Documente Academic
Documente Profesional
Documente Cultură
manual
SDMO
All generating sets
General considerations
Safety instructions
Installation
Special maintenance advice
MUE SD (C_5_EN)
33522903401_5_1
1. Preface........................................................................................................................................................................................3
1.1.
Introduction...................................................................................................................................................................3
1.1.1 General recommendations ............................................................................................................................................3
1.1.2 Description of the reference material............................................................................................................................4
1.2.
Pictograms and their meanings .....................................................................................................................................6
1.3.
Instructions and safety regulations................................................................................................................................7
1.3.1 General advice ..............................................................................................................................................................7
1.3.2 Risks related to feed gas (concerns gas sets) ................................................................................................................8
1.3.3 Risks related to exhaust gases and fuels .......................................................................................................................8
1.3.4 Risks related to toxic products......................................................................................................................................9
1.3.5 Risk of fire, burns and explosion ..................................................................................................................................9
1.3.6 Risks related to electrical networks ............................................................................................................................10
1.3.7 Dangers presented by electric currents (first aid) .......................................................................................................11
1.3.8 Risks related to moving the set...................................................................................................................................11
1.3.9 Recommendation for the operator and environment...................................................................................................11
1.4.
Generating set features................................................................................................................................................13
1.5.
Identifying sets............................................................................................................................................................14
2. Installation................................................................................................................................................................................15
2.1.
Unloading ...................................................................................................................................................................15
2.1.1 Safety during unloading..............................................................................................................................................15
2.1.2 Example of equipment used........................................................................................................................................15
2.1.3 Instructions for unloading...........................................................................................................................................16
2.1.3.1. Slings .............................................................................................................................................................16
2.1.3.2. Fork lift truck.................................................................................................................................................16
2.2.
Handling instructions..................................................................................................................................................17
2.3.
Installation of fixed sets ..............................................................................................................................................19
2.3.1 Position .......................................................................................................................................................................20
2.3.2 Measurements and layout ...........................................................................................................................................20
2.3.2.1. Static requirements ........................................................................................................................................20
2.3.2.2. Dynamic requirements...................................................................................................................................21
2.3.2.3. Construction...................................................................................................................................................21
2.3.2.4. Base of the set................................................................................................................................................21
2.3.2.5. Openings........................................................................................................................................................21
2.3.2.6. Lifting ............................................................................................................................................................22
2.3.2.7. Soundproofing ...............................................................................................................................................22
2.3.2.8. Ventilation .....................................................................................................................................................23
2.3.2.9. Fuel ................................................................................................................................................................24
2.3.2.10.
Burnt gas exhaust : general information....................................................................................................25
2.3.2.11.
Burnt gas exhaust : pipes...........................................................................................................................26
2.3.2.12.
Burnt gas exhaust : expansion bellows and hoses .....................................................................................26
2.3.2.13.
Burnt gas exhaust : condensation and rainwater bleed ..............................................................................26
2.3.2.14.
Burnt gas exhaust : bulkhead crossing - roof outlet ..................................................................................27
2.3.2.15.
Burnt gas exhaust : exhaust outlet .............................................................................................................27
2.3.2.16.
Burnt gas exhaust : suspension line...........................................................................................................27
2.3.2.17.
Burnt gas exhaust : needle frame...............................................................................................................28
2.3.2.18.
Burnt gas exhaust : column base ...............................................................................................................28
2.3.2.19.
Burnt gas exhaust : silencer suspension line .............................................................................................28
2.3.2.20.
Burnt gas exhaust : heat insulation ............................................................................................................28
2.3.2.21.
Burnt gas exhaust : silencers .....................................................................................................................29
2.3.2.22.
Electricity ..................................................................................................................................................30
2.3.2.23.
Cooling......................................................................................................................................................32
2.3.2.24.
Special arrangements.................................................................................................................................32
3. Installation of mobile site sets ..................................................................................................................................................33
3.1.
General information....................................................................................................................................................33
3.2.
Specific arrangements.................................................................................................................................................33
4. Road trailer...............................................................................................................................................................................34
4.1.
Trailer linkage.............................................................................................................................................................34
4.2.
