection nozzle
Glow plug
Water pump
(coolant inlet)
Oil cooler
Front Rear
Fuel return port
Coolant drain plug

Fuel injection pump
Fuel feed pump

Oil level gauge
Crankshaft pulley
Oil filter
Fuel inlet Flywheel

Oil drain plug

S4S-DT in-line type fuel injection pump right view
Air inlet Turbocharger (exhaust outlet)
Oil filler Front hanger
Coolant outlet
Rear hanger
Thermostat case
Flywheel housing
Rear Front
Alternator
Starter
Belt
Oil pan
2-2
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S4S distoributor type fuel injection pump left view
Fuel inlet
Fuel filter
Air inlet
Fan
Fuel return port
Water pump
(coolant inlet) Magnetic valve
(stop solenoid)
Front Rear
Coolant drain plug
Crankshaft pulley Oil level gauge
Fuel injection pump Flywheel
Oil filter
Oil drain plug

S4S distoributor type fuel injection pump right view
Exhaust outlet Front hanger
Oil filler Coolant outlet
Rear hanger Thermostat case
Alternator
Flywheel housing
Rear Front
Belt
Starter Oil pan
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S4S-DT distoributor type fuel injection pump left view
Fuel inlet Fuel injection nozzle

Fuel filter
Glow plug
Fan Oil cooler
Water pump Fuel return port

(coolant inlet)
Magnetic valve
(stop solenoid)
Front Rear
Coolant drain plug
Crankshaft pulley
Oil level gauge
Fuel injection pump
Flywheel
Oil filter
Oil drain plug

S4S-DT distoributor type fuel injection pump right view
Turbocharger Air inlet

Exhaust outlet
Front hanger
Oil filler
Coolant outlet
Flywheel housing
Rear Front
Alternator
Belt
Starter Oil pan
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S6S in-line type fuel injection pump left view
Fuel filter Governor

Stop solenoid
Fan
Air inlet
Water pump Fuel injection nozzle

(coolant inlet)
Front Rear
Fuel injection pump Coolant drain plug
Fuel feed pump

Oil filter
Fuel inlet
Flywheel
Fuel return pipe Oil level gauge
Oil drain plug

S6S in-line type fuel injection pump right view
Oil filler Oil filler

Front hanger
Exhaust outlet
Coolant outlet
Rear hanger
Thermostat case
Rear Front
Damper
Starter Belt
Oil pan
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S6S distoributor type fuel injection pump left view
Fuel inlet Magnetic valve

Fuel filter Air inlet
(stop solenoid)
Fan
Fuel return port
Water pump
(coolant inlet)
Coolant drain plug
Front Rear
Fuel injection pump Oil filter
Flywheel
Oil level gauge

Oil drain plug

S6S distoributor type fuel injection pump right view
Oil filler
Oil filler
Front hanger
Exhaust outlet
Coolant outlet
Rear Front
Damper
Starter
Belt
Oil pan
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S6S-T distributor type fuel injection pump left view
Magnetic valve Fuel injection nozzle

(Stop solenoid)
Oil cooler
Fan Fuel filter
Water pump
Coolant
(Coolant inlet)
drain plug
Front Rear
Fuel injection pump
Oil filter
Relief valve Flywheel
Oil level gauge
Oil drain plug

S6S-T distributor type fuel injection pump right view
Turbocharger
Air inlet
Oil filler
Exhaust outlet
Coolant outlet
Oil filler
Front hanger
Rear hanger
Thermostat case
Fuel return port
Fuel inlet Alternator
Rear Front
Damper
Starter
Belt
Oil pan
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128/242
Equipment and instrument

The installed equipment and shapes differ on the engine type.
Starter switch
The starter switch is used to start the engine.
HEAT OFF
HEAT ON
When the key is turned to this position, the glow plugs START
become hot and allow easy startup of a cold engine.
OFF
When the key is turned to this position, power supply
to the electric circuits is cut off, and the key can be
removed and inserted at this position. To sotp engine,
turn the key to this position.
ON
When the key is at this position, power is supplied to Fig. 2-15 Starter switch
the electric circuits. After the engine starts, the key is
set to this position.
START
When the key is turned to this position, the starter
cranks the engine and the engine starts. When the
key is released, ti automatically returns to the "ON"
position.
Preheat indicator
The preheat indicator shows the condition of the glow
plugs.
As soon as the glow plugs are heated, the preheat
indicator turns red.
Fig. 2-16 Preheat indicator
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Water temperature meter and thermo unit

The engine coolant temperature detected by the
thermo unit is displayed by the water temperature
meter.
When the water temperature meter shows 95°C
[203°F], idle the engine in low gear until the tempera- 80 120
50 C
ture becomes normal. After the temperature becomes
normal, perform cooling operation for 5 or 6 minutes
and then inspect the cooling system.
Thermo unit
Fig. 2-17 Water temperature meter and thermo unit
Ammeter
It indicates the battery charging condition while the
engine is running.
When the battery is charged, the pointer swings to the
positive (+) side. When the battery is discharged, the
pointer swings negative (-) side.

Fig. 2-18 Ammeter
Hour meter
It indicates the operating time of the engine.
When performing the periodic inspection and mainte-
nance, check the time interval with this meter.
0 0 0 0 1
1/10
HOUR METER
Fig. 2-19 Hour meter
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Stop solenoid
The stop solenoid operates for normal shutdown of
engine operation.
The stop solenoid moves the rack of fuel injection Stop solenoid (ETR)
pump to cut the fuel, and consequently stops the
engine.
Two types of stop solenoids are available.
RUN OFF (ETS: Energized To Stop) type
Not energized while the engine is running. Energized
by a stop signal to stop the engine.
RUN ON (ETR: Energized To Run) type
Energized while the engine is running, and de-ener- Fig. 2-20 Stop solenoid
gized to stop the engine.
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Engine protection devices

The engine protection device is a device to prevent the engine from the accident by generating the alarm when
abnormality occurs. Stop the engine if the protection device is activated, investigate the cause of abnormality and
restore it. When the cause of abnormality is unknown, contact a dealer of Mitsubishi Heavy Industries, Ltd. The
installed protection devices, type (set value) or shapes varies according to the specifications.
Oil pressure switch

The oil pressure switch activates the alarm system or
stops the engine suddenly when the engine oil pres-
sure becomes abnormally low.
Oil pressure switch
Fig. 2-21 Oil pressure switch
Thermo switch
The oil pressure switch generates an alarm when the
engine coolant temperature becomes high and
reaches the specified temperature.
Thermo switch
Fig. 2-22 Thermo switch
Air cleaner indicator

The air cleaner indicator alarms with its red signal
when air cleaner elements become clogged, the differ- Reset button
ence in pressure between front air cleaner and rear air Signal
cleaner, and reaches the specified value. The signal (red)
indicates only, and does not generate an alarm,
Therefore, the periodic visually inspection is needed.
Press the reset button on the top of air cleaner indica-
tor and restore the signal after cleaned the air cleaner
indicator or replaced with a new one.
Fig. 2-23 Air cleaner indicator
2-11
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133/242
Chapter 3 OPERATION
Preparations for operation
Should an engine abnormality be observed during operation, stop the engine and correct the problem, or contact a
Always conduct the following inspection before starting the engine.
Engine external - Inspect
Be sure to keep combustible materials away from the engine, especially from the hot engine parts such as exhaust
manifolds, or the battery. Check for fuel and oil leakage. Clean the top surface of the battery. A fire can be caused
by combustible materials placed near hot engine parts. If any abnormality is found, be sure to repair it or contact a
Inspect the engine exterior as described below.
1. Make sure there is no combustible material near the engine or battery. Also, check to make sure that the engine
and battery are clean. If combustible materials or dust are found near the engine or battery, remove them.
2. Check the electrical wiring for such components as the starter and alternator for looseness.
3. Check the entire engine for fuel leakage, engine oil or coolant. If leakages are found, repair or contact a dealer
of Mitsubishi Heavy Industries, Ltd.
4. Make sure the following valves, plugs and cocks are open or closed (tightened) properly:
Fuel feed valve: Open
Coolant drain cock (plug): Closed (Tightened)
Oil drain valve: Closed
Battery electrolyte level - Inspect
If battery electrolyte is spilled on your skin or clothes, flush immediately with plenty of water. If battery electrolyte
get into your eyes, flush them immediately with plenty of water and then get medical attention.
Do not use open flames or other fire hazards near the battery. When handling the battery, be careful of sparks gen-
erated by accidental shorting. For other cautions in handling the battery, refer to "Service battery" (1-6).
Battery electrolyte evaporates during use and the
electrolyte level gradually decreases. Proper electro-
lyte surface level is between the "LOWER LEVEL"
10 to 15 mm
and "UPPER LEVEL" lines. [0.394 to 0.591 in.]
For the battery without level lines, proper electrolyte Proper
LEVEL level
surface level is about 10 to 15 mm [0.394 to 0.591 in.] UPPER
VEL
R LE
LOWE
above the top of the plates.
If the electrolyte level is low, remove the caps and add
distilled water to the proper level.
Note: When adding distilled water, pour in carefully.
Fig. 3-1 Battery electrolyte level - Inspect
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Chapter 3 OPERATION
Fuel tank oil level - Check
When working around fuel, make sure there are no open flames, heaters or other fire hazards.
Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire.
Do not remove the strainer when filling the fuel tank.

For fuel to be used, refer to "FUEL" (4-1).
Make sure the fuel tank is full.
If the fuel level is low, refill the tank to the "FULL" level
line.
Fig. 3-2 Fuel tank oil level - Check
Engine oil level - Check
For engine oil to be used, refer to "ENGINE OIL" (5-1).

1. Pull out the oil level gauge and wipe it clean using
Oil filler
a waste cloth. Oil level gauge
2. Insert the oil level gauge fully into the oil level
gauge guide, then pull out the gauge again.
3. The proper oil level is between the high and low
Improper
marks on the oil level gauge. If the oil level is low, High H
Proper
add engine oil of the specified type. L
Low
Improper
4. Install the oil filler cap after refilling.
5. Check the oil pan and other area for oil leakage.
Oil level gauge
Fig. 3-3 Oil filler and Oil level gauge
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Chapter 3 OPERATION
Coolant level - Check
Turn the cap about Stand the lever to

Remove the radiator filler cap only after the engine
half a turn the upright position
has cooled to room temperature. Place a waste cloth
over the cap, and loosen the cap about a half-turn or
stand the lever to the upright position to release inter-
nal pressure. Never open the radiator filler cap while
the engine is hot, otherwise the steam or hot coolant
spurts out and you may be scald with it.
1. Open the radiator filler cap and check the coolant
level. Fig. 3-4 Radiator filler cap
2. If the coolant level is low, add coolant to the speci-
fied level.
Always use the coolant with the same LLC concen-

tration.
Note: Determine the quantities of LLC based on the

coolant capacity and the LLC concentration
chart.
For the coolant, refer to "COOLANT" (6-1). For
the coolant capacity, refer to "MAIN SPECIFICA- Fig. 3-5 Radiator coolant level
TIONS" (12-1).
3. If a reserve tank is equipped, fill the reserve tank
with coolant up to the "FULL" level line.
Fig. 3-6 Reserve tank coolant level
3-3
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Chapter 3 OPERATION
Starting
The starting method changes based on the application and specifications.Start the engine according to the specified
procedure.
Before starting the engine, check to make sure no one is near the engine and that tools are not left on or near the
engine.In a loud voice, notify people in the area when starting the engine.
Do not apply a load to the engine at starting. (Disengage the clutch if installed.)
Continuous operation of the starter will drain the battery power and cause the starter to seize. Do not use the
starter for more than 10 seconds at a time. When the engine does not start, wait for more than one minute before
cranking again.
Warm up operation
Do not approach rotating parts during operation. Entanglement by rotating parts can cause serious injury.
After the engine starts, operate the engine in a no load condition at low idling speed for 5 to 10 minutes to warm up
the engine.
Checking engine oil pressure

During warm up operation, check if the oil pressure is
in the range of standard value (0.15 MPa {1.5 kgf/cm2}
[21 psi] or more).
Also, make sure the oil pressure gauge is operating
properly.
Note: The oil pressure gauge may indicate a higher
level than normal level immediately after the en-
gine starts, due to the low oil temperature. The
pressure gradually lowers to the normal level as
the oil temperature rises.
External inspection during warm up

Visually check the external view of the engine for fuel,
engine oil and coolant leakage, or exhaust gas leak-
age from joints.
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Chapter 3 OPERATION
Operation
Cautions when operating Inspection during operation
Carefully check the exterior of engine such as piping
Do not approach rotating parts during operation. joints for leaks.
Entanglement by rotating parts can cause serious Check for abnormal engine noises or vibrations such
injury. as knocking.
Check the color of exhaust gas from the exhaust muf-
fler.
Do not touch any hot part of the engine such as Check the instruments and gauges for proper opera-
exhaust pipes during operation or immediately after tion and make sure they indicates normal values.
shut down. A hot engine can cause burns. Table 3-1 Standard values at rated speed
Item Standard
0.29 to 0.49 MPa
Always provide adequate ventilation in the engine Engine oil pressure {3 to 5 kgf/cm2}
room. If air supply to the engine room is not sufficient, [43 to 71 psi]
the room temperature rises and can affect engine 70 to 90°C
Coolant temperature
output and performance. [158 to 194°F]
For the first 50 hours, operate the engine under a Note: (a) When the oil pressure drops below 0.15 MPa
light load for break-in operation. Operating the engine {1.5 kgf/cm2} [21 psi] in normal operation, or
under heavy load or severe conditions during the below 0.05 MPa {0.5 kgf/cm2} [7 psi] at low
break-in period can shorten the service life of the idling, stop the engine immediately.
engine. Be sure to locate the cause of problem and
Do not turn the battery switch to "OFF" position when correct it before restarting the engine.
the engine is running. Turning off the battery switch (b) When the thermo switch is activated in nor-
during operation not only stops the instrument opera- mal run, idle the engine in low gear immedi-
tions but also may deteriorate the alternator diode ately until the engine temperature becomes
and regulator. normal. Then, perform cooling operation for 5
Never turn the key to the "START" position during or 6 minutes before stopping the engine.Be
operation. The starter may be damaged. sure to locate the cause of problem and cor-
When operating the engine with a 30 % of rated load rect it before restarting the engine.
or lower, limit each operation to an hour. Prolonged
warm up operation causes carbon build-up in the cyl-
inders that leads to incomplete combustion. Operate
the engine with a 30 % of rated load or more for over
5 minutes after continuous operation for an hour to
prevent causing carbon build-up.
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Chapter 3 OPERATION
Stopping
Stopping the engine abruptly while engine parts are hot due to high-speed operation can be a cause for heat up of
the engine parts and shorten the engine life. Before stopping the engine, idle the engine in low gear immediately
until the engine temperature becomes normal except in an emergency. Then, perform cooling operation for 5 or 6
minutes before stopping the engine and inspect the whole engine.
Never accelerate the engine immediately before shutting it down.
Do not restart the engine immediately after abnormal shut down. When the engine stops with alarms, be sure to
locate the cause of the problem and correct the problem before restarting the engine. After restarting the opera-
tion, inspect the whole engine for any abnormalities again. If the engine has an abnormality, repair it immediately.
Engine stopping method may differ depending on the specifications.
Follow the instructions according to the specifications of the equipment.
Inspection after stopping

Inspect the engine for fuel, oil or coolant leakage. If any leakage is found, repair the leakage or contact a dealer of
Mitsubishi Heavy Industries, Ltd.
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Chapter 4 FUEL
Recommended fuel
Use a fuel specified in this manual only. Do not refill

the fuel tank more than the specified level, as it may Diesel fuel
result in a fire.
equivalent
Use a diesel fuel equivalent for "JIS K 2204 diasel for
fuel".
It is necessary to use a fuel that has a pour point suit- JIS K2204
able for the ambient temperature.
Fig. 4-1 Recommended fuel

Handling fuel
When using fuel stored in a storage tank, leave it to sit for more than 24 hours so that dust and water can settle at
the bottom. Then, use the upper clean fuel.
Fill up the fuel tank or service tank after each operation.
This prevents water from mixing with fuel in the tank and also gives time for dust and water to separate and settle at
the bottom of the tank.
Before refilling, clean the areas around the caps thoroughly and remove the caps from the drum and tank. Also
clean your hands and the hose before refueling. When using a hand-operated pump, be careful not to pump water
or sediment accumulated at the bottom of the storage tank.
Be sure to use a strainer when filling fuel tank. For a complete filtration, it is recommended to use a clean lint-free
cloth together with the strainer.
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Chapter 4 FUEL
Table 4-1 Recommended limit and use limit of fuel property

Properties Recommended limits Use limits Test method
JIS K 2265:2007
Flash point 50°C [122°F] or higher 45°C [113°F] ISO 3769
ISO 2719
Initial boiling point 170°C [338°F] or higher
JIS K 2254:1998
Distillation 90 % distillate
330 to 380°C [626 to 716°F] ISO 3405
temperature
JIS K 2269:1987
Pour point (PP) 6°C [42.8°F] or lower than ambient temperature
ISO 3016
JIS K 2269:1987
Cloud point (CP) Below ambient temperature
ISO 3015
JIS K 2288:2000
Cold filter plugging point (CFPP) 3 °C [37.4 °F] or lower than ambient temperature
IP 309/96
JIS K 2270:2000
Carbon residue (10 % bottom oil) 0.1 weight % or lower 0.4 weight % or lower ISO 6615
ISO 10370
JIS K 2280:1996
Cetane number 45 or higher 40 or higher
ISO 5165
JIS K 2280:1996
Cetane index (new type) 45 or higher 40 or higher
ISO/DIS 4264
2.0 mm2/s [0.0031 in2/s] or more at 30 °C [86 °F] JIS K 2283:2000
Kinematic viscosity
8.0 mm2/s [0.0124 in2/s] or more at 30 °C [86 °F] ISO 3104
JIS K 2541:2003
(The content
0.2 weight % or lower should be as
Sulfur content (Except in cases the value is specified low as the
by the emission control.) diesel fuel.)
ISO 4260
ISO 8754
JIS K 2275:1996
Water content and sediment 0.1 volume % or lower
ISO 3733
JIS K 2272:1998
Ash content 0.01 % by mass or less 0.03 weight % or lower
ISO 6245
Copper corrosion JIS K 2513:2000
Color change = Copper plate No.3 or less
(3 hrs at 50 °C [122 °F]) ISO 2160
0.83 to 0.87 g/cm3 0.80 to 0.87 g/cm3 JIS K 2249:1995
Density at 15 °C [59 °F]
[49.9424 to 54.3123 lb/ft3] [49.9424 to 54.3123 lb/ft3] ISO 3675
24 hrs at 250 °C
75 % carbonization or less 80 % carbonization or less
[482 °F]
24 hrs at 230 °C
Caulking 55 % carbonization or less - Fed 791B
[446 °F]
48 hrs at 180 °C
Tar-free -
[356 °F]
JIS K 2536:2003
Aromatics substances (by HPLC) 35 % by volume or less (total of aromatic components)
ISO 3837
JIS K 2536:2003
Polycyclic aromatic content 8 % by volume or less
IP 391
Asphaltene 0.1 weight % or lower -
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Chapter 4 FUEL
Table 4-1 Recommended limit and use limit of fuel property