Check before towing...................................................................................................................................................34
4.3.
Driving........................................................................................................................................................................35
4.4.
Unhitching the trailer ..................................................................................................................................................35
4.5.
Implementation for installation...................................................................................................................................35
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1. Preface
1.1.Introduction
1.1.1 General recommendations
Thank you for choosing an electrical generating set from our company.
This manual has been designed to help you operate and maintain your electrical generating set correctly.
The information contained in this manual is taken from technical data available at the time of print. In the intention
of permanently improving the quality of our products, this information may be amended without warning.
We are interested in your comments!
This manual is updated regularly. We are interested in your comments and suggestions as they enable this
document to be made increasingly more useful.
You can contact us with any comments or suggestions at:
- fax: technical documentation department, number: + 00 33 (0)2 98 41 15 55
- by e-mail: doctech@sdmo.com
Read the safety instructions carefully in order to prevent any accident, incident or damage. These instructions must
always be followed.
You are likely to encounter several warning symbols in this manual.
This symbol indicates a definite risk to the health and life of people. Not following this instruction
may seriously affect the health of people or prove fatal.
Danger
This symbol draws attention to the potential risk to the health and life of people. Not following
this instruction may seriously affect the health of people or prove fatal.
Warning
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Contact your local dealer for the available repair manuals and to make the necessary arrangements for training
personnel in implementation and maintenance.
Warning
Some user manuals and maintenance manuals that come with the generating sets have
instrument units and show the starting and stopping procedures for the engines.
For the generating sets fitted with command and control boxes that are specific to the sets, only
the information that appears in the documentation for the sets' boxes should be taken into
consideration.
Based on this and depending on the manufacture criteria for the generating sets, some engines
may be fitted with specific electric cables different from those described in the engine's
documentation.
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Part required.
This part is number 7
the workshop/repair manual which contains information necessary for major maintenance work on a
generating set or power station and which allows an experienced user to carry out a repair after a fault or
damage of some description.
The manual includes: Illustrated text (e.g. labels, notes, procedures, operation time, skills prerequisites) and a
list of tooling.
This reference material is generally written in English regardless of the engine manufacturer.
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Warning danger
Publications
delivered with
the generating set
must be referred
to
Warning, risk of
electric shock
Protective
clothing must be
worn
Entry prohibited
to non-authorised
persons
Warning, toxic
materials
Earth
Warning,
pressurised
liquids
Periodic
maintenance
must be carried
out
Naked flames
and unprotected
lights prohibited.
No smoking
Warning, high
temperature, risk
of burns
Battery level
must be checked
Extinction by
water prohibited
Warning,
rotating or
moving parts
(risk of getting
caught in the
machinery)
Lifting point
required
When on a
trailer, earth the
set before
starting it
Warning,
corrosive product
Stacking point
required
Emergency cutout
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Warning, risk of
explosion
33522903401_5_1
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Read and understand the manuals provided with the generating set in full.
Do not wear loose clothing and do not go near the machines when operating. Note that the fans are not
clearly visible when the engine is running.
Warn all people present to keep well back during operation.
Disconnect the battery and pneumatic starter (if there is one) before carrying out any repair, to prevent the
engine from starting accidentally. Fit a panel over the controls to prevent any attempt at starting.
Do not modify the engine.
Only use the correct techniques for turning the crankshaft to rotate the crankshaft manually. Do not try to
rotate the crankshaft by pulling or exerting force on the lever on the fan. This method can cause serious
physical or material harm or damage the fan blade (s), leading to premature breakdown of the fan.
Always use tools in good condition. Check that you have understood how to use them before starting a
procedure.
Only fit original spare parts.
Use tools that correspond to the work being carried out.
Clean all traces of oil or coolant with a clean cloth.
Never use petrol or other flammable substances to clean parts. Use only approved cleaning solvents.
Do not use a high-pressure cleaner for cleaning the engine and fittings. The radiator, hoses, electrical
components etc. could be damaged.
Avoid accidental contact with parts that reach high temperatures (exhaust manifold, exhaust)
Engage the parking brake when the generating set on its trailer is installed on the operating site.
33522903401_5_1
Request the user technical notes and LPG or NG safety data sheets from your gas supplier.
Gas supply procedures must be carried out in fresh air (outside) in accordance with local regulations, in an
area well away from fire, people or animals.
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Always follow the local regulations in force regarding generating sets and use of fuel (petrol, diesel and
gas) before using your generating set.
Fuel filling should be carried out when the engine is stopped (except for sets with an automatic filling
system)
Engine exhaust gases are toxic: do not operate the generating set in non ventilated areas. When installed in
a ventilated area, the additional requirements for protection against fire and explosions must be observed.
If a burnt gas exhaust leaks, the generating set may become more noisy. In order to be sure of its
efficiency, you should periodically examine the burnt gas exhaust.
Pipes must be replaced as soon as their condition requires it.
33522903401_5_1
Warning
The corrosion inhibitor contains alkali. This Glycol is a toxic product and dangerous if
substance should not come into contact with the absorbed. Avoid any contact with skin or eyes.
eyes. Avoid any prolonged or repeated contact Read the instructions on the packaging.
with skin. It should not be swallowed. In the
event of skin contact, wash thoroughly with
water and soap. In the event of contact with
eyes, rinse immediately with plenty of water for
at least 15 minutes. CALL A DOCTOR
IMMEDIATELY. KEEP THE PRODUCT OUT
OF THE REACH OF CHILDREN.
The anti-rust product is toxic and dangerous if
absorbed. Avoid any contact with skin or eyes.
Read the instructions on the packaging.
Never expose the equipment to liquid splashes or rainfall, and do not place it on wet ground.
Always use the recommended fuels. Using low quality fuels risks damaging the engine and altering
performance
The battery electrolyte is harmful to skin and especially eyes. If splashes get into eyes, rinse immediately
with running water and/or a 10% diluted boric acid solution.
Wear protective eyewear and strong base resistant gloves for handling the electrolyte .
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Beware of creating sparks or flames and do not smoke near batteries as the electrolyte gases are highly
flammable (especially when the battery is being filled). Their acid is also harmful to the skin and
particularly the eyes.
Never clean, lubricate or adjust an engine when it is in operation ( unless you are qualified to do so, in
which case extreme care must be taken to avoid accidents)
Never make adjustments that you are not familiar with.
Never cover the generating set with any material while it is working or just after it stops (wait until the
motor cools down)
Do not touch hot components such as the exhaust pipe and do not put combustible material on them.
Keep all flammable or explosive products (petrol, oil, cloth, etc.) well away when the set is running.
Good ventilation is required for your generating set to work properly. Without ventilation, the engine will
quickly reach an excessive temperature that could lead to accidents or damage to the equipment and
surrounding items.
Do not take off the radiator cap when the engine is hot and the coolant is pressurised due to risk of burns.
33522903401_5_1
Depressurise the air, oil and coolant circuits, before removing or disconnecting any unions, ducts or
connected components. Be aware of any possible pressure that might be present when disconnecting a
device from a pressurised system. Do not look for pressure leaks manually. High pressure oil can cause
physical accidents.
Some preservative oils are flammable. Also, some are dangerous to inhale. Check that ventilation is good.
Use a protective mask.
Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before
carrying out any procedures. Never start or run the engine when the oil filling cap is off as oil may be
ejected.
Never start or run the engine when the oil filling cap is off as oil may be ejected.
Never cover the generating set with a fine layer of oil for anti-rust protection.
Never fill up the oil or coolant when the generating set is running or when the engine is hot.
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The electrical equipment supplied with the generating set complies with standard NF C15.100 or the
standards of the relevant countries
Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency
are shown. Check that these values match the supply use.
Never accidentally touch naked wires or disconnected connections.
Never handle a generating set with wet hands or feet.
Keep electrical wires and connections in good condition. Using equipment in poor condition can lead to
electrocution and damage to equipment.
Operations should only be carried out on the generating set when the installation or the equipment is
switched off.
Electrical connections must be made in accordance with the standards and regulations in force in the
country where the equipment is to be used.
Do not use faulty, poorly insulated or temporarily connected wires.
Do not invert the positive and negative terminals of batteries when connecting them. This could cause
severe damage to the electrical equipment. Follow the wiring diagram supplied by the manufacturer.