Properties Recommended limits Use limits Test method
Foreign materials
JIS B 9931:2000
(foreign materials at engine fuel 5.0 mg/liter or less
ISO 4405
inlet)
Lubricity: MWSD (Measured mean
460 μm [0.02 in.] or less
Wear Scar Diameter) by HFRR
(calculated wear scar diameter at ISO 12156-1
wear test at 60 °C [140 °F] fuel tem-
WS 1.4 kPa {0.0143 kgf/cm2} [0.2031 psi])
perature
BDF quality shall meet JIS K 2390, JIS K 2390:2008
EN14214, or ASTM D6751 (FAME for
BDF: Biodiesel fuel (FAME: Fatty
BDF blending of 5 % by volume or less is approved mixture)
Acid Methyl Ester)
(Except in cases the value is specified ASTM D 6751
by the emission control.) EN 14214
Note: When using fuel less than use limits, white smoke, worsening start up or unstable rotation may occur.
4-3
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143/242
Chapter 5 ENGINE OIL
Recommended engine oil
Use only the engine oils recommended in this manual. Never use other oils.
The use of inappropriate or inferior oils will result in sticking of piston rings, seizure between piston and cylinder, or
premature wear of bearings and moving parts, and significantly shortens the service life of the engine.
Many oil standards, which are established through
special engine tests, are available to determine the
quality of oil depending on the engines to which they
will be applied and on operating conditions. Among
OIL OIL
those standards, API (American Petroleum Institute)
service classifications are mostly used to classify Class CF Class CH-4
engine oils. SAE specifies the viscosity only, while the
API Service API Service
API service classification indicates the quality level of Classification Classification
engine oil.
For engine lubrication oil, please use API service clas-
sification CF. Fig. 5-1 Recommended engine oil
Selection of oil viscosity
Use the following chart to select the appropriate oil
viscosity according to the ambient temperature.
Excessively high oil viscosity causes power loss and Temperature -30 -20 -10 0 10 20 30 40 50
°C [°F] [-21] [-4] [14] [32] [50] [68] [86] [104] [122]
an abnormal rise of oil temperature, while excessively
low oil viscosity accelerates wear due to inadequate SAE10W

SAE30
lubrication, and also causes a decrease in engine out- Engine oil
viscosity SAE40
put due to leakage of combustion gas.
SAE15W-40
Fig. 5-2 Selection of oil viscosity

Handling engine oil
Before filling the engine with engine oil, stop the engine and make sure there are no open flames and other fire
hazards near the engine. Leaked or spilled oil on hot surfaces or electrical components can cause a fire. Wipe off
any spilled oil immediately and thoroughly. After filling, securely close the filler cap.
Never mix different brands of engine oil. Mixing different brands of engine oil may cause a chemical reaction of
additives in the engine oil that could degrade the engine oil quality.
When handling oil in greater than the legally specified quantities, be sure to have the work performed by a service
station in compliance with the law. When removing oil from the engine or oil can, use an oil pump. Do not suck oil
with the mouth to siphon it.
Be sure to close the cap on the oil can after use.
Keep oil in a well-ventilated area and out of direct sunlight.
Be sure to obtain the MSDS of the engine oil used and follow the instructions of the MSDS.
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Abrasion powder in the engine oil also accelerates

Engine oil performance
deterioration as it can catalyze oxidation reaction.
requirements Dust and dirt entered from outside deteriorate the en-
Engine oil requires the following performances.
gine oil as well. Contamination and deterioration pro-
Excellent dispersion performance (the ability of oil to
cess accelerates with operation time.
disperse sludge in the oil) at high temperature that
Deterioration products and contaminants in the en-
prevents engine oil deterioration due to sludge accu-
gine oil, if it is a small amount, are harmless as they
mulation and soot contamination.
can be dispersed in oil. However, if it is a large
Excellent acid-neutralizing performance that prevents
amount, they become harmful. Since such products
oxidative degradation due to fuel sulfur content.
and contaminants flow out of the oil pan and start to
Excellent high temperature oxidation stability that en-
accumulate inside the piston and in the oil system,
dures continuous operation under prolonged high-
they eventually lead to serious problems such as pis-
load.
ton ring sticking and bearing scuffing.
Sufficient viscosity concentration to maintain the cold
Sulfur content in fuel is burned and transformed into
start performance, and lubrication performance at
sulfurous acid gas and sulfuric gas that cause corro-
high temperature.
sive wear of cylinders and piston rings. A detergent
Good rust and corrosion resistance to water.
additive in the engine oil neutralizes them into harm-
Good foam resistance to prevent the lubricating qual-
less substances. As the detergent additive is con-
ity from lowering due to oxidation.
sumed in its role of neutralizing, the engine oil total
Engine oil deterioration base value decreases. A decrease in the total base
value indicates a corresponding decrease in soot dis-
mechanisms
persion ability. As a result, deposits on the pistons in-
Engine oil deteriorates due to natural deterioration
crease.
and due to the contamination. The natural deteriora-
Due to oxygen in the air, oil temperature rise under
tion of oil has two primary causes; one is the degrada-
high-load continuous operation causes oxidation deg-
tion caused by oxidation reaction or thermo
radation. As oxidation degradation accelerates, oxi-
decomposition of base oil and additives, and the other
dative products are polymerized. The polymerized
is the degradation in the performance due to con-
oxidative products cause the oil viscosity to increase,
sumption of additives during use.
which leads to the generation of sludge and varnish.
Contaminants such as fuel and combustion products
As a result, problems such as lubrication failure and
(soot, water vapor or oxidation products) that intrude
piston ring sticking occur. Also acid substances gen-
into oil have critical influence on oil quality. Soot ad-
erated by oxidation can cause problems like main
heres to the oil film of cylinder wall, and is scraped off
bearing corrosion.
the cylinder wall by the piston ring. Such soot increas-
es the rate of insoluble substances in the engine oil
and can cause the wear of piston rings and cylinder
walls.
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Definition of properties of engine oil

Viscosity Water content
Viscosity is a basic physical property of engine oil and
Water in oil promotes corrosion/wear, and decreases
is considered as the most important aspect when eval-
lubricity in sliding parts.
uating oil.
Contamination of oil by blow-by gas and deterioration Flash point
of oil by its natural aging in crease the viscosity and The flash point is lowered by contamination with fuels.
degrade the performance of viscosity, which will cause Flash point is measured to check the dilution of fuel.
the deposition of sludge inside the engine and oil filter The dilution of fuel reduces oil film, and causes insuffi-
clogging. Contamination of oil by fuel and sheared cient lubrication that will cause friction or wear of
molecules of viscosity index improver in oil decrease engine parts.
the viscosity and degrade the performance of viscos-
ity, which will cause insufficient lubrication and friction/
Insoluble
Insoluble includes acid products of engine oil, imper-
wear of engine parts.
fect combustion products, sludge or soot, metal abra-
Total base number sive particles and dust. Insoluble is an indication of

Total base number (TBN) shows the ability to neutral- degradation/contamination of oil.
ize acids such as organic acid due to engine oil oxida- Dispersant detergent, which is an additive in engine
tion, or sulfurous or sulfuric acid due to the sulfur oil, absorbs sludge particles, and disperses them as
content of fuel. fine particles in oil. Total insoluble density and remain-
Because TBN indicates the amount of dispersant ing dispersibility can be obtained by measuring insolu-
detergent in oil, it can be used to estimate consump- ble and coagulated insoluble (using chemical
tion of basic dispersant detergent. The ability to dis- specialities to stop action of disperse detergent and to
perse sludge declines as dispersant detergent is used collect the sludge dispersed in oil) by which piston ring
up. seizure or premature wear can be prevented before it
occurs.
Total acid number
The total acid number in oil increases as the organic
acid is being derived by the engine oil oxidation, or
sulfurous acid or sulfuric acid derived by the combus-
tion of sulfur content of fuel, or the oil becomes con-
taminated with imperfect combustion products.
An increase in the total acid number will result in cor-
rosion or wear of the inner parts of the engine (such
as cylinder liners or metal) due to sulfur content, and
piston ring seizure due to sludge.
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Service Limits of engine oil

Engine oil degrades through the use and by lapse of time.
To determine the timing of engine oil replacement, analyze the used oil, and understand the condition of oil deterio-
ration and oil defacement. It is also required to compare the oil analysis results and the engine analysis results
including inside contamination and wear condition of engine, and to consider the engine operating condition.
The engine oil affects the engine oil quality to use, the engine operating condition and the quality of fuel.Analyze the
used oil, and understand the condition of oil deterioration and oil defacement. To determine the timing of engine oil
replacement, the stabiration of engine is required.
Refer to the following table for the determination of engine oil performance degradation. If any of the following devi-
ate the limit, replace the engine oil with new oil.
Table 5-1 Engine oil properties
Properties Standard Test method
JIS K 2283:2007
mm2/s [in2/s] +30% or less
Viscosity -15% or more of new oil ISO 3107
@100°C [212 °F]
ISO 2909
2.0 or more with hydrochloric acid
(HCL) method JIS K 2501:2003
Total base number mgKOH/g
1/2 of new oil or more with perchlo- ISO 3771
ric acid (PCA) method
JIS K 2501:2003
Total acid number mgKOH/g Up to +3.0 of new oil
ISO 3771
JIS K 2275:1996
Water content Vol % 0.2 or less
ISO 9029
JIS K 2265:2007
Flash point (open cup) °C [°F] 180 [356] or higher ISO 3769
ISO 2719
Pentane insoluble Wt % 0.5 or less ASTM D 893
Pentane insoluble coag-
Wt % 3.0 or less ASTM D 893
ulated
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Chapter 6 COOLANT
Note: In this operation manual, the word "coolant" represents the liquid combined water and LLC.
Recommended water for coolant

Use soft water for the engine cooling system. The water quality must meet the requirements in the Table below.
Basically, the water quality should be within the recommended value, however, up to the limit is acceptable.
Table 6-1 Water quality standards
Chemical Recommend
Item Unit Limit Main adverse effect
symbol value
Corrosion and rust, scale
pH (25 °C [77 °F]) - - 6.5 to 8.0 6.5 to 8.5
formation
Electrical conductivity Corrosion and rust, scale
- mS/m < 25 < 40
(25 °C [77 °F]) formation
Total hardness CaCO3 ppm < 95 < 100 Scale formation
M alkalinity CaCO3 ppm < 70 < 150 Scale formation
Chlorine ion Cl- ppm < 100 < 100 Corrosion and rust
Sulfuric acid ion SO42- ppm < 50 < 100 Corrosion and rust
Total iron Fe ppm < 1.0 < 1.0 Scale formation
Silica SiO2 ppm < 30 < 50 Scale formation
Residue from evaporation - ppm < 250 < 400 Scale formation
Note: Figures in parentheses are the standard value. In addition to the items specified above, turbidity is specified to
be below 15 mg/liter.
Long life coolant (LLC)

Should coolant or LLC be accidentally consumed, induce vomiting immediately and seek medical attention. If LLC
should enter eyes, flush immediately with plenty of water and seek medical attention.
Be sure to use Mitsubishi Heavy Industries, Ltd. genuine long life coolant (LLC) "GLASSY long life coolant (Ethyl-
ene glycol type)" or "PG GLASSY long life coolant (Non-amine type)" as coolant. When using other brand LLCs by
necessity, be sure to use the LLC that meets the specification in Mitsubishi Heavy Industries, Ltd. Mitsubishi heavy
industries, Ltd. disclaim the warranty claim concerning malfunctions caused by the use of LLC that does not meet
the following specification.
Genuine LLC
Mitsubishi Heavy Industries, Ltd. recommends the use
of our genuine long life coolant "GLASSY long life
coolant (Ethylene glycol type)", and Eco-friendly prod-
uct "PG GLASSY long life coolant (Non-amine type)",
which are most appropriate coolant for diesel engine
from Mitsubishi Heavy Industries, Ltd.
Fig. 6-1 GLASSY - LLC
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Chapter 6 COOLANT
Other brand LLCs Standard for other brand

LLC
Never mix Mitsubishi Heavy Industries, Ltd. genuine When using other brand LLCs by necessity, be sure to
LLC with other brand LLCs. Mixing with other brand use the LLC that meets following specification. Mit-
LLCs degrades the performance of Mitsubishi Heavy subishi heavy industries, Ltd. disclaim the warranty
Industries, Ltd. genuine LLC. claim concerning malfunctions caused by the use of
LLC that does not meet the following specification.
When using LLC other than Mitsubishi Heavy Indus-
tries, Ltd. genuine long life coolant (LLC) "GLASSY General demands of LLC
long life coolant (Ethylene glycol type)" or "PG  LLC shall be a homogeneous liquid.
GLASSY long life coolant (Non-amine type)", be sure  Engine cooling system shall not receive troubles
to use the LLC which meets specification in Mitsubishi such as corrosions and precipitation products etc. by
Heavy Industries, Ltd. LLC when the LLC is diluted to 30 to 60 % density.
The quality and performance of commercially avail-  LLC shall be mixed with other LLC that satisfies this
able LLCs as well as their component variations are specification, and shall not separate elements each
the responsibility of LLC suppliers. other, and shall not decrease the performance each
Before purchasing commercial LLC, be sure to dis- other.
cuss the suitability of LLC with the LLC supplier.  LLC shall not allow the container to be corroded, and
Use only all-season LLC (non-amine type). Do not use shall not has precipitation products etc. even if LLC is
antifreeze alone instead of LLC. left in the container for 6 months.
 LLC shall not has extraction products etc. even if LLC
is kept in -20 to -25°C [-4 to -13°F]
 The validity term of the quality that provides with this
specification is 2 years after it delivers with the indoor
normal temperature keeping.
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Chapter 6 COOLANT
LLC specification
LLC shall examine according to JIS K2234 section 7 (examination methods), and satisfy this specification. General
matters and the sample to the examination is shown in JIS K2234.
Table 6-2 LLC specification
Property Standard
External Not precipitation
Minimum 1.112 g/cm3 [69.4199 lb/ft3]
Density
(20/20 °C) [68/68 °F] (Stock solution)
Water content Maximum 5.0 weight % (Stock solution)
30 vol % Maximum -14.5 °C [6 °F]
Frozen temperature
50 vol % Maximum -34.0 °C [-29 °F]
Boiling temperature Minimum 155 °C [311 °F] (Stock solution)
pH 7.0 to 11.0 (30 vol %)
30 vol % Maximum 4.0 ml
Bubbling character
(ASTM D 3306-01) Maximum 150 ml, Disappearance of bubble
331/3 vol %
within 5 sec.
Hard water adaptability Maximum 1.0 (50 vol %)
Aluminum ±0.30 mg/cm2
Cast iron ±0.15 mg/cm2
Mass Steel ±0.15 mg/cm2

change Brass ±0.15 mg/cm2
Test piece
Solder ±0.30 mg/cm2
Metallic causticity
(88±2°C Copper ±0.15 mg/cm2
[190±36°F], External of test piece after the Not corrosion on surface excluding between
336±2 Hr, examination test piece and spacer. Discoloration is OK.
30 vol % (E.G),
50 vol % (P.G)) Bubbling while examination Not bubbling overflow
pH 6.5 to 11.0
Properties of pH change ±1.0

liquid after the Precipitation Maximum 0.5 vol %
examination
Not remarkable discoloration, separation
External of liquid
and gel.
Aluminum, Cast
Mass
iron, Steel, Brass, ±0.30 mg/cm2
change
Test piece Solder, Copper
External of test piece after the Not corrosion on surface excluding between
examination test piece and spacer. Discoloration is OK.
Circulation
metallic causticity pH 7.0 to 9.0
(98±2°C
[208±36°F], pH change ±1.0
1000 Hr, Pre-alkalinity change ±15 %
30 vol % (E.G), Properties of
50 vol % (P.G)) liquid after the Precipitation 1.0 vol %
examination
Not remarkable discoloration, separation
External of liquid
and gel.
Density Fe, Cu, Al, Zn, Pb,
Maximum 10 ppm
of ion NH4+
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Chapter 6 COOLANT
Table 6-2 LLC specification

Property Standard
Aluminum ±0.60 mg/cm2
Cast iron ±0.30 mg/cm2
Mass Steel ±0.30 mg/cm2

change Brass ±0.30 mg/cm2
Test piece
Solder ±0.60 mg/cm2
Circulation
metallic causticity Copper ±0.30 mg/cm2
(88±3°C External of test piece after the Not corrosion on surface excluding between
[190±37°F], examination test piece and spacer. Discoloration is OK.
1000±2 Hr,
30 vol % (E.G)) pH 6.5 to 11.0
Properties of
pH change Maximum ±1.0
liquid after the
examination Not remarkable discoloration, separation
External of liquid
and gel.
Condition of Pump seal Not trouble while the examination

parts Inside of pump case and blade Not remarkable corrosion
Tensile strength change -60 to 0 %
Elongation change -40 to +20 %
Silicon
Volume change 0 to +40 %
Hardness change -20 to +10 %
Tensile strength change 0 to +10 %
Rubber
adaptability Acrylonitrile Elongation change -15 to +15 %
(30 vol %, butadiene
115°C [239°F], rubber Volume change 0 to +40 %
360 Hr)
Hardness change -10 to 0 %
Tensile strength change 0 to +10 %
Ethylene Elongation change -30 to 0 %
propylene
diene monomer Volume change 0 to +10 %
Hardness change -10 to 0 %
Storage stability vol % (30 vol %, room temperature, 6 Hr) Maximum 0.3
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Chapter 6 COOLANT
Maintenance of LLC
Should coolant or LLC be accidentally consumed, induce vomiting immediately and seek medical attention. If LLC
should enter eyes, flush immediately with plenty of water and seek medical attention.
LLC is toxic. Never dispose of coolant containing LLC drained from engine into regular sewage. For disposal of
used coolant, consult LLC distributor.
Replacement intervals of LLC
Be sure to renew LLC at the intervals specified in the maintenance schedule of this manual.
Failure to renew LLC may cause malfunctions due to performance degradation of preventing rust and cavitation.
The coolant mixed with LLC which Mitsubishi Heavy Industries, Ltd. recommended expires in 2 years. Be sure to
change coolant at least once every 2 years.
LLC concentration
Keep the LLC concentration of 30 % (GLASSY) and 40 % (PG GLASSY) on any temperature conditions. LLC of
less than 30 % concentration does not provide sufficient corrosion protection. If the LLC concentration is lower than
10 %, it may accelerate corrosion.
When adding coolant, do not add plain water. Always use coolant with the same LLC concentration.
Table 6-3 Recommended LLC concentration
Lowest ambient temperature
Item Type External -10 °C [14 °F] -20 °C [-4 °F] -30 °C [-22 °F] -45 °C [-40 °F]
or above or above or above or above
LLC concentration GLASSY Green 30 40 50 60

(%) PG GLASSY Red 40 55 70 -
Note: (a) If the outside air temperature is -30 °C or less, use "GLASSY".
(b) The concentration above is based on Mitsubishi Heavy Industries, Ltd. genuine LLC "GLASSY long life
coolant (Ethylene glycol type)" or "PG GLASSY long life coolant (Non-amine type)".
For determining the accurate LLC concentration, refer to the instructions for the LLC used.
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Chapter 6 COOLANT
Importance of LLC Examples of abnormali-