The generating set should not be connected to any other power sources, such as the public distribution
network. In specific cases where there is provision for a reserve connection to existing electrical networks,
this must only be carried out by a qualified electrician, who should take the operating differences of the
equipment into account, according to whether the public distribution network or generating set is being
used.
Protection against electric shocks is ensured by an assembly of specific equipment. If the assembly needs
to be replaced, it should be replaced by components with identical nominal values and specifications.
If protection plates (blanking covers) need to be removed for cable routing, the plates must be put back into
place after the work has been carried out.
Due to strict mechanical specifications you should only use flexible resistant rubber sleeved cables or
equivalent wires which comply with CEI 245-4.
33522903401_5_1
Use lifting units to lift the generating set. Always make sure that the lifting equipment is in good condition
and has a sufficient lifting capacity.
In order to work in complete safety and prevent the components fitted to the top of the engine from being
damaged, the engine should be lifted with an adjustable boom. All chains and cables should be parallel to
one another and as perpendicular as possible to the top of the set.
If other equipment fitted to the generating set alters its centre of gravity, special lifting devices may be
required to maintain the correct balance for working in total safety.
Never carry out work on a generating set that is suspended on a lifting device only.
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Operating personnel should be aware of the safety and operating instructions. These will be regularly
updated.
Operating should be monitored, directly or indirectly, by someone designated by the operator who is
familiar with the installation and dangers and problems regarding products stored and used in the
installation.
No-one from outside the establishment should be able to access the installations freely, unless designated
by the operator.
The user should check the service pressures of the different pressure stages, making sure that they are in
accordance with the prescribed operating requirements. The user is also responsible for making the
apparatus adjustments according to the manufacturer's instructions and should check that the apparatus is
operating correctly.
The user should create or obtain a document describing modifications and showing alterations made to the
installations in relation to the original document.
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Written operating instructions must be available for operations that involve dangerous handling procedures
and driving installations. In particular, these instructions prescribe:
9 Operating modes
9 Frequency of testing for safety devices and devices for handling pollution and other harmful substances
generated by the installation
9 Methods for maintenance, checking and use of adjustment equipment and safety devices.
The operator should make the necessary arrangements to satisfy site aesthetic requirements. The whole site
must be kept clean and in good condition.
The premises must be kept clean and cleaned regularly with in order to avoid piles of dangerous or
pollutant material or dust that could be susceptible to catching fire or causing an explosion. The cleaning
equipment must be adapted to accommodate the risks presented by such products and dust.
The presence of dangerous or combustible materials on premises where combustion apparatus is sheltered
is limited to what is required for the operation.
The installations must be operated under the constant supervision of a qualified person. This person should
periodically check that the safety devices are working properly and ensure the correct fuel supply to the
combustion apparatus.
Apart from combustion apparatus, flames in any form are prohibited. This should be displayed in bold on a
sign.
Residual water, mud and waste spray is prohibited.
The fuels to be used should correspond to the ones in the declaration file and the specifications prescribed
by the combustion apparatus manufacturer.
The fuel is considered as being in the physical state that is introduced into the combustion chamber.
Burning waste in the open air is prohibited.
Except for where a specific agreement has been made, once the gas supply main unit has been closed, it
can only be reopened by the gas distributor. However the user may conditionally have access to it. Check
for each site.
Always protect your hands when detecting leaks. Pressurised fluids can enter body tissues and cause severe
harm. Risk of blood poisoning.
Drain and discard engine oil in a designated container (the fuel distributors can collect your used oil).
33522903401_5_1
10
12
1
3
11
9
Figure 1.4.: Main features of a generating set
Console
Control unit
3
4
Circuit breaker
Air filter
7
8
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Radiator
Protective grille for rotating
parts
Alternator
Identification plate
33522903401_5_1
Starter battery
10
Engine
11
12
Chassis
Suspension mounts
1.5.Identifying sets
Generating sets and their components are identified by means of identification plates.
The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's
documents contained in this manual.
Examples of identification plates
Generating set
Engines
Diagram 1.2 : Examples of identification plates
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Alternator
Cabinet
Diagram 1.3 : Examples of identification plates
2. Installation
Sections 3, 4 and 5 contain only general recommendations.
It is recommended that you use a professional to ensure correct installation and start-up.
The company cannot be held responsible for breakdowns related to the conditions of installation.
Warning
2.1.Unloading
2.1.1 Safety during unloading
In order to unload generating sets from their transport mountings, under optimum conditions of safety and
efficiency, you should check that the following points are being followed correctly.
- Suitable lifting vehicles or equipment for the work.
Slings positioned in the rings provided for this procedure or lifting arms resting fully
underneath the frame cross beams.
- Suitable ground to accommodate the load of the set and lifting vehicle, without strain (if not, put down
sufficiently strong and stable boards).
Remove the set as close as possible to its place of use or transport, in a clear space with free access.
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Slings
- attach the lifting vehicle slings to the rings on the generating set designed for this procedure.
- hang the slings carefully.
- check that the slings are correctly attached and the equipment is solid.
- lift the generating set carefully.
- direct and stabilise the set towards the chosen position.
- carefully set down the equipment while continuing to position it.
- release the slings, then detach and remove the lifting rings.
2.1.3.2.
- position the arms of the fork lift under the frame, making sure that only the cross beams are resting on the arms.
- lift and handle the equipment carefully.
- set down the generating set in its unloading position.
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2.2.Handling instructions
- carefully lift the edge on the engine side with 2 jacks then slide 3 pipes under the frame
- leave the frame under the pipes then move the set by pushing manually.
- while the set is being moved, use the freed pipes by sliding them one after another under the frame.
- when it has reached the desired location, position the set then lift it up using jacks to support it.
- remove the pipes and put down the set checking that it is in the correct position, then remove the jacks.
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If you are using a rail or crab once it is in position, continue in the same way as described in the "slings" paragraph
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AIR EMISSIONS
FIREPROOF DOOR
FUEL STORAGE
AIR INLET
ELECTRIC WIRES
SECURING
THE UNIT TO
THE FLOOR
PLATE
EARTH
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2.3.1 Position
It should be determined on the basis of use. There are no specific rules governing the choice of location, other than
proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas
evacuation, and the direction of these gases and the noises emitted should be taken into account.
The choice of its position will be based on carefully considered compromise!
Examples of problems that may be encountered:
Reduced access
2.3.2.1.
Static requirements
These are the dimensions of the equipment installed and its surroundings, namely: daily service fuel tank, cabinet,
silencer, batteries etc.
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2.3.2.2.
Dynamic requirements
2.3.2.3.
Construction
The fire test should comply with current legislation according to the type of building.
Warning
2.3.2.4.
An operating generating set generates a certain amount of vibratory energy. This vibratory energy makes its way to
the floor plate via the frame. As a rule, our generating sets do not require a specific floor plate as they are fitted to
elastic mountings. However, the floor plate will be sufficiently strong and detached from the rest of the
construction. It will also be level, smoothed by the flow and unshackled.
If there is a risk of vibrations being transmitted, the set can be mounted on a vibration-mounted floor plate insulated
if necessary by a resilient material.
This solution is mainly used with very powerful generating sets.
2.3.2.5.
Openings
The room should include a certain number of openings which are required for it to operate:
- a door, giving access to the generating set and its accessories, preferably in line with the set's floor plate
- ventilation openings (fresh air inlet and hot air outlet) located so that scavenging takes place in the direction from
the alternator towards the engine. Their surfaces depend on the power of the generating set being installed,
general atmospheric conditions, the cooling system selected and the soundproofing procedure.
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2.3.2.6.
Lifting
2.3.2.7.
Soundproofing
Sound trap
Silencer
Sound trap
Soundproofed doors
33522903401_5_1
2.3.2.8.
Ventilation
A heat engine generates a certain amount of heat, which must be evacuated outside the room to ensure the set
works properly.
The heat released by the set originate from different sources:
- cylinder cooling
- radiation from the engine unit and exhaust duct
- alternator cooling.
Also the room must be fitted with air inlet and outlet openings suitable for the conditions of use and cooling
system. As you know, insufficient ventilation will cause the atmospheric temperature to rise and lead to problems
ranging from, at least, a loss of engine power to the set stopping altogether.