Today's trend is toward smaller and lighter engines
ties caused by LLC (amine
offering greater output, lower fuel consumption and
lower exhaust emission levels. type)
Conditions to which engine coolant is subjected, Pitting of iron parts
therefore, are becoming severer due to longer operat- Amines are generally effective in suppressing the rust-
ing hours, higher coolant temperature and higher cooling of ferrous metals, but they are said to cause prob-
ant circulating speed. lems for copper parts.
Many different materials such as steel, aluminum, Dissolved copper (copper corrosion) in the cooling
copper, solder and rubber are used in the cooling sys- system deposits on iron parts and the copper deposits
tem, and they are also subjected to the severe condi- cause corrosion and then pitting on iron parts that
tions described above. Those materials have different have a high ionization characteristics due to galvanic
ionization characteristics, and this difference acceler- or local-cell action.
ates corrosion through the medium of engine coolant.
To prevent such a problem, the use of LLC that con- Corrosion of aluminum parts
Silicate is highly effective in protecting aluminum
tained the additive to prevent rust is very important.
against rusting. However, it is unstable in a solution in
Characteristics of LLC which the pH is 9 or lower, and can turn to gel and pre-
additive and important cipitate in the solution. For this reason, the pH is usu-
ally specified to be about 10 to ensure a high alkaline
notes level.
LLC contains several chemicals in such proportions
This means, after silicate is used up, the high alkalinity
as to produce chemical reactions that suppress corro-
causes chemical attacks on aluminum. To prevent this
sion (ionization) of engine parts in contact with the
problem, proper maintenance of the coolant is
coolant. LLC loses its effectiveness by hours of use as
required. For case example, rapid wear of mechanical
well as lapse of time.
seals in the water pump due to secondary effects of
Moreover, if the chemicals in LLC are not maintained,
silicate gel formed. Corrosion of aluminum parts after
certain chemicals in the LLC become rapidly used up
silicate is consumed.
and result in dissolution of metals instead of protecting
metals from corrosion. Consequently, other corrosion Pitting and clogging of the radi-
preventing chemicals react with dissolving metals and ator
accelerate corrosion. This condition generates more When LLC deteriorates or when its concentration in
severe corrosion than when plain soft water is used. the coolant is too low, the anti-corrosion performance
This is a typical problem caused by the use of inap- of LLC lowers and results in the corrosion of met-
propriate LLC. als.Brass and solder tend to corrode faster than other
metals, and corrosion of these metals is said to cause
water leakage and clogs. Example: Holes and clogs in
radiator
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Chapter 7 MAINTENANCE SCHEDULE
How to use the maintenance schedule
Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation. Be sure
to conduct inspections and maintenance according to the maintenance schedule.
The maintenance schedule shows the standard service intervals. If you notice any abnormalities such as abnormal
noise, black exhaust smoke, white exhaust smoke, extremely high temperature of exhaust gas, abnormal vibration,
and fuel, oil or exhaust gas leakage, make sure to conduct the inspection and maintenance work, regardless of rec-
ommended service intervals in the "Maintenance schedule."
Note: Appropriate service intervals vary depending on the usage and operating conditions as well as consumption
of fuel, oil and coolant. Check the operating record of the engine to determine the most appropriate service
intervals. (Feel free to consult a dealer of Mitsubishi Heavy Industries, Ltd. regarding service intervals.)
Service the items at multiples of the original requirement. For example, at 1000 service hours, also service those
items listed under every 250 service hours and every 50 service hours.
Items marked with * in the maintenance schedule require special tools or large equipment. For the servicing of
those items, contact a dealer of Mitsubishi Heavy Industries, Ltd.
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Chapter 7 MAINTENANCE SCHEDULE
Maintenance schedule
Table 7-1 Maintenance schedule
Interval and Service item Page
Fuel tank - Drain water 8-2
Every 50 service hours
Air cleaner - Check 8-14
First 50 service hours for Engine oil and Oil filter - Replace 8-8
a new or overhauled
engine Bolts and nuts on the engine - Retighten *
Engine oil and Oil filter - Replace 8-8
Belt and belt tension - Inspect and Adjust 8-3
Radiator fins - Check and Clean 8-13
Add grease to link joints, etc. *
Fuel filter (in-line type fuel injection pump) - Replace 8-6
Fuel system (distributor type fuel injection pump) - Bleed air 8-5
Every 500 service hours Valve clearance - Inspect *
Cleaning the fuel tank (Every 500 service hours or Every 1 years) *
Checking glow plug *
Starter - Inspect 8-18
Every 1000 service hours Alternator - Inspect 8-18
Bolts and nuts on the engine - Retighten *
Every 1500 service hours Nozzle tip - Clean *
Fuel injection nozzle - Check and Clean *
Turbocharger - Inspect 8-14
Every 2 years Coolant - Change 8-11
As required Pre-cleaner - Clean, Inspect and Replace 8-15
Air cleaner element - Clean, Check and Replace 8-16
Fuel filter - Drain water 8-3
Fuel system (in-line type fuel injection pump) - Bleed air 8-4
Fuel system (distributor type fuel injection pump) - Bleed air 8-5
Specific gravity of battery electrolyte - Check 8-17
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Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES
Basic engine
Belt and belt tension - Inspect and Adjust
If defects such as cuts or surface separations are found during inspection, replace the belt.
Keep oil and grease away from the belt. They may cause the belt to slip and shorten the service life.
Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.
Adjust the belt tension accurately by following the procedures below.
Belt - Inspect
1. Inspect the belt visually for separation or damage. If any abnormality is found, replace the belt with a new one.
2. Inspect belt tension (deflection).
Push the belt downward at the midway between pulleys. If the deflection is 12 mm [0.47 in.], the tension is correct.
Belt pushing force: Approx. 98 N {10 kgf} [22 lbf]
If the deflection of belt is not within the standard, adjust the belt tension.
Belt tension (Alternator side) - Adjust
1. Remove the belt cover.
2. Loosen all retaining bolts of the alternator and ad-
justing plate.
3. Move the alternator to adjust the belt tension.
4. After adjusting the belt tension, tighten all retaining
bolts of the alternator and adjusting plate.
5. Install the belt cover.
Belt
Fig. 8-1 Belt and belt tension - Inspect and Adjust
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Fuel system
Fuel tank - Drain water
When working around fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled
fuel completely. Spilled fuel can ignite and cause a fire.
Do not remove the strainer when filling the fuel. For fuel to be used, refer to "FUEL" (4-1).
Bleeding water procedure described below is a commonly used procedure. Some application may be equipped
with different fuel tank.
If fuel gets mixed with particles of foreign materials
such as dust, dirt, or water, it can cause not only
decrease of output but also malfunctions of the fuel
system. To avoid such a problem, drain fuel tank as
described below.
1. Place a fuel tray (capacity of 2 L [0.5 U.S. gal.] or Drain cock
more) under the drain cock of fuel tank.

2. Open the drain cock of fuel tank and drain fuel at
least 1 to 2 L [0.3 to 0.5 U.S. gal.].
3. Make sure that water and particles of foreign mate-
rials discharged with fuel. Close the drain cock. Fig. 8-2 Fuel tank - Drain water
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Fuel filter - Drain water
When handling fuel, make sure there are no open flames or other fire hazards near the engine.
Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire.
Drain water for the fuel filter if the warning of water
draining for fuel filter is occurred.
1. Place a drip tray under the drain hose.
2. Loosen the drain plug and drain water from the fuel
filter.
Drain plug
Fig. 8-3 Fuel filter - Drain water (1)

3. Feed fuel by pushing down on the priming pump
(about seven strokes) to facilitate draining.
4. After draining, tighten the drain plug securely.
5. After drain the fuel filter, bleed the fuel system.
For bleeding air from fuel system, refer to "Fuel
system (distributor type fuel injection pump) - Bleed
air" (8-5). Priming pump
Fig. 8-4 Fuel filter - Drain water (2)
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Fuel system (in-line type fuel injection pump) - Bleed air

While depressing,
When fuel overflow from the air vent plug, wipe thor- turn coockwise
Turn counter- Move cap up
oughly with a cloth. Spilled fuel causes fire hazard clockwise and down
After bleeding, lock the priming pump securely.If the

cap is not locked tightly, the priming pump can be
damaged, causing a fuel leakage that could lead to a
fire.
[Lock release] [Priming] [Lock]

Tighten the priming pump before closing the air vent
Fig. 8-5 Priming pump - Handle
plug.
Do not close all air vent plugs and cocks before lock-
ing the priming pump, as the priming pump will not
return to the original position due to internal pres-
sure.
Bleed air at fuel filters and then at the fuel injection
pump. Bleeding from upstream to downstream is
effective for this job.
Fuel filter - Bleed air
Air vent plug

If air vent plugs, the thread portion of the bracket, or
sealing washers are damaged, replace them with
new ones.
1. Loosen the air vent plug on the fuel filter about 1.5 Fuel filter
turns.
2. Turn the priming pump counterclockwise to unlock,
and prime the fuel filter.
3. When the fuel from the air vent plug becomes free
from air bubbles, stop priming and tighten the air Fig. 8-6 Fuel filter - Bleed air
vent plug to the specified torque.
Fuel injection pump - Bleed air
1. Loosen the air vent plug on the fuel injection pump
Air vent
by rotating about 1.5 turns. plug
2. Move the priming pump up and down. When the
fuel flow from the air vent plug becomes free of
bubbles, push and turn the priming pump clockwise
to lock.
3. Tighten the air vent plug on the fuel injection pump.
Priming pump
Fig. 8-7 Fuel injection pump - Bleed air
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Fuel system (distributor type fuel injection pump) - Bleed air
When handling fuel, make sure there are no open flames or other fire hazards near the engine.
When fuel overflows from the air vent plug, wipe thoroughly with a cloth.Spilled fuel can ignite and cause a fire.
After replacing fuel filter or draining water from fuel fil-
ter, or when running out of fuel, bleed the fuel system
as follows:
1. Loosen the air vent plug on the fuel filter about 1.5
turns.
2. Apply a cloth to the air vent plug.
Air vent plug
Fig. 8-8 Fuel filter - Bleed air (1)

3. Repeat pumping until the fuel flow from air vent
plug becomes free of bubbles.
4. Repeat pumping until the fuel flow from air vent
plug becomes free of bubbles.
Priming pump
Fig. 8-9 Fuel filter - Bleed air (2)
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Fuel filter (in-line type fuel injection pump) - Replace
Air vent plug

When handling fuel, make sure there are no open
Filter bracket
flames or other fire hazards near the engine. Wipe off
any spilled fuel completely. Spilled fuel can ignite and
cause a fire. Fuel filter
1. Clean the area around the fuel filters.

2. Place a fuel tray under the fuel filter.
3. Using a filter wrench, remove the fuel filters.
4. Wipe off fuel on the fuel filter cartridge mounting
surface of the filter bracket with a waste cloth. Fig. 8-10 Fuel filter - Replace
5. Check new fuel filters for proper seating of the gas-
ket. Apply fuel
to gasket
Do not use a filter with the dented case. Fillter dam-

age or fule leakage may occur and it can cause fire
hazard.
6. Apply clean fuel to the gasket on the new fuel filter.

7. Install the fuel filter to the filter bracket.
Do not use a filter wrench to install the fuel filter. Fig. 8-11 Fuel filter
Do not dent or scratch the fuel filter surfaces.
8. After installing the new fuel filter, bleed the fuel sys-
tem.
Note: For bleeding fuel system, refer to "Fuel filter (in-
line type fuel injection pump) - Replace" (8-6).
9. Start the engine and let it idle for several minutes.
10. Make sure that there is no fuel leakage during the
engine operation. If fuel leakage is found, loosen
the fuel filter and check the gaskets for damage. If
there is no damage, retighten the fuel filter.
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Fuel filter (distributor type fuel injection pump) - Replace

fuel filter.
When handling fuel, make sure there are no open Body

flames or other fire hazards near the engine.Wipe off
any spilled fuel completely.Spilled fuel can ignite and Level sensor
cause a fire.
1. Clean the area around the fuel filters.
2. Disconnect the fuel filter level sensor from its con- Element
nector. Drain plug
Element tightening torque
3. Place a fuel tray under the fuel filter. 15±3N・m｛1.53±0.3kgf・m｝ O-ring
4. Loosen the drain plug and drain fuel from the fuel [11.06±2.21lbf・ft]
filter. Fig. 8-12 Fuel filter - Replace
5. Remove the level sensor from the fuel filter.
6. Remove the fuel filter element.
7. Wipe off fuel on the fuel filter element mounting
surface of the fuel filter body with a waste cloth.
8. Check new fuel filter elements for proper seating of
the gasket.
Do not use a filter with the dented case.Fillter dam-

age or fule leakage may occur and it can cause fire
hazard.
9. Install the fuel filter element to the filter body.
Do not dent or scratch the fuel filter surfaces.
10. Using new O-ring, install the level sensor to the fuel
filter element.
11. After installing the new fuel filter, bleed the fuel sys-
tem.
Note: For bleeding fuel system, refer to "Fuel system
(distributor type fuel injection pump) - Bleed air"
(8-5).
12. Start the engine and let it idle for several minutes.
13. Make sure that there is no fuel leakage on mount-
ing sureface of fuel filter element. If fuel leakage is
found, loosen the fuel filter and check the gaskets
for damage. If there is no damage, retighten the
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Lubricating system
Engine oil and Oil filter - Replace
When draining oil or changing the oil filter, wear gloves. Hot engine oil and parts may cause burns.
Do not dump waste oil. It is forbidden by law. For disposal of waste oil, consult a dealer of Mitsubishi Heavy Indus-
tries, Ltd.
Change engine oil and the oil filter at the same time.
Also checking and analyzing the oil properties is recommended when changing the engine oil.
Do not reuse the oil filter element, as it is a paper type.When replacing filters, always replace gasket with new
ones.
Engine oil - Drain

After the engine has stopped, drain engine oil from the
engine oil drain port.
Note: Draining by suction should be avoided.
Engine oil drain plug

Fig. 8-13 Engine oil drain plug
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Engine oil - Refill

1. Make sure that the oil drain plug is tightened.
Oil filler
2. Remove the oil filler cap. Oil level gauge
3. Fill the engine oil pan with specified engine oil to
the specified level.
Note: For engine oil, refer to "ENGINE OIL" (5-1). For
Improper
engine oil capacity, refer to "MAIN SPECIFICA- High H
Proper
TIONS" (12-1). L
Low
Improper
4. Check the oil level in the oil pan as follows:
5. Pull out the oil level gauge, and wipe it with a waste
Oil level gauge
cloth.
6. Insert the oil level gauge fully into the oil level Fig. 8-14 Engine oil - Refill
gauge guide, then pull out the gauge again.
7. The proper oil level is between the high and low
marks on the oil level gauge. If the oil level is low,
add engine oil of the specified type.
8. Check the oil pan and other area for oil leakage.
Repair any oil leakage found.
9. Run the engine with starter for approx. 10 seconds
while pulling the stop lever and feed engine oil to all
parts of engine. Stop the operation for 1 minute,
then, repeat the operation two or three times. Cir-
culate engine oil to all parts of the engine.
Note: Prepare for the Cooling system.
10. Check the oil level with the oil level gauge again,
and add oil to the specified level.
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Oil filter - Change
Do not use a dented filter cartridge.

Filter damage or fule leakage may occur while
engine is running and it can cause fire hazard.
To avoid damage to the filter, do not use a filter

wrench when installing. Tighten the filter by hand.
Oil filter
1. Clean around the oil filters.
2. Place a drip pan under the oil filter.
Fig. 8-15 Oil filter - Change
3. Using a filter wrench, remove the oil filter.
Note: Check the element of the oil filter that has been
Apply engine oil
removed. If metal particles are found, consult a
4. Thoroughly wipe off oil on the mounting surface of
oil filter with a waste cloth.
5. Check the new oil filter for proper seating of gasket.
6. Apply clean engine oil to gasket.
7. Install the oil filter. When the filter gasket contacts
the mounting surface of filter, tighten the filter with
specified torque. Fig. 8-16 Oil filter
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Cooling system
Coolant - Change
Turn the cap about Stand the lever to

Remove the radiator filler cap only after the engine
half a turn the upright position
has cooled to room temperature. Place a waste cloth
over the cap, and loosen the cap about a half-turn or
stand the lever to the upright position to release inter-
nal pressure. Never open the radiator filler cap while
the engine is hot, otherwise the steam or hot coolant
spurts out and you may be scald with it.
Coolant (containing LLC) drained from the engine is
toxic. Never dispose of coolant into regular sewage. Fig. 8-17 Radiator filler cap
For disposal of used coolant, consult a dealer of Mit-
subishi Heavy Industries, Ltd. or a industrial waste
disposer.
The service life of LLC is 2 years. Be sure to change

coolant at least once every 2 years.
Coolant - Drain
1. When draining coolant immediately after engine
Radiator filler cap
operation, idle the engine in low gear for 5 to 6 min-
utes until the coolant temperature drops to 70 to 80
°C [158 to 176 °F].
2. Open the radiator filler cap.
3. Place coolant receiving can under the drain cocks
and plugs, and open the coolant drain cocks and
plugs to drain the coolant.
Coolant drain cock
Fig. 8-18 Coolant drain cock (radiator)
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Cooling system - Clean
Clean the cooling system when operating the engine Water drain plug
first time, or restarting the engine after storage with
coolant drained.
1. Close coolant drain cocks and plugs.
2. Pour in a cleaning solution (a solution that is non-
corrosive to rubber and metals) in the cooling sys-
tem, and operate the engine at 800 to 900 min-1 for
about 15 minutes, then drain the cleaning solution.
3. Close coolant drain cocks and plugs. Fig. 8-19 Coolant drain plug (engine)
4. Pour in fresh water, and operate the engine at 800
to 900 min-1 for about 10 minutes.
Repeat rinsing until the draining water becomes
clear and clean.
Coolant - Refill
1. Tighten the coolant drain cocks and plugs.
2. Remove the radiator filler cap, and pour in undilut-
ed LLC.
Note: Determine the amounts of LLC and water to be
added by using the LLC concentration chart.
For the coolant, refer to "COOLANT" (6-1). For
the coolant capacity, refer to "MAIN SPECIFICA-
TIONS" (12-1).
3. Pour in water (soft water with minimal impurities,
such as tap water) slowly to "FULL" level line.
4. Check the radiator and other parts for coolant leak- Fig. 8-20 Radiator coolant level
age. If any coolant leakage is found, repair it.
5. When coolant reaches "FULL" level line, close the
radiator filler cap securely.
6. Run the engine with starter for approx. 10 seconds
while pulling the stop lever.
Stop the operation for 1 minute, then, repeat the
operation two or three times to bleed the cooling
system.
7. Check the coolant level in the radiator.
If the engine is equipped with a reserve tank, fill the
Fig. 8-21 Reserve tank
reserve tank with coolant to "FULL" level line as
well.
Always use the coolant with the same LLC concen-

tration.
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Radiator fins - Check and Clean
When handling compressed air, wear safety goggles,

a hardhat, gloves and other necessary protective
gear. Works without wearing proper protective gear
could result in serious injuries.
Check the radiator fins for holes and cracks.
To clean the radiator fins, blow compressed air from
the opposite direction of the normal air flow.
Fig. 8-22 Radiator fins - Clean
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Inlet and exhaust systems

Air cleaner - Check
Reset button
Checking procedure described below is a commonly
Signal
used procedure. Some application may be equipped (red)
with different air cleaner.
1. Check the air cleaner indicator for the element
clog.
2. If the element is clogged, the red signal mark is vis-
ible.
3. Immediately clean or replace the air cleaner ele-
ment when the signal turns red. Fig. 8-23 Air cleaner - Check
Note: For cleaning of the air cleaner element, refer to
"Air cleaner element - Clean, Check and Re-
place" (8-16).
Turbocharger - Inspect
Turbocharger
Check the turbocharger when the engine is cold.
Also, make sure that the compressor wheel is not Compressor wheel
rotating before inspecting the turbocharger.
If the color of the exhaust gas is abnormal, also

inspect the turbocharger.
Disconnect the pipe from the air inlet side. Hold the
compressor wheel nut by hand and turn the wheel to
Fig. 8-24 Turbocharger - Inspect
check for looseness or abnormal noise. Replace the
turbocharger if looseness or abnormal noise is found.
Note: When removing and inspecting turbocharger,
contact a dealer of Mitsubishi Heavy Industries,
Ltd.
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Pre-cleaner - Clean, Inspect and Replace
Mild
Never service the pre-cleaner while the engine is detergent
running. Servicing the air cleaner while the engine is
running can cause particles of foreign matter to enter Water
the engine and result in rapid wear of parts, leading (Wash) (Rinse)
to a shorter service life of the engine.
The pre-cleaner is equipped to the silencer of the tur- Install
bocharger to prevent foreign items from sucking and (Dry)

keep the engine clean for optimum performance. Be
sure to clean the pre-cleaner as described below. Fig. 8-25 Pre-cleaner - Clean
1. Remove the pre-cleaner from the silencer, and
hand-wash the pre-cleaner with a mild detergent.
2. Rinse the pre-cleaner with fresh water.
3. After drying thoroughly, inspect the pre-cleaner for
defect. If any defect are found, replace the pre-
cleaner with a new one.
4. After cleaning, inspecting or changing the pre-
cleaner, reinstall it to the silencer.
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Air cleaner element - Clean, Check and Replace
When handling compressed air, wear safety goggles, a dust mask, a hardhat, gloves and other necessary protec-
tive gear. Works without wearing proper protective gear could result in serious injuries.
Never service the air cleaner while the engine is running. Servicing the air cleaner while the engine is running can
cause particles of foreign material to enter the engine and result in rapid wear of parts, leading to a shorter service
life of the engine.Never knock or hit the element.
Cleaning, inspecting and replacing procedure described below is a commonly used procedure. Some application
may be equipped with different air cleaner.
1. Remove the air cleaner cap and wing bolt.
2. Remove the air cleaner element from the body.
3. Blow compressed air (0.69 MPa {7 kgf/cm2} [100
psi] or lower) onto the inside surface of the element Wing
to remove foreign materials. bolt
4. To remove dust stuck on the air cleaner element,
blow dry compressed air onto the outside surface Air cleaner
from a distance. element
Blow compressed air on the inside surface toward