Air must flow through the set room from alternator engine radiator.
This solution also supplies the quantity of fresh air needed for combustion. The openings should be of ample size.
Air intake and emission will be as direct as possible. The cooling system will be connected to a sealed emission
sleeve or cover to prevent hot air from being recycled. The air inlet and emission openings should not be located
close to one another.
Warning
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Crankcase ventilation
The vapours from the crankcase should preferably be removed outside the room in which the
generating set is located, to prevent these vapours from being deposited on the radiator, causing it
become dirty and thereby reducing its cooling capability.
33522903401_5_1
2.3.2.9.
Fuel
Since the fuel is classed as a "dangerous product", certain regulations for storage and distribution must be followed.
It is also necessary to consult current laws when carrying out the installation.
It is usual to fit fixed installations with a daily service tank and storage tank. These two tanks can be joined into one
if the generating set consumption is low.
Do not used galvanised receptacles or brass coated receptacles for storing fuel.
Warning
Manual filling tank
Solution for a manual starting generating set that is visually monitored. This tank is often part of the frame and has
a mechanical gauge, filler neck and drain port.
Automatic filling tank located in the room
Solution for automatic starting generating sets. The tank is automatically filled by an electric drawing pump in a
main storage tank.
This type of installation is subject to regulations. Moreover, it should be fitted with a retention container capable of
collecting leaks with a capacity at least equal to that of the tank. There must be an overflow pipe going back to the
main tank. Its section should be at least twice that of the supply pipes.
To prevent unpriming, the tank is fitted slightly filled in relation to the diesel engine (except in covered parking
areas).
This tank must also be fitted with a shut-off valve for which the control must be located outside the room.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Fuel supply
Fuel return
Electrical wiring
Mechanical cable
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2.3.2.10.
Studying the evacuation of burnt gases by a generating set should not be seen as a minor detail due to the fact that a
pipe can always be installed, even in the most inaccessible areas. In fact, there are a certain number of constraints
to be considered such as drops in pressure caused by the exhaust, insulation, suspension, noise level and air
pollution. It should be noted that the more complicated a circuit, the more it causes drops in pressure and
consequently, its diameter will be large and heavy and its supports and silencers expensive.
NOTE
Generating sets with a silencer fitted in the enclosure must be fitted with an exhaust compensator. This
compensator or hose will be fitted to the exhaust outlet in the cover.
1
2
3
4
5
6
7
8
9
10
11
12
- exhaust pipes
- elbows
- expansion bellow
- condensation bleed
- bulkhead crossing - roof outlet
- exhaust outlet
- suspension line
- needle frame
- base of column
- silencer suspension
- heat insulation
- silencers
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2.3.2.11.
Figure 1 : Pipes
It is recommended that you use seamless pipes.
However, for weight reasons, rolled steel pipes can
be used. In any event, welded "bars" inside the duct
are to be avoided.
Figure 2: elbows
The elbow should have a minimum curve radius of
2D if possible in a single component. If the elbow is
made of welded steel, check that it includes at least
3 sectors for 90 elbows.
Diagram 2.13 : Pipes and unions
2.3.2.12.
2.3.2.13.
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2.3.2.14.
2.3.2.15.
2.3.2.16.
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2.3.2.17.
2.3.2.18.
2.3.2.19.
2.3.2.20.
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2.3.2.21.
"Adapted" silencer
The "adapted" silencer is fitted directly to the set
or cover. It is an absorption type silencer.
A compensator is fitted between the engine and
exhaust in the covered version'.
Absorption silencer
The gas passes through a sound proof duct made
of acoustic high efficiency absorbent material
protected by a perforated metal sheet.
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2.3.2.22.
Electricity
Drain current
(A)
0 50 metres
1.5 mm2
1.5 mm2
2.5 mm2
2.5 mm2
2.5 mm2
4.0 mm2
4.0 mm2
6.0 mm2
6.0 mm2
Cable lengths
51 100 metres
1.5 mm2
2.5 mm2
4.0 mm2
6.0 mm2
10.0 mm2
10.0 mm2
10.0 mm2
16.0 mm2
16.0 mm2
Table 2.1. cable sizes - 50 Hz
Load in watts
# 10 AWG
(5.27 mm2)
2.5
300
600
1000 ft.
5
600
1200
500 ft.
7.5
900
1800
350 ft.
10
1200
2400
250 ft.
15
1800
3600
150 ft.
20
2400
4800
125 ft.
WARNING: a voltage which is too low can damage the equipment.
AWG: American Wire Gauge.
Table 2.2. cable sizes - 60 Hz
at 120 Volts
at 240 Volts
# 16 AWG
(1.31 mm2)
250 ft.
125 ft.
100 ft.
c) Battery cables
Install the battery or batteries in the immediate vicinity of the electric starter motor. The cables will be connected
directly from the battery terminals to the starter motor terminals.
The first instruction to follow is to check that the polarities of battery and starter motor correspond. Never reverse
the positive and negative battery terminals when fitting them. This could cause severe damage to the electrical
equipment.
The minimum section of the wires is 70 mm2. It varies according to the power of the starter motor but also the
distance between the batteries and the generating set (voltage drops on the line).
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33522903401_5_1
d) Safety guidelines
References: NFC 15-100:2002 - CEI : 60364-5-54
The generating set must be earthed. To do this, use a minimum 25 mm2 stripped copper wire and a 16 mm2
insulated cable, connected to the generating set earth connection and a galvanised steel earthing rod embedded
vertically into the ground.
The resistance value of this earthing rod must correspond with the values indicated in the following table.
Note: use the highest differential setting from the installation as a guideline.
R = Vl
I n
R Earth ()
Vl: 50 V
500 A
500
167
100
50
17
10
5
R Earth ()
Vl: 25 V
> 500
250
83
50
25
8
5
2.5
The V1: 25 V value is required for worksite installations and rearing buildings, for
example.
For example
For a default voltage of 25 V and default current of 30mA:
Nature of ground
Rich arable land, moist compact
ballast
Bare arable land, Bare arable land,
Gravel, Coarse ballast
Bare, stony ground, dry sand,
impermeable rocks
Length of
rod in
metres
1
1
3.6
31/59
33522903401_5_1
2.3.2.23.
Cooling
2.3.2.24.
Special arrangements
Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or
manoeuvring.
The company does not accept any responsibility regarding damage caused by these occurrences.
However, lightning conductors can be installed, on the understanding that this does not give total protection.
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33522903401_5_1
3.2.Specific arrangements
An area will be reserved to install the generating set. Its should be flat and strong enough so that the generator does
not sink into it. It could be made of concrete or even large planks fitted together.
It should be noted that a generating set that does not rest correctly on its base (frame or trailer) will be subject to
vibrations that could cause damage to all the equipment.
The location of the set on site should be chosen for ease of fuel supply and distribution of current to the users.
Access to the set's doors should be available at all times for safety and maintenance reasons.
Ventilation of the generating set should not be affected if there are different objects close by. It will cause abnormal
heating and reduced power.
Burnt gas evacuation will take place in such a way that there is no reaspiration into the air filter or cooling system.
The generating set's neutral speed must be used to protect people.
The generating set will need to be earthed. To do this, use a minimum 25 mm2 stripped copper wire and a 16 mm2
insulated cable, connected to the generating set earth socket and a galvanised steel earthing rod embedded
vertically into the ground.
These sets are to be covered or protected from bad weather by a suitable construction (see previous sections).
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4. Road trailer
4.1.Trailer linkage
Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly.
Warning
Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious
accidents.
Also check:
- no incipient fractures or excessive wear on the hitching system.
- locking system is operating properly.
CORRECT
CORRECT
Tow vehicle
Tow vehicle
Trailer
Trailer
INCORRECT
INCORRECT
Tow vehicle
Tow vehicle
Trailer
33522903401_5_1
Trailer
4.3.Driving
"On-site" type trailer
These trailers are not fitted with a main brake and so cannot brake when operating; the tyres are designed for a
speed of 17 mph (27 Km/h). Therefore, it is absolutely forbidden to exceed this speed .