Body
the outside along the pleats. Then, blow com-
pressed air on the outside and inside surface Fig. 8-26 Air cleaner element - Remove
again.
5. After cleaning, hold the air cleaner element near a
light bulb to illuminate the inside, to check for de-
fects such as cuts, pinholes or local wear.
6. If any defect is found, replace the air cleaner ele-
ment with a new one.
7. Reassemble the air cleaner element as it is.
Clean Check
If defects such as cuts, pinholes or local wear are Fig. 8-27 Air cleaner element - Clean and Check
found in the element, or if the air cleaner indicator
shows a red sign soon after the cleaned element is Reset button
installed, change it for new one. Signal
(red)
After cleaning or replacing the air cleaner element,
press the reset button to reset the indicator.
Fig. 8-28 Air cleaner - Check
8-16
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Electrical system
Battery - Inspect
If battery electrolyte is spilled on your skin, flush immediately with plenty of water. If battery electrolyte enters the
eyes, flush them immediately with lots of fresh water and seek medical attention at once.
Do not use open flames or other fire hazards near the battery. When handling the battery, be careful of sparks gen-
erated by accidental shorting.
Battery electrolyte level - Inspect

Battery electrolyte evaporates during use and the f
electrolyte level gradually decreases. The proper elec-
trolyte surface level is between the "LOWER LEVEL"
10 to 15 mm
and "UPPER LEVEL" lines. [0.394 to 0.591 in.]
For the battery without level lines, the proper electro- Proper
LEVEL level
lyte surface level is about 10 to 15 mm [0.394 to 0.591 UPPER
VEL
R LE
LOWE
in.] above the top of the plates.
If the electrolyte level is low, remove the caps and add
distilled water to the proper level.
Note: When adding distilled water, pour in carefully.
Fig. 8-29 Battery electrolyte level - Inspect
Specific gravity of battery electrolyte - Check
If the specific gravity measured at 20 °C [68 °F] is
Float
lower than 1.22, then charge the electrolyte. Electrolyte
surface
Table 8-1 Specific gravity of electrolyte
Specific gravity
Condition Remedy
at 20 °C [68 °F]
From 1.26 to 1.28 Fully charged -
Electrolyte
From 1.22 to 1.26 Charged Charge
Glass tube
Less than 1.22 Discharged Charge
Fig. 8-30 Specific gravity of battery electrolyte - Check
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Starter - Inspect
Visually check the starter for damage.
If the starter is dusty, blow dirt using compressed air.
Note: If the starter is defective, consult a dealer of Mit-
subishi Heavy Industries, Ltd.
Starter
Fig. 8-31 Starter - Inspect
Alternator - Inspect
Visually check the alternator for damage.
If the alternator is dusty, blow foreign material using
Alternator
compressed air.
Remove the belt and check that the movement is
smooth when rotating the pulley by hand.
Note: If the alternator is defective, consult a dealer of
Mitsubishi Heavy Industries, Ltd.
Fig. 8-32 Alternator - Inspect
8-18
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Chapter 9 LONG-TERM STORAGE
Long-term storage
The following describes how to store the engine in a non-operable condition for 3 months or more and in an opera-
ble condition for 3 months or more.
If the engine has been left unattended for 3 months or more, the internal engine parts can rust, and that may cause
damage to the engine.
When storing the engine for an extended period of time, be sure to follow the directions below.
Storing the engine in a non-operable condition

for 3 months or more
Preparation for storage
1. Drain the engine oil in-use, pour new oil.
2. Prepare a fuel mixture containing 50 % rust-preventive oil (NP-9), and fill the fuel tank with it.
3. Operate under non-load minimum engine speed for 5 to 10 minutes.
4. Immediately before stopping the engine, spray volatile corrosion inhibitor (VCI) through the inlet port to prevent
rust on the air intake system.
5. With the engine stopped, drain the fuel mixture from the fuel tank.
6. Apply rust-preventive oil (NP-3) liberally on the exposed sections of the machining.
7. Seal the air inlet, exhaust outlet, breather and other openings with an adhesive cloth tape.
8. Cover the entire engine.
Note: (a) Store the engine in a well-ventilated indoor area.
(b) It is not necessary to drain coolant since it contains LLC. (Add LLC to increase the concentration to between
30 to 60 %.)
(c) Post a sign at an easily noticeable place to warn that the rust-preventive oil in the engine must be replaced
with engine oil, and the fuel tank must be filled with fuel before operating the engine for the first time after
storage.
(d) New engine oil can substitute for rust-preventive oil (NP-10-2) of lubrication system.
Recommended rust-preventive oil and corrosion inhibitor
Table 9-1 Recommended rust-preventive oil and corrosion inhibitor
JIS No. Recommended product Application
Prevention of rust on
Nippon Oil Corporation
NP-3 exposed machine sur-
Anti Rust P-1600
faces
K 2246 Nippon Oil Corporation Prevention of rust in fuel
NP-9
Anti Rust P-2400 system
NP- Nippon Oil Corporation Prevention of rust in
10-2 Anti Rust P-230 lubricating system
Ryoukou Kagaku
Prevention of rust in air
Z 1519 - VCI Diana ND volatile corrosion
intake system
inhibitor
Maintenance during storage

Charge the battery once a month. First, check the battery electrolyte for proper level and then charge the battery.
9-1
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Chapter 9 LONG-TERM STORAGE
Using the engine after storage

1. Remove the cover from the engine.
2. Connect a fully charged battery.
3. Remove the covers from the starters and alternator.
4. Adjust the tension of belt.
Note: Inspect and adjust V-belt tension. Refer to "Belt and belt tension - Inspect and Adjust" (8-XX).
5. Remove sealing tapes from the openings of the engine.
6. Connect pipes.
Note: For engine oil, refer to "ENGINE OIL" (5-1).
7. Fill the fuel tank with fuel, and bleed the fuel system.
Note: For bleeding fuel system, refer to "Fuel system (in-line type fuel injection pump) - Bleed air" (8-4) or "Fuel sys-
tem (distributor type fuel injection pump) - Bleed air" (8-5).
8. Inspect the entire engine.
9. Remove the rocker covers, and lubricate the valve mechanisms.
10. Run the engine with starter for approx. 10 seconds while pulling the stop lever. Stop the operation for approx. 1
minute, then, repeat the operation two or three times.
11. Make sure the engine oil pressure rises.
12. Conduct a warm up operation for a sufficient duration.
Note: For starting the engine, refer to "Starting" (3-4).
13. Apply load and increase the engine speed to the rated speed.
Storing the engine in an operable condition

for 3 months or more
When the engine is not operated during storage of 3 months or more, internal engine parts can rust and lose oil film.
As a result, the engine can seize when it is started after storage. To prevent such a risk, the engine must be oper-
ated periodically during storage.
Operating the engine for maintenance

Operate the engine for maintenance at least once a month as described below.
1. Run the engine with starter for approx. 10 seconds while pulling the stop lever. Stop the operation for approx. 1
minute, then, repeat the operation two or three times.
2. Make sure the engine oil pressure rises.
3. Operate the engine about 5 to 10 minutes under no load as the maintenance operation.
Note: For starting the engine, refer to "Starting" (3-4).
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Chapter 10 TRANSPORTATION
Lifting the engine
To lift the engine, use wire ropes, shackles and slings Rear hanger Front hanger
capable of supporting the weight of the engine.
Attach the wire rope to the hangers provided on the
engine using a correct sling.
Keep the engine balanced during lifting by consider-
ing the engine's center of gravity.
Keep the angle formed by slings attached to hangers
within 60°. If the angle exceeds this limit, excessive
load could be imposed on the hangers and this could Fig. 10-1 Hangers
damage the hangers and result in a serious accident.
Engine center
Engine center
Attach wire ropes to the hangers after removing the
pipe cover and the insulator near the hangers. To
prevent wire ropes from contacting the engine, use a Y X
cloth or other soft padding.
Z
Crankshaft center
The center X Y Z The center

of gravity S4S 2 5 85 of gravity
S6S 28 -34 117 (mm)
Fig. 10-2 Engine's center of gravity

(standard specification)
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Chapter 11 TROUBLESHOOTING
General precautions
Contact a dealer of Mitsubishi Cautions against contamination
Heavy Industries, Ltd. for repair Dust and foreign materials are the most common
service cause of rapid wear of parts.
Repairing a malfunctioning engine may require special When disassembling a component, take measures to
equipment or involve potentially dangerous work, prevent dust and foreign materials from entering the
except for relatively simple procedures such as the component being disassembled.
change and addition of fuel, engine oil and coolant. In
the event of the engine failure, contact a dealer of Mit- Cautions regarding parts han-
subishi Heavy Industries, Ltd. dling
Handle parts carefully.
Considerations before work When replacing parts, use only genuine parts by refer-
Before troubleshooting, consider possible causes of
ring to the parts catalogue.
the problem and try to find out if the same problem
has occurred in the past. Work safety
Check the parts that may be causing the problem in Be sure to use wrenches of the correct size. Using a
the most efficient order. wrench of the wrong size not only damages nuts but
When disassembling a component, pay close atten- can also cause the personal injury.
tion to the disassembly sequence so that you can Use correct tools and perform work with utmost cau-
reassemble the component in reverse order of disas- tion.
sembly. Be sure to accurately estimate the weight of the part
being dismounted. If the removed part is much heavier
than you have estimated, it may fall down during lifting
and can result in the damage to the parts or personal
injury.
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Troubleshooting
The starter does not crank or cranks slowly, resulting in start failure
Table 11-1 The starter does not crank or cranks slowly, resulting in start failure
Cause Remedies
Check the DC fuse.
Faulty wire connection Check wiring connection between battery, starter and starter
switch.
Check alternator. (Refer to P8-18)
Insufficiently charged battery
Electrical Check and adjust belt. (Refer to P8-1)
system
Check specific gravity of battery electrolyte. (Refer to P8-17)
Faulty battery Charge battery.
Change battery.
Faulty starter or starter relay Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Oil viscosity too high Use appropriate engine oil. (Refer to P5-1)
Lubricating
system Check amount of engine oil and lubrication system.
Excessive oil
(Refer to P3-2)
Engine Rapid wear of sliding parts, or Consult a dealer of Mitsubishi Heavy Industries, Ltd.
mechanical locked
The starter cranks, but the engine does not start

Table 11-2 The starter cranks, but the engine does not start
Cause Remedies
Inspect fuel tank, supply fuel, bleed air. (Refer to P8-2)
Run out of fuel, blocked pipe
Check fuel pipes, valves.
Use appropriate fuel. (Refer to P4-1)
Improper fuel property
Remove dust, water impurities. (Refer to P8-2)
Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes.
injection pipes. Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Fuel system
Inspect and replace fuel filter. (Refer to P8-6) or (Refer to P8-7)
Clogged fuel filter
Gauze filter - Clean
Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Check the rack movement.
Faulty fuel injection pump
Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Air intake Clean, inspect and replace pre-cleaner. (Refer to P8-15)

Insufficient amount of air
system Clean, inspect and replace air cleaner element. (Refer to P8-16)
Control Fuel control link - Check

Faulty governor
system Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Basic engine Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.
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Output decrease
Table 11-3 Output decrease
Cause Remedies
Improper fuel property Use appropriate fuel. (Refer to P4-1)
Inspect and replace fuel filter. (Refer to P8-6) or
Clogged fuel filter (Refer to P8-7)
Gauze filter - Clean
Fuel system
Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Check fuel injection pump rack stroke.
Improper amount of injected fuel
Check fan and radiator.
Cooling
Overheat, overcooled Check control system.
system
Check turbocharger. (Refer to P8-14)
Clean, inspect and replace pre-cleaner. (Refer to P8-15)
Clean, inspect and replace air cleaner element.
Insufficient amount of air (Refer to P8-16)
Inlet and Check intake air pressure and leakage of intake air.
exhaust
systems Check intake air temperature and ventilation device.
Increase resistance of exhaust air. Check exhaust pipes and silencer.
Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Control Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Faulty governor control
system
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Exhaust smoke is white or blue

Table 11-4 Exhaust smoke is white or blue
Cause Remedies
Improper fuel property Check cetane index, and use appropriate fuel. (Refer to P4-1)
Fuel system
Check ignition noise, exhaust smoke temperature.
Uneven fuel injection
Incorrect fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Check amount of engine oil and lubrication system.
Lubricating
Combustion of engine oil (Refer to P3-2)
system
Check radiator. (Refer to P8-13)
Cooling Check control system.
Overcooled
system Thermostat - Inspect
Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Basic engine
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Exhaust smoke is black or charcoal

Table 11-5 Exhaust smoke is black or charcoal
Cause Remedies
Improper fuel property Use appropriate fuel. (Refer to P4-1)
Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Fuel system Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Check exhaust smoke temperature.
Uneven fuel injection
exhaust
Control Check control system.

Increase in load
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Fuel consumption is high

Table 11-6 Fuel consumption is high
Cause Remedies
Fuel system Improper fuel property Use appropriate fuel. (Refer to P4-1)
Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes.
injection pipes. Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Overcooled
exhaust
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Engine oil consumption is high

Table 11-7 Engine oil consumption is high
Cause Remedies
Fuel system Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Check oil leakage.
Oil leakage to the outside of engine
Engine oil viscosity too low Use appropriate oil viscosity. (Refer to P5-3)
Lubricating
system Check amount of engine oil and lubrication system.
(Refer to P3-2)
Engine oil temperature is high.
Check oil cooler and oil thermostat.
Overheating
Check oil leakage to the turbocharger.
Inlet and Spread oil to intake part
exhaust Consult a dealer of Mitsubishi Heavy Industries, Ltd.
systems
Wear of valve operating system Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Control Check control system.

Increase in load
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Overheating
Table 11-8 Overheating
Cause Remedies
Check coolant leakage.
Low coolant level
Check coolant level. (Refer to P3-3)
Cooling sys- Faulty water pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.
tem Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Check and clean radiator and radiator filler cap.
Faulty radiator operation
(Refer to P8-13)
Check fuel injection pump rack stroke.
Control
Increase in load Check control system.
system
Basic engine Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Low engine oil pressure

Table 11-9 Low engine oil pressure
Cause Remedies
Check amount of engine oil and lubrication system.
Insufficient amount of engine oil
(Refer to P3-2)
Faulty engine oil property (viscos- Analyze oil property. Use appropriate engine oil.
ity) (Refer to P5-1)
Lubricating Check coolant system.
system Oil temperature too high
Oil filter clogged Inspect and replace oil filter. (Refer to P8-8)
Faulty oil pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Faulty relief valve operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.
Control Check control system and wire.

Faulty pressure unit operation
Check control system.
Increase in load
Basic engine
Increase clearance of sliding part. Consult a dealer of Mitsubishi Heavy Industries, Ltd.
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When fuel has run out

When fuel runs out while engine is running and the engine has stopped, restart the engine as described below.
1. Return the starter switch to the "OFF" position.
2. Add fuel to the fuel tank.
For filling fuel tank, refer to "Fuel tank oil level - Check" (3-2).
3. Bleed air from the fuel system.
For bleeding fuel system, refer to "Fuel system (in-line type fuel injection pump) - Bleed air" (8-4) or "Fuel system
(distributor type fuel injection pump) - Bleed air" (8-5).
4. Restart the engine.
For starting the engine, refer to "Starting" (3-4).
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Chapter 12 MAIN SPECIFICATIONS
Main specifications
Table 12-1 Main specifications
Item Specifications
Engine model S4S S4S-DT
Water cooled, 4 stroke cycle 4-cycle water-cooled turbocharged
Type
diesel engine diesel engine
No. of cylinders - arrangement 4 cylinder in-line
Cylinder bore × stroke φ94 × 120 mm [3.70 x 4.72 in.]
Displacement 3.331 L [0.9 U.S. gal.]
Conbustion type Swirl chamber Direct injection system
17 to 19 : 1
Compression ratio 22 : 1
(vary among specifications.)
Firing order 1-3-4-2
Direction of rotation Counterclockwise as viewed from flywheel side
781 × 567 × 717 mm 781 × 567 × 815 mm
Dimensions (L x W x H)
[30.75 x 22.32 x 28.23 in.] [30.75 x 22.32 x 32.09 in.]
Dry weight 245 kg [540 lbs] 250 kg [551 lbs]
Fuel Diesel fuel (equivalent for JIS K 2204)
Fuel injection pump In-line type or distributor type (VE type)
Fuel filter Cartridge type pape-element (with water separator)
Fuel injection nozzle Throttle type Hole type
Initial fuel injection pressure 11.77 MPa {120 kgf/cm2} [1707 psi] 17.65 MPa {180 kgf/cm2} [2560 psi]
Lubrication method Forced circulation (pressure feed by oil pump)
Lubrication oil Class CF or CH-4 oil (API service classification)
Whole engine: Approx. 10 L [2.6 U.S. gal.],
Engine oil capacity
Oil pan: Approx. 9 L [2.4 U.S. gal.]
Oil filter Cartridge type paper-element
Water cooled multi-plate
Oil cooler -
(built-in crankcase)
Cooling method Forced water cooling by centrifugal pump
Approx. 5.5 L [1.5 U.S. gal.] Approx. 5 L [1.5 U.S. gal.]
Coolant capacity
(basic engine only) (basic engine only)
Starting system Electric motor starting
Starter DC 12 V - 2.2 kW or DC 24 V - 3.2 kW
Alternator DC 12 V - 50 A or DC 24 V - 25 A
Turbocharger - Mitsubishi TD04H
Note: (a) The specifications above are subject to change without prior notice.
(b) The specifications above are described for the standard model. The special model specifications may differ
from those of standard model.
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Chapter 12 MAIN SPECIFICATIONS
Table 12-2 Main specifications

Item Specifications
Engine model S6S S6S-DT
Water cooled, 4 stroke cycle 4-cycle water-cooled turbocharged
Type
diesel engine diesel engine
No. of cylinders - arrangement 6 cylinder in-line
Cylinder bore × stroke φ94 × 120 mm [3.70 x 4.72 in.]
Displacement 4.996 L [1.3 U.S. gal.]
Conbustion type Swirl chamber Direct injection system
17 to 19 : 1
Compression ratio 22 : 1
(vary among specifications.)
Firing order 1-5-3-6-4-2
Direction of rotation Counterclockwise as viewed from flywheel side
1038 × 567 × 750 mm 1038 × 567 × 842 mm
Dimensions (L x W x H)
[40.87 x 22.32 x 29.53 in.] [40.87 x 22.32 x 33.15 in.]
Dry weight 345 kg [761 lbs] 355 kg [783 lbs]
Fuel Diesel fuel (equivalent for JIS K 2204)
Fuel injection pump In-line or distributor type (VE type)
Fuel filter Cartridge type pape-element (with water separator)
Fuel injection nozzle Throttle type Hole type
Initial fuel injection pressure 11.77 MPa {120 kgf/cm2} [1707 psi] 17.65 MPa {180 kgf/cm2} [2560 psi]
Lubrication method Forced circulation (pressure feed by oil pump)
Lubrication oil Class CF or CH-4 oil (API service classification)
Whole engine: Approx. 12 L [3.2 U.S. gal.],
Engine oil capacity
Oil pan: Approx. 11 L [2.9 U.S. gal.]
Oil filter Cartridge type paper-element
Water cooled multi-plate
Oil cooler -
(built-in crankcase)
Cooling method Forced water cooling by centrifugal pump
Approx. 9 L [2.4 U.S. gal.] Approx. 8 L [2.1 U.S. gal.]
Coolant capacity
(basic engine only) (basic engine only)
Starting system Electric motor starting
Starter DC 12 V - 3.0 kW or DC 24 V - 5.0 kW
Alternator DC 12 V - 50 A or DC 24 V - 25 A
Turbocharger - Mitsubishi TD06H
Note: (a) The specifications above are subject to change without prior notice.
(b) The specifications above are described for the standard model. The special model specification may differ
from those of standard model.
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July 2009 OPERATION & MAINTENANCE MANUAL Pub. No. 99610-29120
Printed in Japan Pub. No. 99610-29120
190/242
10.2. Appendix B - Alternator user and maintenance manual
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User guide and maintenance manual
LEROY SOMER
Alternator
LSA42.2 S4
LSA42.2 S5
LSA42.2 L9
42.2 SHUNT & AREP
3433 g
33522019901_6_1
01/10/2010
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3433 en - 2010.10 / g
49
132
124
120
198
1
4
30
324
323
d
supplie
t b e
u a l mus ser
i s m an e n du
Th e
to th
100
344
343
347
28
37
33
15
LSA 42.2 - 2 & 4 POLE

322
ALTERNATORS
Installation and maintenance
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LEROY-SOMER Installation and maintenance 3433 en - 2010.10 / g
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
This manual concerns the alternator which you WARNING SYMBOLS

have just purchased.
We wish to draw your attention to the contents We would like to draw your attention to the following two safety
of this maintenance manual. By following measures that must be complied with:
a) During operation, do not allow anyone to stand in front of the
certain important points during installation, air outlet guards, in case anything is ejected from them.
use and servicing of your alternator, you can b) Do not allow children younger than 14 to go near the air
look forward to many years of trouble-free outlet guards.
operation. A set of self-adhesive stickers depicting the various warning
symbols is included with this maintenance manual. They
should be positioned as shown in the drawing below once the
alternator has been fully installed.
SAFETY MEASURES
Before using your alternator for the first time, it is important to
read the whole of this installation and maintenance manual.
All necessary operations and interventions on this alternator

must be performed by a qualified technician.
Our technical support service will be pleased to provide any

additional information you may require.
The various operations described in this manual are

accompanied by recommendations or symbols to alert the
user to potential risks of accidents. It is vital that you understand
and take notice of the following warning symbols.
WARNING
Warning symbol for an operation capable of

damaging or destroying the alternator or
surrounding equipment.
WARNING
The alternators must not be put into service until the
Warning symbol for general danger to personnel. machines in which they are to be incorporated have
been declared compliant with Directives EC and
plus any other directives that may be applicable.
Warning symbol for electrical danger to personnel.
Copyright 2004 : MOTEURS LEROY-SOMER

This document is the property of :
Note : LEROY-SOMER reserves the right to modify the MOTEURS LEROY-SOMER
characteristics of its products at any time in order to incorporate It may not be reproduced in any form without prior
the latest technological developments. The information authorization.
contained in this document may therefore be changed without All brands and models have been registered and patents
notice. applied for.
2
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LSA 42.2 - 2 & 4 POLE

ALTERNATORS
1 - RECEIPT 4 - SERVICING - MAINTENANCE
1.1 - Standards and safety measures..................... 4 4.1 - Safety measures........................................... 10
1.2 - Checks............................................................ 4 4.2 - Regular maintenance.................................... 10
1.3 - Identification................................................... 4 4.3 - Fault detection.............................................. 10
1.4 - Storage........................................................... 4 4.4 - Mechanical defects........................................11
1.5 - Applications.................................................... 4 4.5 - Electrical faults...............................................11
1.6 - Contraindications to use..................................4 4.6 - Dismantling, reassembly............................... 13
4.7 - Characteristics table .................................... 15
2 - TECHNICAL CHARACTERISTICS
5 - SPARE PARTS
2.1 - Electrical characteristics................................. 5
5.1 - First maintenance parts................................ 16
2.2 - Mechanical characteristics . ........................... 5
5.2 - Description of bearings................................. 16
5.3 - Technical support service.............................. 16

3 - INSTALLATION - COMMISSIONING
5.4 - Exploded view, parts list................................ 17
3.1 - Assembly........................................................ 6
3.2 - Inspection prior to first use.............................. 6

EC DECLARATION OF INCORPORATION....... 19
3.3 - Electrical diagram........................................... 7
3.4 - Commissioning............................................... 9
3.5 - Setting up........................................................ 9
3
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LSA 42.2 - 2 & 4 POLE

ALTERNATORS
1 - RECEIPT protection on unpainted parts.

For storage over an extended period, the alternator can be
placed in a sealed enclosure (heatshrunk plastic for example)
1.1 - Standards and safety measures with dehydrating sachets inside, away from significant and
frequent variations in temperature to avoid the risk of
Our alternators comply with most international standards. condensation during storage.
See the EC Declaration of Incorporation on the last page. - If the area is affected by vibration, try to reduce the effect of
these vibrations by placing the generator on a damper support
(rubber disc or similar) and turn the rotor a fraction of a turn
1.2 - Inspection once a fortnight to avoid marking the bearing rings.
On receipt of your alternator, check that it has not suffered any
damage in transit. If there are obvious signs of knocks, contact 1.5 - Applications
the transporter (you may able to claim on their insurance) and
after a visual check, turn the machine by hand to detect any These alternators are mainly designed to produce electricity in
malfunction. the context of applications involving the use of generators.
1.3 - Identification 1.6 - Contraindications to use

The alternator is identified by means of a nameplate fixed on Use of the alternator is restricted to operating conditions
the frame. (environment, speed, voltage, power, etc) compatible with the
Make sure that the nameplate on the alternator conforms to characteristics indicated on the nameplate.
your order.
The generator name is defined according to various criteria
(see below).
Example of description for : LSA 42.2 S4 J6/4 -
• LSA : name used in the PARTNER range
M : Marine / C : Cogeneration / T : Telecommunications.
• 42.2 : machine type
• S4 : model
• J : field excitation system
(C:AREP / J:SHUNT / E:COMPOUND)
• 6/4 : winding number / number of poles.
1.3.1 - Nameplate
So that you can identify your alternator quickly and accurately,
we suggest you fill in its specifications on the nameplate below
(the Information on this is not contractually binding).
1.4 - Storage
Prior to commissioning, alternators should be stored :
- Away from humidity : in conditions of relative humidity of more
than 90%, the alternator insulation can drop very rapidly, to just
above zero at around 100%; monitor the state of the anti-rust
ALTERNATEURS ALTERNATORS
LSA Date PUISSANCE / RATING
Tension
N° Hz Voltage V
Min-1/R.P.M. Protection Phase Ph.
Made in FRANCE - 1 024 959/b
Cos Ø /P.F. Cl. ther. / Th.class Connex.

Régulateur/A.V.R.
Continue kVA
Altit. m Masse / Weight
Continuous kW
Rlt AV/D.E bearing
40°C A
Rlt AR/N.D.E bearing
Graisse / Grease Secours kVA
Std by
Valeurs excit / Excit. values kW
en charge / full load 27°C A
à vide / at no load
166631 Conforme à C.E.I 60034-1. According to I.E.C 60034-1.

C US
4
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MAIN FIELD
LSA 42.2 - 2 & 4 POLE

Exciter
Armature
ALTERNATORS
Exciter MAIN FIELD
Aux. winding
Varistor
2 - TECHNICAL CHARACTERISTICS Armature
2.1 - Electrical characteristics
Varistor
Red Black
The PARTNER LSA 42.2 alternator is generator without + Field -

sliprings and revolving field brushes, wound as “2/3 pitch”; 12-
wire, with class H insulation and a field excitation system 6-
available in either “SHUNT” or “AREP” version (see sections

White
5+ Blue R 250
Yellow
Green
Black
+ -
Red
2.3, 2.4). Interference suppression conforms with standard EN Field
55011, group 1, class B.
6-
MAIN FIELD
5+
STATOR : 12 wires (T1 to T12 identification) R 438
Exciter
T1 T7 T2 T8 T3 T9
Armature Varistor
Red Black
T4 T10 T5 T11 T6 T12
+ Field -
6-
5+ R 250 Voltage reference
Exciter MAIN FIELD STATOR : 12 wires (T1 to T 12 identification)

Aux. windings
T1 T7 T2 T8 T3 T9
Armature
Varistor
White Blue
Yellow
Green
Black
+ - T4 T10 T5 T11 T6 T12

Red
Field
6-
5+
R 438 Voltage reference
2.1.1 - Options 2.2.1 - Options

- Stator temperature detection probes. - Protection against harsh environmentsh.
- Space heaters. - Air input filter, air output labyrinth cowling.
Alternators fitted with air inlet filters should be derated by 5%
(power).
2.2 - Mechanical characteristics To prevent excessive temperature rise caused by clogged
- Steel frame filters, it is advisable to fit the stator winding with thermal
- End shields in cast iron sensors (PTC or PT100).
- Mounting arrangement
MD 35 :
single bearing with standard feet and SAE flanges/coupling
discs.
B 34 :
two-bearing with SAE flange and standard cylindrical shaft
extension.
- Drip-proof machine, self-cooled
5
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LSA 42.2 - 2 & 4 POLE

ALTERNATORS
3 - INSTALLATION 3.1.2.2 - Two-bearing alternator

- Semi-flexible coupling
Personnel undertaking the various operations Careful alignment of the alternator and the heat engine is
discussed in this section must wear the appropriate recommended, checking that the differences in concentricity
personal protective equipment for mechanical and and parallelism of the two parts of the coupling do not exceed
electrical hazards. 0.1 mm.
3.1 - Assembly WARNING
This alternator has been balanced with a 1/2 key.
All mechanical handling operations must be 3.1.3 - Location

undertaken using approved equipment and the
alternator must be horizontal. Check how much the Ensure that the ambient temperature in the room where the
alternator weighs (see 4.7.6) before choosing the alternator is placed cannot exceed 40°C for standard power
lifting tool. During this operation, do not allow ratings (for temperatures above 40°C, apply a derating
anyone to stand under the load. coefficient). Fresh air, free from damp and dust, must be able
to circulate freely around the air input louvres on the opposite
3.1.1 - Handling side from the coupling. It is essential to prevent not only the
The generously-sized lifting rings are for handling the alternator recycling of hot air from the machine or engine, but also exhaust
alone. They must not be used to lift the genset. The choice of fumes.
lifting hooks or handles should be determined by the shape of
these rings. Choose a lifting system which respects the integrity 3.2 - Inspection prior to first use
and the environment of the alternator.
3.2.1 - Electrical checks
Under no circumstances should an alternator, new

or otherwise, be operated if the isolation is less than
1 megohm for the stator and 100,000 ohms for the
other windings.
There are two possible methods for restoring the above
minimum values.
a) Dry out the alternator for 24 hours in a drying oven at a
temperature of approximately 110 °C.
b) Blow hot air into the air input, having made sure that the
alternator is rotating with the exciter field disconnected.
c) Run in short-circuit mode (disconnect the AVR)
- Short-circuit the output phases using connections capable of
supporting the rated current (try not to exceed 6 A/mm2).
3.1.2 - Coupling - Insert a clamp ammeter to monitor the current passing through
WARNING the short-circuit connections.
3.1.2.1 - Single bearing alternator
Before coupling the alternator and the heat engine, check they - Connect a 48 Volt battery in series with a rheostat of
are compatible by: approximately 10 ohms (50 Watts), to the exciter field terminals,
- Undertaking a torsional analysis of the transmission. respecting the polarity.
-Checking the dimensions of the flywheel and its housing, the - Open fully all the alternator orifices.
flange, coupling discs and offset. - Run the alternator at rated speed . Adjust the exciter field
current using the rheostat to obtain the rated output current in
the short-circuit connections.
WARNING Note: Prolonged standstill: In order to avoid these problems,
we recommend the use of space heaters, as well as turning
When coupling the alternator to the prime mover, over the alternator from time to time. Space heaters are only
the holes of the coupling discs should be aligned really effective if they are working continuously while the
with the flywheel holes by rotating the engine alternator is stopped.
flywheel. Do not use the fan to turn the alternator
rotor. Make sure the alternator is securely bedded in WARNING
position during coupling.
Tighten the coupling discs screws to the recommended torque Ensure that the alternator has the degree of
(see section 4.6.2.) and check that there is lateral play on the protection matching the defined environmental
crankshaft. conditions.
6
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LSA 42.2 - 2 & 4 POLE

ALTERNATORS
3.2.2 - Physical and visual 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. The winding code is specified on the nameplate.
- the cooling air is drawn in freely
- the protective louvres and housing are correctly in place
- the standard direction of rotation is clockwise as seen from
the shaft end (phase rotation in order 1 - 2 - 3). For anti-
clockwise rotation, swap 2 and 3. Any intervention on the alternator terminals during
- the winding connection corresponds to the site operating reconnection or checks should be performed with
voltage (see section § 3.3). the machine stopped.
Connection codes L.L voltage Factory connection

L1(U) Winding 50 Hz 60 Hz T5 T6
A T11
T12 N
3 phase
T1 T7
6 190 - 208 190 - 240
T10 T4
7 220 - 230 - T9 L3(W)
T4 T10 N
T3
T12 T5
8 - 190 - 208 T8 L2(V)
T9 T2
T11 R 250 voltage detection : T2
T6 0 => (T8) / 110 V => (T11) T7 L1(U)
L2(V) R 438 voltage detection :
L3(W) T3 T8
0 => (T3) / 220 V => (T2) T1 NDE
L1(U) Winding 50 Hz 60 Hz T11

D T1
T12 N
3 phase T4
6 380 - 415 380 - 480 T10
T7
7 440 - 460 - T9 L3(W)
N T6 T3
T10
T12 8 - 380 - 416 T8 L2(V)
T9
T11 T5 R 250 voltage detection : T5 T2
T3 T6 T8 T2 0 => (T8) / 110 V => (T11) T7 L1(U)
R 438 voltage detection :
L3(W) L2(V) T4 T1
0 => (T3) / 380 V => (T2) NDE
FF
Winding 50 Hz 60 Hz T11 T4
T7 M
1 phase 6 220 - 240 220 - 240
T3
T2 T6 T8 T12
7 250 - 260 - T9 L
T3 T10
T5 T11 T9
8 200 220 - 240 T8 T6
T1 T4 T7 T10
L L R 250 voltage detection : T2
M
0 => (T1) / 110 V => (T4) T12 T5 L
Voltage LM = 1/2 voltage LL
0 => (T10) / 220 V => (T1) T1
NDE
Winding 50 Hz 60 Hz T11
F L1(U)
1 phase
T12 T1 6 220 - 240 220 - 240 T6 T3
or T9 L
3 phase
T4
T7 7 250 - 260 - T9 L3(W)
T6
T5
T3 T10 8 200 220 - 240 T8 T10 L2(V)
L3(W) L2(V) R 250 voltage detection : T4 T2
T11 T8 T5 T2
L L 0 => (T8) / 110 V => (T11) L
M T7 T12 L1(U)
Voltage LM = 1/2 voltage LL R 438 voltage detection :
0 => (T3) / 220 V => (T2) T1
NDE
7
201/242
LSA 42.2 - 2R 791

& TConnections
4interference
POLE suppression
A F
kit (standard for CE marking)
B F/F G D
ALTERNATORS
Black T1 T1 T1 T1 T1 T2
Black T3
Connection codes L.L voltage Factory connection T3
T3 T3 T3 T3
Blue N N
L1(V) Winding 50 Hz 60 Hz
White T11 T5
B L
L3(W)
1 phase 6 110 - 120 120 Anti condensation heater
T3
or T12 T1
3 phase 7 120 - 130 - T9
T6 T7 103
T10
L
T9 T3
T4 8 - 110 -101
120 T8 T4 L2(V)
T10 T12 T2
L3(W) T5 T2 L2(V) 0 => (T8) / 110 V => (T11)
102
T7 T6 L1(U)
L L R 438 voltage detection :
T11 T8 T1
0 => (T3) / 110 V => (T2) NDE 104
Connection Winding 50 Hz 60 Hz T11 T5
G not recommended
6 T10 M
1 PH 220 - 240 220 - 240
T4
T6 T1 M
T12
T7 7 250 - 260 - T9 L
T4 T3
T3
T10
T2 8 200 220 - 240 T8 L
T5
T9 L
R 250 voltage detection : T12 T2
L T11 T8 0 => (T8) / 110 V => (T11) T7 T6
LM voltage = 1/2 LL voltage 0 => (T3) / 220 V => (T2) T1 NDE
SINGLE PHASE 4 LEADS - WINDING DEDICATED type M or M1

SERIES CONNECTION PARALLEL CONNECTION
T3 T4
T1 T2 T3 T4
T1 T2
M
L L L L
Voltage 50/60 Hz Output Voltage 50/60 Hz Output
L-L L-M Connect L L M L-L L-M Connect L L M
220 110 110 -
230 115 T2 - T3 T1 T4 T2 - T3 115 - T1 - T3 T1-T3 T2 - T4 -
240 120 120 - T2 - T4
R 250 voltage detection : 0 => (T1) / 110 V => (T2) R 250 voltage detection : 0 => (T1) / 110 V => (T2)
3.3.1 - Connection diagram for options
R 791 T interference suppression kit (standard for CE marking) Voltage potentiometer

Connections A D F B F/F G
Black T2 T2 T2 T2 T9 T4 ST4
Black T3 T3 T3 T3 T3 T3 10
5
20 0
Voltage adjustment
Blue N N
40 30
90 80
0
5 70 via remote potentiometer
White
60
Anti condensation heater Thermistor (PTC) temperature

130 C
103 blue
Ph1
101
150C
Ph2 black
102
Ph3 180 C
104 red/white
8
202/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
3.3.2 - Connection checks 3.4 - Commissioning
Electrical installations must comply with the

The alternator can only be started up and used if the
current legislation in force in the country of
installation is in accordance with the regulations
use.
and instructions defined in this manual.
The alternator is tested and set at the factory. When first used
Check that:
with no load, make sure that the drive speed is correct and
stable (see the nameplate). On application of the load, the
- the differential circuit-breaker conforms to legislation on
alternator should achieve its rated speed and voltage; however,
protection of personnel, in force in the country of use, and has
in the event of abnormal operation, the alternator setting can
been correctly installed on the alternator power output as close
be altered (follow the adjustment procedure in section 3.5).
as possible to the alternator. (In this case, disconnect the blue
wire of the R 791 interference suppression module linking the
If the alternator still operates incorrectly, the cause of the
neutral and protect the terminal).
malfunction must be located (see section 4.4).
- any protective devices in place have not tripped,
- if there is an external regulator, the connections between the

alternator and the cubicle are made in accordance with the 3.5 - Setting up
connection diagram,
- there is no short-circuit between phase or phase-neutral

between the alternator output terminals and the generator set
control cabinet (part of the circuit not protected by circuit-
The various adjustments during tests must be made
breakers or cubicle relays),
by a qualified engineer. The screwdriver for making
- The earth terminal (ref 28) is connected to the electrical earth adjustments must be suitable for use with electrical
circuit, equipment. It is essential that the drive speed
specified on the genset nameplate is reached before
- the alternator should be connected with the terminal lugs on commencing adjustment. The AVR is used to make
top of one another as shown in the terminal connection any adjustments to the alternator. Access to the AVR
diagrams, adjustments is via the panel provided for this
purpose.
- the equipotential earth links have been implemented correctly
After operational testing, replace all access panels
(cross-section and continuity of the earths).
or covers.
9
203/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
4 - SERVICING - MAINTENANCE 4.2.4 - Electrical servicing

Cleaning product for the windings
4.1 - Safety measures
WARNING
Do not use : trichlorethylene, perchlorethylene,

trichloroethane or any alkaline products.
Servicing or troubleshooting must be carried out
strictly in accordance with instructions so as to Certain strictly defined pure volatile degreasing products can
avoid the risk of accidents and to maintain the be used, such as :
alternator in its original state. - Normal petrol (without additives) ; inflammable
- Toluene (slightly toxic); inflammable
- Benzene (or benzine, toxic); inflammable
- Ciclohexare (non toxic); inflammable
The insulating components and the impregnation system are
not at risk of damage from solvents (see the list of authorised
All such operations performed on the alternator
products).
should be undertaken by personnel trained in the
Avoid letting the cleaning product run into the slots. Apply the
commissioning, servicing and maintenance of
product with a brush, sponging frequently to avoid accumulation
electrical and mechanical components, who must
in the housing. Dry the winding with a dry cloth. Let any traces
wear the appropriate personal protective equipment
evaporate before reassembling the alternator.
for mechanical and electrical hazards.
Before carrying out any work on the alternator, ensure that it
These operations must be performed at a cleaning
cannot be started by a manual or automatic system by isolating
station, equipped with a vacuum system that collects
the power in any cabinet or enclosure and make sure you have
and flushes out the products used.
understood the operating principles of the system.
4.2.5 - Mechanical servicing

4.2 - Regular maintenance
4.2.1 - Checks after start-up WARNING
After approximately 20 hours of operation, check that all fixing
Cleaning the alternator using water or a high-
screws on the machine are still tight, plus the general state of
pressure washer is strictly prohibited.
the alternator and the various electrical connections in the
Any problems arising from such treatment are not
installation.
covered by our warranty.
The alternator should be cleaned with a degreasing agent,
4.2.2 - Cooling circuit applied using a brush. Check that the degreasing agent will not
It is advisable to check that circulation of air is not reduced by affect the paint.
partial blocking of the air intake and outlet guards: mud, fibre, Compressed air should used to remove any dust.
WARNING
soot, etc. and to check whether the air outlet guards are If filters have been added to the alternator after manufacture
and do not have thermal protection, the service personnel
corroded or scratched.
should clean the air filters periodically and systematically, as
often as necessary (every day in very dusty atmospheres).
4.2.3 - Bearings Cleaning can be performed using water for dry dust or in a bath
The bearings are greased for life: approximate life of the grease containing soap or detergent in the case of greasy dust. Petrol
(depending on use) = 20,000 hours or 3 years. Monitor the or chloroethylene can also be used.
temperature rise in the bearings, which should not exceed After cleaning the alternator, it is essential to check the winding
90°C above the ambient temperature. Should this value be insulation (see sections 3.2. and 4.8.).
exceeded, the alternator must be stopped and checks carried
out. 4.3 - Fault detection
If, when commissioned, the alternator does not work normally,
the source of the malfunction must be identified.
To do this, check that :
- the protective devices are fitted correctly,
- the connections comply with diagrams in the manuals
supplied with the alternator,
- the speed of the unit is correct (see section 1.3).
Repeat the operations defined in section 3.
10
WARNING
204/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
4.4 - Mechanical defects

Fault Cause
Excessive overheating of one or both - If the bearing has turned blue or if the grease has turned black, change the
Bearing bearings (bearing temperature 80°C above bearing.
the ambient temperature) (With or without - Bearing not fully locked (abnormal play in the bearing cage)
abnormal bearing noise) - End shields incorrectly aligned
- Air flow (inlet-outlet) partially clogged or hot air is being recycled from
Excessive overheating of alternator frame the alternator or engine
Abnormal (more than 40° C above the ambient - Alternator operating at too high a voltage (> 105% of Un on load)
temperature temperature) - Alternator overloaded
- Misalignment (coupling)
Too much vibration - Defective mounting or play in coupling
Vibrations - Rotor balancing fault (Engine - Alternator)
Excessive vibration and humming noise - Phase imbalance
coming from the machine - Stator short-circuit
- System short-circuit
- Misparalleling
Alternator damaged by a significant impact, Possible consequences
Abnormal noise followed by humming and vibration - Broken or damaged coupling
- Broken or bent shaft end
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes/AVR
4.5 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its voltage
is still correct when the battery is - Lack of residual magnetism
removed.
No voltage at no Connect a new battery of The alternator builds up but its voltage - Check the connection of the voltage reference to the
load on start-up 4 to 12 volts to terminals does not reach the rated value when AVR
E- and E+, respecting the the battery is removed. - Faulty diode
polarity, for 2 to 3 seconds - Armature short-circuit
The alternator builds up but its voltage - Faulty AVR
disappears when the battery is - Field windings open circuit (check winding)
removed. - Main field winding open circuit (check the resistance)
Check the AVR connections (possible AVR failure)
- Field windings short-circuited
Correct speed - Rotating diodes burnt out
Voltage too low Check the drive speed - Main field winding short-circuited - Check the
resistance
Increase the drive speed
Speed too low (Do not touch the AVR voltage pot. (P2) before running
at the correct speed.)
Voltage too high Adjust AVR voltage Adjustment ineffective Faulty AVR
potentiometer
Voltage Adjust AVR stability If no effect : try normal / fast recovery - Check the speed : possibility of cyclic irregularity
oscillations potentiometer modes (ST2) - Loose connections
- Faulty AVR
- Speed too low when on load (or LAM set too high)
Voltage between E+ and E–
Voltage correct Run at no load and check SHUNT < 6V - AREP < 10V - Check the speed (or LAM set too high)
at no load and the voltage between E+ et Voltage between E+ and E– - Faulty rotating diodes
too low when on E- on the AVR SHUNT > 10V - AREP > 15V - Short-circuit in the main field. Check the resistance.
load (*) - Faulty exciter armature. Check the resistance.
(*) Warning : During single-phase operation, check that the sensing wires from the AVR are connected to the correct output terminals.
Voltage Check the AVR, the surge The voltage does not return to the rated - Exciter winding open circuit
disappears suppressor, the rotating value. - Faulty exciter armature
during operation diodes, and replace any - Faulty AVR
defective components - Main field open circuit or short-circuited
(**) Warning : The AVR internal protection may cut in (overload lost connection, short circuit).
11
205/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
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 field
You can check the winding insulation by performing a high wires (5+) and (6-).
voltage test. In this case, you must disconnect all AVR wires.
WARNING ASSEMBLY A
6 – Exciter field 5 +
Damage caused to the AVR in such conditions is not Rh. 50 Ω - 300 W
1A diode
covered by our warranty.
4.5.2 - Checking the diode bridge +

-
Anode A C Cathode
12 V battery
A diode in good working order must allow the current
to flow from the anode to the cathode.
Assembly B : Connect a “Variac” variable power supply and a
diode bridge on both exciter field wires (5+) and (6-).
+ ou - ~
~ Both these systems should have characteristics which are
compatible with the alternator field excitation power (see the
~ nameplate).
3) Run the unit at its rated speed.
4) Gradually increase the exciter field current by adjusting the

rheostat or the variac and measure the output voltages on L1-
- ~ ~ ~ - + ~ ~ ~ + L2 - L3, checking the excitation voltage and current at no load
C C C A A A (see the alternator nameplate or ask for the factory test
report).
A A A
When the output voltage is at its rated value and balanced
C C C
within 1 % for the rated excitation level, the alternator is in good
working order. The fault therefore comes from the AVR or its
associated wiring (ie. sensing, auxiliary windings).
4.5.3 - Checking the windings and rotating
diodes using separate excitation
ASSEMBLY B
Variac 6 – Exciter field 5+
40
50 60 +
30
70
1A diode
During this procedure, make sure that the alternator
20
80
10
is disconnected from any external load and inspect

90
0 100
the terminal box to check that the connections are DC

fully tightened. AC -
12 V
220 V
1) Stop the unit, disconnect and isolate the AVR wires.
2) There are two ways of creating an assembly
ASSEMBLY A with separate
excitation. Exciter field
6– 5+
1A diode Rh. 50 Ω - 300 W
+
-
12 V battery
12
206/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
4.6 - Dismantling, reassembly (see sections Balancing bolt M5 4 N.m

5.4.1. & 5.4.2) Discs/shaft screw M 10 66 N.m
Lifting screw M8 4 N.m
Grille screw M6 5 N.m
Cover screw M6 5 N.m
During the warranty period, this operation must only 4.6.3 - Access to connections and the regulation
be carried out in an approved workshop or in our system
factory, otherwise the warranty may be invalidated.
Whilst being handled, the alternator must remain The terminals are accessed by removing the terminal box lid
horizontal (rotor not locked when moved). Check [48].
how much the alternator weighs (see 4.7) before To access the adjustment potentiometers on the AVR, the side
choosing the lifting method. plate should be removed [367].
The choice of lifting hooks or handles should be
determined by the shape of the lifting rings. 4.6.4 - Accessing, checking and replacing
diodes
4.6.4.1 - Dismantling
- Remove the terminal box lid [48].
- Remove the air intake louvre [51].
- Unscrew the fixing clamps on the power output cables,
disconnect E+, E- on the exciter and R 791 module.
- Remove the 4 nuts on the tie rods.
- Remove the NDE bracket [36] using an extractor: eg. U.32 -
350 (FACOM).
- Remove the surge suppressor [347].
- Remove the 4 fixing screws from the diode bridges on the
armature.
- Disconnect the diodes.
- Check the 6 diodes using either an ohmmeter or a battery
lamp (see section 4.5.1).
4.6.1 - Tools required 4.6.4.2 - Reassembly

To fully dismantle the alternator, we recommend using the - Replace the diodes, respecting the polarity (see section
tools listed below: 4.5.1).
- 1 ratchet spanner + extension - Replace the surge suppressor [347].
- 1 torque wrench - Insert a new O ring in the bearing housing.
- 1 7 mm flat spanner - Refit the NDE bracket and pass the bundle of wires between
- 1 8 mm flat spanner the top bars of the flange.
- 1 10 mm flat spanner - Replace the fixing clamps on the cables and the R 791
- 1 12 mm flat spanner module.
- 1 8 mm socket - Refit the air intake louvre [51].
- 1 10 mm socket - Replace the terminal box lid [48].
- 1 13 mm socket
- 1 5 mm Allen key (eg. Facom: ET5)
- 1 6 mm Allen key (eg. Facom: ET6) NDE bracket
- 1 TORX T20 bit
- 1 TORX T30 bit Rotor M8
- 1 puller (eg. Facom: U35) Threaded bar
- 1 puller (eg. Facom: U32/350).
4.6.2 - Screw tightening torque

IDENTIFICATION screw Ø Torque N.m
Field term. block screw M4 4 N.m
Field screw M6 10 N.m
Diode bridge screw M6 5 N.m
Diode nut M5 4 N.m
Assembly rod M8 20 N.m
Earth screw M6 5 N.m
13
207/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
4.6.5 - Replacing the NDE bearing on a single-

bearing alternator
- Dismantle the NDE bracket [36] (see section 4.6.2.1).
- Remove the bearing [70] using a puller.
- Rest the rotor on one of its poles, then slide it out. Use the tube
4.6.5.2 - Reassembly as a lever arm to assist dismantling.
- Heat the inner slipring of a new bearing by induction or in a - After extraction, be careful with the fan. It is necessary to
drying oven at 80 °C (do not use an oil bath) and fit it to the replace the fan in case of disassembling.
alternator.
- Place the preloading wavy washer [79] in the flange and fit a NOTE: If intervention is required on the main field
new O ring seal [349]. (rewinding, replacement of components), the rotor
- Replace the NDE bracket [36] (see section 4.6.2.2). assembly must be rebalanced.
Do not use the fan to turn the alternator rotor
4.6.6 - Replacing the bearings on a two-bearing 4.6.7.2 - Reassembly
alternator - Follow the dismantling procedure in reverse order.
4.6.6.1 - Dismantling Take care not to knock the windings when refitting the rotor in
- Uncouple the alternator from the prime mover. the stator.
- Remove the 8 assembly screws. If you replace the fan, respect the assembly guide according
- Remove the DE flange [30]. the following bellow. Use a tube and a screw.
- Remove the NDE bracket (see section 4.6.2.1).
- Remove both bearings [60] and [70] using a puller.
4.6.6.2 - Reassembly
- Fit new bearings after heating them by induction or in a drying
oven at 80 °C (do not use an oil bath).
- Check that both the preloading wavy washer [79] and new O
ring seal have been fitted [349] on the NDE bracket [36].
- Replace the DE flange [30], and tighten the 8 fixing screws.
- Check that the whole alternator is correctly assembled and
that all screws are fully tightened.
Follow the procedure for reassembling the bearings (see
4.6.7 - Accessing the main field and stator section 4.6.5.2 and 4.6.6.2).
Follow the procedure for dismantling bearings (see
sections 4.6.5.1 and 4.6.5.1.)
- Remove the coupling discs (single-bearing alternator) or the
DE flange (two-bearing alternator) and insert a tube of the
corresponding diameter on the shaft end or a support made
according the following bellow. After final adjustments, the access panels or cover
should be refitted.
14
208/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
4.7 - Electrical characteristics table Field excitation current i exc (A) - 400 V - 50 Hz :
Symbols : “i exc” : excitation current of the exciter field
Table of average values:
LSA 42.2 VS0* VS2* S3* S4* S5 M6 M7 L9
Alternator - 2 and 4 pole - 50 Hz/60 Hz - Standard winding
n°6 and M or M1 in dedicated single phase (400 V for the No-load 0,5 0,6 0,5 0,6 0,6 0,5 0,5 0,5
excitation values). At rated load 1,5 1,6 1,65 1,4 1,6 1,3 1,5 1,5
The voltage and current values are given for no-load operation
* Lister type machine
and operation at rated load with separate field excitation. All
values are given at ± 10% and may be changed without prior 4.7.4 - 3-phase : 4 pole with AREP excitation
notification (for exact values, consult the test report). For 60 Hz Resistances at 20°C (W) :
machines, the “i exc” values are approximately 5 to 10 %
LSA 42.2 VS2* S4 S5 M6 M7 L9
lower.
L/N stator 0,76 0,34 0,34 0,22 0,22 0,2
4.7.1 - 3-phase : 2 pole with SHUNT excitation Rotor 2,1 2,7 2,7 3,3 3,3 3,7
Resistances at 20 °C (W) Auxil. wind. 0,5 0,3 0,3 0,26 0,26 0,23
X1, X2
LSA 42.2 VS0* VS2* S3* S4* M5 M6 L7 VL8 Auxil. wind. 0,6 0,5 0,5 0,44 0,44 0,41
L/N stator 1,01 0,76 0,61 0,4 0,22 0,22 0,16 0,1 Z1, Z2
Field 6 6 6 6 6 6
Rotor 2,93 3,13 3,24 3,53 4,1 4,1 4,7 5,5
Armature 0,5 0,51 0,51 0,51 0,51 0,51
Field 23,5 23,5 23,5 23,5 23,5 23,5 23,5 23,5
Armature 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 Field excitation current i exc (A) - 400 V - 50 Hz :
Field excitation current i exc (A) - 400 V - 50 Hz
Symbols : “i exc” : excitation current of the exciter field TYPE 42.2 VS2* S4 S5 M6 M7 L9
LSA 42.2 VS0* VS2* S3* S4* M5 M6 L7 VL8 No-load 0,9 0,9 0,9 0,8 0,8 0,7
No-load 0,45 0,4 0,4 0,4 0,45 0,45 0,4 0,4 At rated load 2,4 2,1 2,3 2 2,3 2,3
At rated * Lister type machine
1,6 1,7 1,7 1,7 1,55 1,85 1,7 1,65
load
4.7.5 - Dedicated single phase : 4 pole with
* Lister type machine SHUNT excitation
Resistances at 20 °C (W)
4.7.2 - Dedicated single phase : 2 pole with
SHUNT excitation LSA 42.2 VS2 S3 S5 M7 L9
L/N stator 0,330 0,248 0,147 0,072 0,063
Resistances at 20 °C (W)
Rotor 2,1 2,3 2,7 3,3 3,7
LSA 42.2 VS2 S3 S4 M6 L7
Field 25,6 25,6 25,6 25,6 25,6
L/N stator 0,36 0,294 0,190 0,108 0,077
Armature 0,51 0,51 0,51 0,51 0,51
Rotor 3,13 3,24 3,53 4,1 4,7
Field 23,5 23,5 23,5 23,5 23,5 Field excitation current i exc (A) -240 V - 60 Hz
Armature 0,79 0,79 0,79 0,79 0,79
LSA 42.2 VS2 S3 S5 M7 L9
Field excitation current i exc (A) - 240 V - 60 Hz No-load 0,45 0,43 0,46 0,61 0,62
Symbols : “i exc” : excitation current of the exciter field.
At rated load 1,21 1,21 1,1 1,05 1,17
LSA 42.2 VS2 S3 S4 M6 L7
No-load 0,26 0,25 0,27 0,28 0,26 4.7.6 - Table of weights
At rated load 0,9 0,9 0,91 0,9 0,92 LSA 42.2 Total Rotor LSA 42.2 Total Rotor
2P (kg) (kg) 4P (kg) (kg)
4.7.3 - 3-phase : 4 pole with SHUNT excitation VS0 125 40 VS2 125 40
Resistances at 20 °C (W) VS2 125 40 S4 125 40
S3 125 40 S5 125 40
LSA 42.2 VS0* VS2* S3* S4* S5 M6 M7 L9
S4 125 40 M6 145 50
L/N stator 1,54 0,7 0,53 0,32 0,32 0,2 0,2 0,19 M5 125 40 M7 145 50
Rotor 1,71 2,1 2,3 2,7 2,7 3,3 3,3 3,7 M6 125 40 L9 145 60
Field 25,6 25,6 25,6 25,6 25,6 25,6 25,6 25,6 L7 145 45
Armature 0,51 0,51 0,51 0,51 0,51 0,51 0,51 0,51 VL8 165 50
15
209/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
5 - SPARE PARTS
5.1 - First maintenance parts
Emergency repair kits are available as an option.
They contain the following items :
No. Description Qty LSA 42.2 - SHUNT 2 & 4 P Coding

198 Voltage regulator (AVR) 1 R 250 AEM 110 RE 019
343 Diode bridge assembly 1 LSA 411.1.59/60 ESC 025 MD 008
347 Surge suppressor 1 LSA 411.1.17A AEM 000 RE 126
AVR fuse 1 250 V - 8 A / slow
No. Description Qty LSA 42.2 - AREP 4 P Coding

198 Voltage regulator (AVR) 1 R 438 AEM 110 RE 003
343 Diode bridge assembly 1 LSA 411.1.59/60 ESC 025 MD 008
347 Surge suppressor 1 LSA 411.1.17A AEM 000 RE 126
AVR fuse 1 250 V - 8 A / slow
5.2 - Description of bearings
No. Description Qty LSA 42.2 - 2 & 4 P Coding

60 D.E. bearing 1 6309 2RS/C3 RLT 045 TN 030
70 N.D.E. bearing 1 6305 2RS/C3 RLT 025 TN 030
5.3 - Technical support service

Our technical support service will be happy to provide any
WARNING
information you require.
Part numbers should be identified from the exploded
When ordering spare parts, you should indicate the views and their description in the parts list.
complete machine type, its serial number and the Our extensive network of “service stations” can
information indicated on the nameplate. dispatch the necessary parts without delay.
To ensure correct operation and the safety of our
alternators, we recommend the use of original
manufacture spare parts.
In the event of failure to comply with this advice, the
manufacturer cannot be held responsible for any
damage.
16
210/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
5.4 - Exploded view, parts list

5.4.1 - LSA 42.2 single bearing, AREP or SHUNT
48
367
98
49
132
124
120
198
1
4
30
324
323
51
36
90
91
79
349
70
100
344
343
347
28
37
33
15
322
No. Nbr. Description No. Nbr. Description

1 1 Stator assembly 98 3 Corner plate
4 1 Rotor assembly 100 1 Exciter armature
15 1 Fan 120 1 Terminal plate support (AREP)
28 1 Earth terminal 124 1 Terminal plate
30 1 DE flange 132 1 Terminal box
33 1 Air outlet grille 198 1 Regulator (AVR)
36 1 N.D.E. bracket 322 1 Coupling disc
37 4 Tie rod 323 6 Fixing screw
48 1 Terminal box lid 324 1 Clamping washer
49 20 Terminal box fixing screw 343 1 Direct diode assembly
51 1 Air intake grille 344 1 Reverse diode assembly
70 1 NDE bearing 347 1 Surge suppressor
79 1 Preloading wavy washer 367 2 Inspection door
90 1 Wound exciter field 349 1 O ring seal
91 4 Field fixing screw
17
211/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
5.4.2 - LSA 42.2 two-bearing, AREP or SHUNT
48
367
98
49
132
124
120
198
4
15
97
30
410
51
36
90
91
79
349
70
100
344
343
347
28
1
37
98
33
60
No. Nbr. Description No. Nbr. Description

1 1 Stator assembly 91 4 Field fixing screw
4 1 Rotor assembly 97 1 Corner plate male
15 1 Fan 98 3 Corner plate
28 1 Earth terminal 100 1 Exciter armature
30 1 DE flange 120 1 Terminal plate support (AREP)
33 1 Air outlet grille 124 1 Terminal plate
36 1 N.D.E. bracket 132 1 Terminal box
37 4 Tie rod 198 6 Regulator (AVR)
48 1 Terminal box lid 343 1 Direct diode assembly
49 20 Terminal box fixing screw 344 1 Reverse diode assembly
51 1 Air intake grille 347 1 Surge suppressor
60 1 DE bearing 367 2 Inspection door
70 1 NDE bearing 349 1 O ring seal
79 1 Preloading wavy washer 410 1 DE flange
90 4 Wound exciter field
18
212/242
LSA 42.2 - 2 & 4 POLE

ALTERNATORS
Electric Power Generation
DECLARATION of COMPLIANCE
related to CE marking
This Declaration applies to the generators designed to be incorporated into machines complying with the
Machine Directive Nr 2006/42/CE dated 17 May 2006.
MOTEURS LEROY-SOMER
Boulevard Marcellin Leroy
16015 ANGOULEME (France)
Declares hereby that the electric generators of the ranges " PARTNER", Industrial and Professional, as well as
their derivatives, manufactured by Leroy Somer or on Leroy Somer's behalf, comply with the following
International Standards and Directives :
- EN et CEI 60034 -1 et 60034 -5

- ISO 8528 – 3 “ Reciprocating internal combustion engine driven alternating current generating sets.
Part 3. Alternating current generators for generating sets ”
- The Low Voltage Directive Nr 2006/95/CE dated 12 December 2006.
Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore
able to be incorporated into Electrical Gen-Sets complying with the following International Standards and
Directives :
- The Machine Directive Nr 2006/42/CE dated 17 May 2006

- The EMC Directive Nr 2004/108/CE dated 15 December 2004, as intrinsic levels of emissions and
immunity are concerned
WARNING :
The here above mentioned generators should not be commissioned until the corresponding Gen-Sets have
been declared in compliance with the Directives Nr 2006/42/CE et 2004/108/CE, as well as with the other
relevant Directives.
Technical Managers
P Betge – O Cadel
4152 en – 12.2009 / c
19
213/242
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
RCS ANGOULÊME N° B 671 820 223
S.A. au capital de 62 779 000 €
http://www.leroy-somer.com
214/242
4067 en - 2009.05 / b
MAIN FIELD STATOR : 12 wires (marking T1 to T12)

SHUNT SYSTEM
T1 T7 T2 T8 T3
Varistor
Induced
5+ 6-
T4 T10 T5 T11 T6
Field
75 mm
110 0V E+ E- R 250
4 x holes Ø 5.8 x
140 mm
50 x 115 mm
n to
give
to be
F1 Slow fuse
s
250V 8 A
l i er
FREQ. & L.A.M. CONFIG.
ua
man e end us
This th P1 Voltage
STAB VOLT
KNEE
47.5Hz 50Hz LAM

LAM OFF 9
o OFF
1 13%
SPECIAL
8 901 2 25%
Frequency selector 50 H
23
78
KNEE
3 OFF
P2
65Hz 7
456
Stability LAM OFF 4 13% / 60 Hz for U/F fonction

6
and LAM adjustement
KNEE
5 25%
57Hz 60Hz LAM
LAM OFF
ST4 Option
External potentiometrer
for voltage adjusting
R250
A.V.R.
215/242
LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b
R250
A.V.R.
This manual concerns the alternator A.V.R. which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your A.V.R., you can
look forward to many years of trouble-free operation.
SAFETY MEASURES
Before using your machine for the first time, WARNING

it is important to read the whole of this
installation and maintenance manual.
All necessary operations and interventions Warning symbol for an operation capable
on this machine must be performed by a of damaging or destroying the machine
qualified technician. or surrounding equipment.
Our technical support service will be pleased

to provide any additional information you
may require.
The various operations described in this

manual are accompanied by
recommendations or symbols to alert the Warning symbol for general danger to
user to potential risks of accidents. It is vital personnel.
that you understand and take notice of the
following warning symbols.
Warning symbol for electrical danger to

personnel.
Note : LEROY-SOMER reserves the right to

modify the characteristics of its products at
any time in order to incorporate the latest
technological developments.
The information contained in this document
may therefore be changed without notice.
2
216/242
R250
A.V.R.
SUMMARY
1 - SUPPLY...............................................................................................................................4
1.1 - SHUNT excitation system.............................................................................................4
2 - R250 A.V.R..........................................................................................................................5
2.1 - Characteristics.............................................................................................................. 5
2.2 - U/F fonction and LAM....................................................................................................5
2.3 - R250 A.V.R. option........................................................................................................ 5
2.4 - LAM Characteristics .....................................................................................................6
2.5 - Typical effects of the LAM..............................................................................................7
3 - INSTALLATION - COMMISIONING....................................................................................8
3.1 - Electrical checks on the AVR.........................................................................................8
3.2 - Settings.........................................................................................................................8
3.3 - Electrical faults.............................................................................................................. 9
4 - SPARE PARTS.................................................................................................................. 10
4.1 - Designation.................................................................................................................10
4.2 - Technical support service............................................................................................10

Any maintenance or breakdown operations on the A.V.R. are to be done by personnel

trained on commisioning, servicing and maintenance for the electrical and mechanical
elements.
The R250 is an IP00 product. It must be installed inside a unit so that this unit’s cover can provide
IP20 minimum total protection (it must only be installed on LS alternators in the appropriate
location so that when viewed externally, it has a higher degree of protection than IP20).
Copyright 2005: MOTEURS LEROY-SOMER

This document is the property of:
MOTEURS LEROY SOMER.
It may not be reproduced in any form without prior authorization
All brands and models have been registered and patents applied for.
3
217/242
R250
A.V.R.
1 - SUPPLY The regulator controls the excitation current

1.1 - SHUNT excitation system according to the alternator’s output voltage.
With a very simple conception, the SHUNT
The SHUNT excitation alternator is auto- excitation alternator does not have a short
excited with a R 250 voltage regulator. circuit capacity.
MAIN FIELD STATOR : 12 wires (marking T1 to T12)

SHUNT SYSTEM
T1 T7 T2 T8 T3 T9
Varistor
Induced
5+ 6-
T4 T10 T5 T11 T6 T12
Field
75 mm
110 0V E+ E- R 250
4 x holes Ø 5.8 x
140 mm
50 x 115 mm
F1 Slow fuse
250V 8 A
FREQ. & L.A.M. CONFIG.
P1 Voltage
STAB VOLT
KNEE
47.5Hz 50Hz LAM

LAM OFF 9
o OFF
1 13%
SPECIAL
8 901 2 25%
Frequency selector 50 Hz
23
78
KNEE
3 OFF
P2
65Hz 7
456
Stability LAM OFF 4 13% / 60 Hz for U/F fonction

6
and LAM adjustement
KNEE
5 25%
57Hz 60Hz LAM
LAM OFF
ST4 Option
External potentiometrer
for voltage adjusting
4
218/242
R250
A.V.R.
2 - R250 A.V.R. The threshhold position and LAM fonction

2.1 - Characteristics settings are done with the jumper.
- Storage: -55°C; +85°C

- Operation: -40°C; +70°C Operating at 50 Hz: (U/F gradient)
- Voltage regulation: around ± 0,5 %. 0: threshold at 48 Hz without LAM for impacts
- Supply range/voltage detection 85 to 139 V between 30 and 40% of the rated load.
(50/60Hz).
- Rapid response time (500 ms) for a 1: threshold at 48 Hz with LAM 13% for
impacts between 40 and 70% of the rated
transient voltage variation amplitude of
load.
± 20 %.
- Voltage setting P1. 2: threshold at 48 Hz with LAM 25% for
- Stability setting P2. impacts > 70% of the rated load.
- Power supply protected by 8 A fuse, Operating at 60 Hz: (U/F gradient)
replacement product: Ferraz-Shawmut
T084013T fast-blow fuse, 8 A FA 250 V, 3: threshold at 58 Hz without LAM for impacts
breaking capacity 30 kA. between 30 and 40% of the rated load.
4: threshold at 58Hz with LAM 13% for

2.2 - U/F Fonction and LAM impacts 40 and 70% of the rated load.
The threshold position (50 Hz - 60 Hz) to 5: threshold at 58Hz with LAM 25% for
action the U/F fonction as well as the LAM impacts > 70% of the rated load.
setting type is selected using the
potentionmeter. Specific operating
KNEE
50Hz LAM 6: threshold at 57Hz without LAM for speed
47.5Hz o OFF variations at a steady state > 2 Hz
LAM OFF 9
1 13%
SPECIAL
8 901 2 25% 7: threshold at 65Hz without LAM for variable
speed and tractelec / gearlec (U/F
23
78
KNEE
3 OFF
65Hz 7 gradient).
456
LAM OFF 4 13%
KNEE 6 8: special: the factory setting 48Hz 2U/F
5 25%
57Hz 60Hz LAM gradient ; a special programme is possible
LAM OFF
on request. This programme must be
specified before ordering, during the project
study.
9: threshold at 47.5 Hz without LAM for

speed variations at a steady state > 2 Hz.
WARNING: The jumper settings must For hydraulic applications, it is advisable to
correspond to the rated operating select:
frequency (see the nameplate on the - position 0 for 50 Hz
alternator). - position 3 for 60 Hz
Risk of destruction for the alternator.
5
219/242
R250
A.V.R.
2.3 - R250 A.V.R. option It is advised to use the “LAM” at 25% for load
impacts > at 70% of the genset rated power.
Potentiometer for voltage setting, 1000 W /
0,5 W min: setting range ± 5 %.
Voltage
- Remove the ST4 jumper.
Voltage
UN
U/f
0,85 UN LAM
For wiring up the external potentiometer;

the “earth” wires must be isolated as
well as the potentiometer terminals 48 or 58 Hz 50 or 60 Hz
(wires at the same voltage as the power). 0
fC fN
ST3
2.4 - LAM characteristics (Load

Acceptance Module)
2.4.1 - Voltage drop 2.4.2 - Gradual voltage return function
The LAM system is integrated in the A.V.R. During load impacts, the function helps the
It is active as standard. It can be adjusted to genset to return to its rated speed faster
13% or 25%. thanks to a gradual increase in voltage
according to the following principles:
- Role of the «LAM» (Load Adjustment
Module): - if the speed drops between 46 Hz and 50 Hz,
the rated voltage follows a fast gradient as it
On application of a load, the rotation speed is restored.
of the generator set decreases. When it
passes below the preset frequency - if the speed drops below 46 Hz, since the
threshold, the LAM causes the voltage to engine needs more help, the voltage follows
drop by approximately 13% or 25% and a slow gradient as it returns to the reference
consequently the amount of active load value.
applied is reduced by approximately 25% to
50%, until the speed reaches its rated value
again.
Hence the “LAM” can be used either to U

reduce the speed variation (frequency) and
its duration for a given applied load, or to Drop N < 46 Hz
increase the applied load possible for one
speed variation (turbo-charged engines). Drop N > 46 Hz
Time
To avoid voltage oscillations, the trip 0
threshold for the “LAM” function should be
set approximately 2 Hz below the lowest
frequency in steady state.
6
220/242
R250
A.V.R.
2.5 - Typical effects of the LAM with

a diesel engine or without a LAM
(U/F only)
2.5.1 - Voltage
Transient voltage drop
UN
0,9
(U/f)
with without LAM
0,8
LAM
Time
0 1s 2s 3s
2.5.2 - Frequency
Max speed drop with
fN LAM
0,9
without
LAM
0,8 Time
0 1s 2s 3s
2.5.3 - Power
LAM
shaft (kW)
Load on
Load variation
Shedding due to "LAM"
Time
0 1s 2s 3s
7
221/242
R250
A.V.R.
3 - INSTALLATION - 3.2.2 - Special type of use
COMMISSIONING
3.1 - Electrical checks on the AVR WARNING
- Check that all connections have been
Excitation circuit E+, E- must not be left
made properly as shown in the attached
open when the machine is running:
wiring diagram.
A.V.R. damage will occur.
- Check that the position of the jumper
corresponds to the operating frequency. 3.2.2.1 - R250 field weakening (SHUNT)
- Check whether the ST4 jumper or the
remote adjustment potentiometer have
been connected.
3.2 - Settings
E+
0V
110
E-
The exciter is switched off by disconnecting
the A.V.R. power supply (1 wire - 0 or 110V).
The different settings made during the Contact rating: 16A - 250V AC
trial are to be done by qualified personnel.
Respecting the load speed specified on Do not reclose the power supply until the
the nameplate is vital in order to start a voltage has reached a value ≤15% of the
rated voltage (approximately 5 seconds
settings procedure. After operational after opening)
testing, replace all access panels or
covers. 3.2.2.2 - R250 field forcing
The only possible settings on the (400V - 10A) Diode
machine are to be done with the A.V.R.
t - +
3.2.1 - R250 settings (SHUNT system) Battery (B Volt)
Initial potentiometer positions

- voltage setting potentiometer P1 for the Excitation Inducer
A.V.R.: full left
E+
0V
110
E-
- remote voltage setting potentiometer: in

the middle.
Operate the alternator at its rated speed: if
the voltage does not rise it is necessary to
re-magnatise the magnetic circuit.
- slowly adjust the voltage potentiometer of
the A.V.R. P1 until the output voltage reaches The battery must be isolated from the
its rated value. mass.
- Stability setting with P2.
Exciter field may be at line potential.
8
222/242
R250
A.V.R.

Fault Action Effect Check/cause
The alternator starts up and its
voltage is still correct when the - Lack of residual magnetism
battery is removed.
Connect a new battery The alternator starts up but its - Check the connection of the voltage
No voltage at of 4 to 12 volts to voltage does not reach the rated reference to the A.V.R.
no load on terminals E- and E+ value when the battery is - Faulty diodes
start-up respecting the polarity removed. - Induced short circuit
for 2 to 3 seconds - Faulty A.V.R.
The alternator starts up but its
- Exciter field short-circuited
voltage disappears when the
- Short-circuit in the main field. Check the
battery is removed
resistance
Check the A.V.R. connections (A.V.R. may
be faulty)
Correct speed
- Rotating diodes burnt out
Voltage too - Main field winding short-circuited
Check the drive speed
low - Check the resistance
Speed too low (Do not touch the A.V.R. pot (P1) before
returning to the correct speed.)
Voltage too Adjust A.V.R. - Faulty A.V.R.
Adjustment ineffective
high potentiometer - 1 faulty diode
- Check the speed: possibility of cyclic
irregularity
Voltage Adjust A.V.R. stability - Loose terminals
oscillations potentiometer - Faulty A.V.R.
- Speed too low on load
(or U/F gradient set too high)
- Check the speed (or U/F gradient set too
Voltage high)
Run at no load and
correct at no
check the voltage - Faulty rotating diodes
load and too
between E+ and E- on - Short-circuit in the main field. Check the
low when on
the A.V.R. resistance
load (*)
- Faulty induced excitaion
(*) Warning: For single-phase operation, check that the sensing wires coming from the A.V.R. are correctly connected to
the operating terminals (see the alternator manual).
Check the A.V.R., the
Voltage - Exciter winding open circuit
surge suppressor, the
disappears The voltage does not return to the - Faulty induced excitation
rotating diodes and
during rated value - Faulty A.V.R.
replace any defective
operation - Main field open circuit or short-circuited
components
Warning: after setting-up or trouble-

shooting, replace all access panels or
covers.
9
223/242
R250
A.V.R.
4 - SPARE PARTS
4.1 - Designation
Description Type Code
A.V.R. R 250 AEM 110 RE 019

to help you with any information needed.
For replacement part orders, it is necessary

to indicate the type and the code number of
the A.V.R.
Please contact your usual correspondant.
An extensive network of service centres is

available to rapidly supply any necessary
parts.
In order to ensure the correct operation and
safety of our machines, we strongly
recommend that original manufacturer’s
spare parts are used.
Failure to do so, will discharge the
manufacturer from liabilty in the case of
damage.
10
224/242
R250
A.V.R.
11
225/242
338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 ¤
www.leroy-somer.com
226/242
3971 en - 2010.11 / f
T1 T7 T2 T8 T3 T9
5+ 6-
T4 T10 T5 T11 T6 T12
iven to
be g
a l i s to er
u
man e end us
This th
140 mm
X2 Z1 X1 Z2 E+ E- 0V 110 220 380

F1
200 mm
ST5
P1
AREP
50Hz 60Hz ST9
R 438
PMG
ST10 T.I. S2 P2
LAM
R438
13 % 25 %
S1 Ph.1
P1
P5
ST4
ST11
A.V.R.
ST2 ST1 P2
R731
P3

227/242
LEROY-SOMER Installation and maintenance 3971 en - 2010.11 / f
R438
A.V.R.
This manual concerns the alternator A.V.R. which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your A.V.R., you can
look forward to many years of trouble-free operation.
SAFETY MEASURES
Before using your machine for the first time,

it is important to read the whole of this instal- WARNING
lation and maintenance manual.
All necessary operations and interventions

on this machine must be performed by a Warning symbol for an operation ca-
qualified technician. pable of damaging or destroying the ma-
chine or surround-ing equipment.
to provide any additional infor-mation you
may require.
The various operations described in this

manual are accompanied by recommen-da-
tions or symbols to alert the user to potential
risks of accidents. It is vital that you unders- Warning symbol for general danger to
tand and take notice of the following warning personnel.
symbols.
This A.V.R. can be incorporated in a ma-

chine marked C.E.
Warning symbol for electrical danger to

personnel.
Note: LEROY-SOMER reserves the right to

modify the characteristics of its products at
any time in order to incorporate the latest tech-
nological developments. The information
contained in this document may therefore be
changed without notice.
2
228/242
R438
A.V.R.
CONTENTS
1 - SUPPLY...............................................................................................................................4
1.1 - AREP excitation system................................................................................................4
1.2 - PMG excitation system..................................................................................................5
1.3 - SHUNT or separate excitation system...........................................................................5
2 - R438 A.V.R.......................................................................................................................... 6
2.1 - Characteristics.............................................................................................................. 6
2.2 - Frequency compared with voltage (without LAM)..........................................................6
2.3 - LAM (Load Acceptance Module) characteristics...........................................................6
2.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only)........... 7
2.5 - R438 A.V.R. options......................................................................................................7
3 - INSTALLATION - COMMISSIONING..................................................................................8
3.1 - Electrical checks on the AVR.........................................................................................8
3.2 - Settings.........................................................................................................................8
3.3 - Electrical faults............................................................................................................ 11
4 - SPARE PARTS.................................................................................................................. 12
4.1 - Designation................................................................................................................. 12
4.2 - Technical support service............................................................................................12

All such operations performed on the A.V.R. should be undertaken by personnel trained
in the commissioning, servicing and maintenance of electrical and mechanical
components.
The R438 is an IP00 product. It must be installed inside a unit so that this unit’s cover can
provide IP20 minimum total protection (it must only be installed on LS alternators in the ap-
propriate location so that when viewed externally, it has a higher degree of protection than
IP20).
Copyright 2005 : MOTEURS LEROY-SOMER

This document is the property of :
MOTEURS LEROY-SOMER
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.
3
229/242
R438
A.V.R.
1 - SUPPLY to that of the alternator (characteristic

1.1 - AREP excitation system Shunt), the second has a voltage in propor-
tion to the stator current (compound charac-
For both AREP & PMG excitation systems, teristic: Booster effect).
the alternator voltage regulator is the R438. The power supply voltage is rectified and
With AREP excitation, the R438 electronic filtered before being used by the AVR moni-
AVR is powered by two auxiliary windings toring transistor. This principle ensures that
which are independent of the voltage match regulation is not affected by distortions ge-
circuit. nerated by the load.
The first winding has a voltage in proportion
STATOR : 6 wires (marked T1 to T6)

MAIN FIELD STATOR : 12 wires (marked T1 to T12)
AREP SYSTEM Aux. windings
T1 T7 T2 T8 T3 T9
Varistor
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
10 Yellow
11 Red
12 Black
9 Green
according voltage
140 mm
X2 Z1 X1 Z2 E+ E- 0V 110 220 380 4 x holes Ø 5.8 x

F1 Slow fuse
200 mm
175 x 115 mm
250V 8 A
ST5
P1
with LAM without LAM Quad
droop
ST3 AREP
Frequency 50Hz 60Hz ST9
R 438
PMG
ST10 T.I. S2 P2
LAM 13 % 25 %
Option
S1 Ph.1
P1
Excitation
P5 ceiling
ST4 Option
ST11 open
knee-point: 65 Hz
External potentiometer
for adjusting the voltage
ST2 Response
time
normal
fast ST1 P2 Option
Single- Voltage R731 3-ph. detection

P3 Stability phase
detection in 3-ph. detection ST1 open
4
230/242
R438
A.V.R.
1.2 - PMG excitation system alternator winding. As a result the machine

has a short-circuit current capacity and
This excitation system consists of a «PMG»
good immunity to distortions generated by
(permanent magnet generator). This is fitted
the load.
at the rear of the machine and connected to
The AVR monitors and corrects the alterna-
the R438 AVR.
tor output voltage by adjusting the excitation
The PMG supplies the AVR with constant
current.
voltage which is independent of the main
- 50/60 Hz selection via the ST3 jumper.
STATOR : 6 wires (marked T1 to T6)
MAIN FIELD STATOR : 12 wires (marked T1 to T12)
PMG SYSTEM
T1 T7 T2 T8 T3 T9
Varistor
PMG
Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
according voltage
14 15 16
140 mm
X2 Z1 X1 Z2 E+ E- 0V 110 220 380 4 x holes Ø 5.8 x

Slow fuse
F1
200 mm
250V 8 A 175 x 115 mm
ST5
Quad
with LAM without LAM
P1 droop
ST3 AREP
Frequency 50Hz 60Hz ST9 PMG
R 438
ST10 T.I. S2 P2
LAM 13 % 25 %
Option
Ph.1
S1
P1
Excitation
P5 ceiling
ST4 Option
ST11 open
knee-point: 65 Hz
External potentiometer
for adjusting the voltage
normal
ST2 Response
time fast ST1 P2 Option
Single- Voltage R731 3-ph. detection

P3 Stability phase
detection in 3-ph. detection ST1 open
1.3 - SHUNT or separate excitation system

A.V.R. can be operated with SHUNT supply (with a transformer / secondary 50V or a 48V battery).
5
231/242
R438
A.V.R.
2 - R438 A.V.R. 2.1.2 - Setting potentiometers

2.1 - Characteristics function
- Storage : -55°C ; +85°C Delivrery
Pot. Function
- Operation : -40°C ; +70°C position
- Standard power supply: AREP or PMG. 0 P1 Quadrature droop ; // operation with C.T.
- Rated overload current: 8 A - 10 s 400V P2 Voltage
- Electronic protection (overload, short-cir-
Centre P3 Stability
cuit on opening of voltage sensing circuit):
excitation overload current for 10 seconds Maxi P5 Excitation current ceiling
then return to approximately 1A. The alter-
nator must be stopped (or the power
switched off) in order to reset the protection. 2.2 - Frequency compared with
- Fuse : F1 on X1, X2. 8A ; slow - 250V voltage (without LAM)
- Voltage sensing : 5 VA isolated via trans-
former ; Voltage Bend 57.5 Hz
• 0-110 V terminals = 95 to 140 V, 100 %
48 Hz
• 0-220 V terminals = 170 to 260 V, U/UN 50 Hz

• 0-380 V terminals = 340 to 520 V. 60 Hz
- Voltage regulation ± 1%.
- Normal or rapid response time via ST2 Frequency
jumper (see below). 50 Hz 60 Hz Hz
- Voltage adjustment via potentiometer P2.
other voltages via adapter transformer
- Current sensing (parallel operation): C.T. 2.3 - LAM (Load Acceptance
2.5 VA cl1, secondary 1 A (optional). Module) characteristics
- Quadrature droop adjustment via potentio-
2.3.1 - Voltage drop
meter P1.
- Max. excitation current adjustment via P5 The LAM system is integrated in the R 438
(see below). AVR as standard.
Role of the «LAM» (Load Adjustment Mo-
2.1.1 - Configuration jumpers function dule) :
On application of a load, the rotation speed
Delivrery
Pot. config. Position Function
of the generator set decreases. When it
Open Closed passes below the preset frequency thres-
ST1 3-ph. Mono
Open for module hold, the LAM causes the voltage to drop by
installation tri detection approximately 13% or 25% and conse-
ST2 Fast Normal Response time
quently the amount of active load applied is
ST3 50 ou 60 Hz Frequency selection
External
reduced by approximately 25% to 50%, until
ST4 potentio Without Potentiometer the speed reaches its rated value again.
meter Hence the LAM can be used either to reduce
ST5 Without With LAM the speed variation (frequency) and its dura-
Others
ST9
(PMG...)
AREP Supply tion for a given applied load, or to increase
LAM voltage drop the applied load possible for one speed va-
ST10 13% or 25%
amplitude riation (turbo-charged engine).
ST11 65 Hz
48 or U/f function bend To avoid voltage oscillations, the trip thres-
58 Hz position
hold for the LAM function should be set ap-
proximately 2 Hz below the lowest frequen-
cy in steady state.
6
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R438
A.V.R.
- LAM : action eliminated by cutting the ST5 2.4 - Typical effects of the LAM with
jumper. a diesel engine with or without a
Voltage LAM (U/F only)
Underspeed and LAM
ST5 disconnected
UN Voltage 2.4.1 - Voltage
P2
Transient voltage drop
U/f UN
0.85 UN LAM
0,9
(U/f)
48 or 57.5 Hz 50 or 60 Hz with without LAM
0 0,8
ST3 fC fN LAM
Time
0 1s 2s 3s
2.3.2 - Gradual voltage return function

2.4.2 - Frequency
During load impacts, the function helps the
genset to return to its rated speed faster Max speed drop with
thanks to a gradual increase in voltage ac- fN LAM
cording to the principle:

- If the speed drops between 46 and 50 Hz,
0,9
the rated voltage follows a fast gradient as it without
is restored. 0,8
LAM
Time
- If the speed drops below 46 Hz, since the
0 1s 2s 3s
engine needs more help, the voltage follows
a slow gradient as it returns to the reference
value.
2.4.3 - Power
LAM
U
Load on the
Drop N ≤ 46 Hz
shaft (kW)
Variation in the load

Drop N > 46 Hz
Time
0 Load shedding due to "LAM"
Time
0 1s 2s 3s
7
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R438
A.V.R.
2.5 - R438 A.V.R. options
- Current transformer for parallel operation

of ....../1A. 5 VA CL 1.
- Remote voltage adjustment potentiometer:

470 Ω, 0.5 W min: adjustment range ± 5%
(range limited by internal voltage potentio-
meter P2). Remove ST4 to connect the po-
ten-tiometer. (A 1 kΩ potentiometer can also
be used to extend the adjustment range).
For wiring up the external potentiometer;

the “earth” wires must be isolated as
well as the potentiometer terminals
(wires at the same voltage as the power).
- R 731 external module: sensing of 3-phase

voltage 200 to 500 V, compatible with parallel
operation. Disconnect ST1 to connect the
module; set the voltage via the module po-
tentiometer.
- R 734 module: detection of 3-phase current

and voltage for parallel operation on unba-
lanced installations (imbalance > 15%).
- R 726 module: 3 functions (mounted exter-

nally).
P.F. regulation (2F) and voltage sensing cir-
cuit before paralleling (3 F).
- Control through DC voltage used monito-

ring apply to the terminals for connection of a
potentiometer DC voltage :
• internal impedance 1,5 kΩ
• ± 0,5V enable a voltage setting of 10%.
8
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R438
A.V.R.
3 - INSTALLATION - COMMISSIONING a) Initial potentiometer settings (see table

3.1 - Electrical checks on the AVR below)
- Remote voltage adjustment potentiometer :
- Check that all connections have been centre (ST4 jumper removed).
made properly as shown in the attached wi-
ring diagram. Action Factory setting Pot.
- Check that the ST3 frequency selection
jumper is on the correct frequency setting. Voltage 400V - 50 Hz
(Input
- Check whether the ST4 jumper or the re- minimum fully anti-clockwise
0 - 380 V) P2
mote adjustment potentiometer have been
connected. Not set
- Optional operating modes. Stability
(centre position)
P3
• ST1 jumper : open to connect the R 731or
Voltage quadrature droop Not set
R 734 3-phase (// operation with C.T.) (fully anti-
sensing module. - 0 quadrature loop fully clockwise) P1
• ST2 jumper : open if rapid response time anti-clockwise.
used Excitation ceiling
• ST5 jumper : open to suppress the LAM Limit of excitation and 10 A
function. short-circuit current, maximum P5
minimum fully anti-clockwise.
3.2 - Settings
Stability adjustments in standalone
operation
b) Install a D.C. analogue voltmeter (needle
dial) cal. 50V on terminals E+, E- and an
A.C. voltmeter cal 300 - 500 or 1000V on the
The machine is tested and set at the fac- alternator output terminals.
tory. When first used with no load, make
sure that the drive speed is correct and c) Make sure that the ST3 jumper is positio-
stable (see the nameplate). After opera- ned on the desired frequency (50 or 60 Hz).
tional testing, replace all access panels
or covers. d) Voltage potentiometer P2 at minimum,
The only possible adjustments to the fully anti-clockwise.
machine should be made on the AVR.
e) Stability potentiometer P3 to around 1/3
of the anti-clockwise limit.
3.2.1 - R438 settings (AREP or PMG
system) f) Start the engine and set its speed to a fre-
quency of 48 Hz for 50 Hz, or 58 for 60 Hz.
WARNING g) Set the output voltage to the desired va-
lue using P2.
Before any intervention on the A.V.R.,
- Rated voltage UN for solo operation (eg.
make sure that the ST9 jumper is closed 400 V)
with AREP excitation and disconnected - Or UN + 2 to 4% for parallel operation with
with PMG or SHUNT or separate excita- C.T. (eg. 410 V)
tion. If the voltage oscillates, use P3 to make ad-
justments (try both directions) observing the
voltage between E+ and E- (approx. 10V
D.C.).
9
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R438
A.V.R.
The best response times are obtained at the 3.2.2 - Max. excitation setting (excitation
limit of the instability. If no stable position ceiling)
can be obtained, try disconnecting or repla-
Depending on
cing the ST2 jumper (normal/fast). Max. excitation the mains frequency
Main
(50/60 Hz supply)
h) Check LAM operation : ST5 closed. ST3

48 V
X2
P5
i) Vary the frequency (speed) around 48 or 50Hz 60Hz Z1
A
58 Hz according to the operating frequency, X1
Z2
and check the change in voltage from that Field
observed previously (~ 15%). P3 R 438 E+ – + ~ 5 ohms
E- A
10 A CC/DC
0V
j) Readjust the speed of the unit to its rated 110 V
no-load value. P2
ST4 220 V
Adjustments in parallel operation 380 V
110/220/380 V D
Before any intervention on the alterna- Voltage

tor, make sure that the speed droop is
identical for all engines. Static adjustment of the current limit,
potentiometer P5 (factory setting: 7.5 A,
k) Preset for parallel operation (with C.T. fuse rating: 8 A - 10 seconds).
connected to S1, S2) The maximum factory setting corresponds
- Potentiometer P1 (quadrature droop) in to that of the excitation current required to
centre position. obtain a 3-phase short-circuit current of
Apply the rated load (cos ϕ = 0.8 inductive).
approximately 3 IN at 50 Hz for industrial
The voltage should drop by 2 to 3%. If it in-
power, unless otherwise specified(*).
creases, check that V and W and also S1
and S2 have not been reversed. A static method can be used to reduce this
value or adapt the Isc to the actual operating
l) The no-load voltages should be identical power (derated machine), which is safer for
for all the alternators intended to run in pa- the alternator and the installation.
rallel. Disconnect power supply wires X1,X2 and
- Couple the machines in parallel. Z1,Z2 and the voltage reference
- By adjusting the speed, try to obtain 0 KW (0‑110V-220V-380V) on the alternator.
power exchange.
- By altering the voltage setting P2 on one of Connect the mains power supply using a
the machines, try to cancel (or minimise) the transformer (200-240V) as indicated
current circulating between the machines. (X1,X2 : 48V). Install a 10A D.C. ammeter
- From now on, do not touch the voltage set- in series with the exciter field. Turn P5 fully
tings. anti-clockwise and activate the power
supply. If there is no output current from the
m) Apply the available load (the setting is only AVR, turn potentiometer P2 (voltage)
correct if a reactive load is available) clockwise until the ammeter indicates a
- By altering the speed, match the kW (or di- stable current. Switch the power supply off,
vide the rated power of the units proportionally) then on again, turn P5 clockwise until the
- By altering the quadrature droop potentiome- required max. current is obtained (no more
ter P1, match or divide the currents. than 8 A).
10
236/242
R438
A.V.R.
Checking the internal protection : The exciter is switched off by disconnecting

Open switch (D) : the excitation current the AVR power supply (1 wire on each auxi-
should increase to its preset ceiling, remain liary winding) - contact rating 16 A - 250V
at that level for ≥ 10 seconds and then drop A.C.
to < 1A. Connection is identical for resetting the AVR
To reset, switch off the power supply by ope- internal protection.
ning switch (A).
Note: After setting the excitation ceiling as
described, adjust the voltage again (see
section 2.1.1)
(*) In some countries it is a legal requirement
to have a short‑circuit current of 3 In, so as
to offer selective protection. In case of using the de-excitation, pro-
vide a forced excitation.
3.2.3 - Special type of use
3.2.3.3 - R438 field forcing
WARNING (400V - 10A) Diode
X2
Excitation circuit E+, E- must not be left Z1 t - +
open when the machine is running : AVR X1 Battery (B Volt)
damage will occur. Z2
E+
3.2.3.1 - R438 field weakening (SHUNT) E-
Exciter field
X2 Forced excitation
Z1 B Volt
X1 t
Z2 Time
E+
E-
Applications B volts Time t
The exciter is switched off by disconnecting
the AVR power supply (1 wire - X1 or X2). Guaranteed voltage build-up 12 (1A) 1-2 s
Contact rating 16 A - 250V A.C. Parallel operation, de-energized 12 (1A) 1-2 s
3.2.3.2 - R438 field weakening (AREP/ Parallel operation, at standstill 12 (1A) 5 - 10 s

PMG) Frequency starting 12 (1A) 5 - 10 s
Sustained voltage on overload 12 (1A) 5 - 10 s

X2
Z1
X1
Z2
E+
E-
11
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R438
A.V.R.

Fault Action Effect Check/Cause
The alternator builds up and its
voltage is still correct when the - Lack of residual magnetism
battery is removed.
Connect a new battery The alternator builds up but its - Check the connection of the voltage
No voltage at of 4 to 12 volts to voltage does not reach the rated reference to the AVR
no load on terminals E- and E+, value when the battery is - Faulty diodes
start-up respecting the polarity, removed. - Armature short-circuit
for 2 to 3 seconds - Faulty AVR
The alternator builds up but its
- Field windings disconnected
voltage disappears when the
- Main field winding open circuit - check the
battery is removed
resistance
Check the AVR connections (AVR may be
faulty)
Correct speed
- Rotating diodes burnt out
Voltage too - Main field winding short-circuited - Check
Check the drive speed
low the resistance

(Do not touch the AVR voltage pot. (P2)
Speed too low
before running at the correct speed.)
Voltage too Adjust AVR voltage
Adjustment ineffective Faulty AVR
high potentiometer
- Check the speed : possibility of cyclic
irregularity
Voltage Adjust AVR stability If no effect : try normal / fast - Loose connections
oscillations potentiometer recovery modes (ST2) - Faulty AVR
- Speed too low when on load (or U/F bend
set too high)
Voltage between E+ and E-
- Check the speed (or U/F bend set too
Voltage SHUNT < 20 V
Run at no load and high)
correct at no AREP / PMG < 10V
check the voltage
load and too - Faulty rotating diodes
between E+ and E- on Voltage between E+ and E-
low when on - Short-circuit in the main field. Check the
the AVR SHUNT > 30V
load (*) resistance
AREP / PMG > 15V
- Faulty exciter armature.
(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the
operating terminals
Check the AVR, the
Voltage - Exciter winding open circuit
surge suppressor, the
disappears The voltage does not return to the - Faulty exciter armature
rotating diodes, and
during rated value. - Faulty AVR
replace any defective
operation (**) - Main field open circuit or short-circuited
components
(**) Caution : Internal protection may be activated (overload, open circuit, short-circuit)
Warning : after operational testing,

replace all access panels or covers.
12
238/242
R438
A.V.R.
4 - SPARE PARTS
4.1 - Designation
Description Type Code
A.V.R. R 438 AEM 110 RE 017

Our technical support service will be happy
to provide any information you require.
When ordering spare parts, you should in

dicate the complete machine type, its serial
number and the information indicated on the
nameplate.
Part numbers should be identified from the

exploded views and their description in
the parts list.
Our extensive network of «service stations»

can dispatch the necessary parts without
delay.
To ensure correct operation and the safety
of our machines, we recommend the use of
original manufacture spare parts.
In the event of failure to comply with this ad
vice, the manufacturer cannot be held res
ponsible for any damage.
13
239/242
R438
NOTES
14
240/242
R438
NOTES
15
241/242
338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 €
www.leroy-somer.com
242/242

User and Maintenance Manual For Generating Sets: Translation of The Original Instructions

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User and Maintenance Manual For Generating Sets: Translation of The Original Instructions

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User and maintenance manual

for generating sets

Translation of the original instructions

Figure 1 : Warning pictograms .................................................................................................................................................................. 5

1.1. General recommendations

The safety pictograms present on the equipment are explained below.

Important, Important, Danger: automatic

Figure 1 : Warning pictograms

Figure 2 : Pictograms indicating prohibited activities

Lifting point Forklift required for Battery charge

Figure 3 : Pictograms indicating compulsory operations

Battery isolating External fuel

Diesel fuel Drain the fuel Inspection flap

Fill the oil Drain the oil

Retention container Drain the retention

Figure 4 : Information pictograms

Figure 5 : Specific pictograms

Rinse any splashes of acid on the skin or

Figure 6 : Pictograms relating to battery operations

1.4.1 General guidelines

Using the equipment

- Before starting any operations on the equipment:

- Information for personnel:

- Protection for individuals and equipment:

- Cleaning the equipment:

- Respecting the environment:

1.4.2 Electrical safety precautions

ELECTRICAL EQUIPMENT - RISK OF ELECTRIC SHOCKS

1.4.4 Safety precautions relating to fire, burns and explosions

FUELS / FLAMMABLE PRODUCTS / PRESSURISED FLUID

Supply gas (concerns generating sets running on gas)

EXHAUST GAS - TOXIC PRODUCTS

Corrosion inhibitor in the coolant (contains alkali)

- Read the instructions on the packaging.

In the event of contact with the eyes:

1. Rinse immediately with plenty of water for at least 15 minutes.

In the event of contact with the skin:

1. Wash thoroughly with water and soap.

Fuels and oils

- Do not swallow it.

If splashes get into the eyes:

1.4.6 Precautions for risks relating to handling phases

HANDLING PHASES - RISK OF DROPPING

1.4.7 Precautions for risks relating to noise

HIGH SOUND LEVEL - RISK OF HEARING LOSS

Figure 7 : General description of the generating set

1 Acces to maintenance area 4 Acces to control unit

Figure 8 : General description of the generating set (Continuation)

1 Protective grille 4 Alternator

Figure 9 : General description of the generating set (control)

1 Control unit 4 Working hours counter

Note : Photo presented with the Nexys control unit.

Weights and Dimensions

Dimensions with high autonomy tank

Sound pressure level at 1 m : 72 dB(A)

Measurement uncertainty : 0.66

1 - Generating set 9 - Maximum ambient temperature for the rated

Figure 10 : Example of a generating set identification plate

Figure 11 : Fluid retention container