"Road" type trailer
The driving speed should be adapted to road conditions and the trailer handling.
Driving at sustained speed causes tyres to heat up; therefore it is important to stop from time to time to check them.
Excessive heating can lead to a blow out and hence a serious accident. When reversing, do not forget to lock the
overrun brake.
Warning
Particular attention must be paid to wheel torquing on new vehicles. Indeed, during the first few
miles, heat build-ups on the wheel hubs and brake drums lead to reduced wheel torquing. It is
therefore essential to check the torquing every 6 miles (10 kilometres) until no further loosening is
noted.
The torque test should nevertheless be carried out before towing.
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33522903401_5_1
When the generating set is working in manual start mode, the air evacuation doors must be open
before it starts.
Danger
When the generating set has been started and the doors have remained closed, they are formally
prohibited from being opened (very severe risk of injury owing to sudden opening of doors).
Danger
Warning
Before beginning handling procedures, you must ensure that the operating personnel has the
necessary qualifications. All handling procedures must be carried out under the instruction of one
co-ordinator only.
It is essential to use an adapted lifting vehicle (lifting and travel limit, etc.) fitted with a lifting
beam to ensure that the container is moved correctly.
attach the lifting vehicle slings to the handling rings on the container .
carefully stretch the slings without lifting the container.
check that the sling hooks are correctly attached and the equipment is solid.
lift the container carefully and without jerking
direct and stabilise the container towards its final position.
position the container, while still lifted, in accordance with its final position.
carefully set down the container without jerking while continuing to position it.
once the container is on the ground and in the correct position, release the slings, check that the container is stable
and correct it if not
- detach the slings and remove them from the lifting rings.
- earth the generating set. To do this, use a minimum 25 mm2 stripped copper wire and a 16 mm2 insulated cable,
connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the
ground.
- the procedure has been completed when the container is in position.
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33522903401_5_1
Example of grip by an
ordinary hook
Example of shackle
grip
Example of lifting
37/59
lifting
33522903401_5_1
5.1.2 Transport
The transport of containers should be in accordance with the highway code (for the relevant countries).
The transport equipment (trailer, semi-trailer, container holder, etc.) should be suitable for this use and provide all
safety guarantees in terms of its capacity to support the load and the attachment devices.
Driving should be on roads suitable for vehicles of sufficient quality not to damage the equipment stored inside the
container.
Maritime transport approval (CSC)
Our containers are available in 4 different versions.
Version
CIR 20
EUR 20
ISO 20
ISO 40
CSC approval
YES
NO
X
X
X
X
Our CIR 20 and EUR 20 containers cannot carry additional loads (no stacking).
Warning
38/59
33522903401_5_1
NO
NO
YES
Diagram 5.4 : Positioning containers
39/59
33522903401_5_1
The environmental impact should also be analysed so that the disturbances to be caused by the equipment will not
affect those living close by.
Therefore, it is essential to be aware of the regulations in force, in order not to be vulnerable to future legal action.
On this subject, the sound level of the set and reverberation effects on buildings must be taken into account .
Diagram 5.5 : Examples of increase in sound level caused by reverberations and the sound directivity.
The equipment should also be installed so that the vents controlling the air intake should be opposite so that there
are no difficulties in difficult weather conditions (intake of air, snow, sand etc.).
Remove the blanking piece(s) from the exhaust outlet(s) (used for transporting it) and replace them
with the extension cable(s) supplied with the generating set.
Warning
o
n
5.2.Maintenance
-
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33522903401_5_1
Warning
The inspections referred to in this section enable the electrical generating set to operate.
Specific skills are required to carry out these operations.
They must only be entrusted to personnel with the necessary skills.
Failure to follow these instructions in any way could lead to incidents or very serious
accidents.
Generating sets fitted with MTU engines of the 4000 series : it is essential to dismount the
flywheel blocking device (for protection of the crankshaft during transport) at set commissioning
(before first start-up).
Warning
6.1.Installation checks
check that the general recommendations from the installation section (ventilation, exhaust,
fluids etc.) are followed
check the levels (oil, water, diesel, battery)
ensure the generating set earth socket is earthed
6.2.Connection checks
check the remote controls by section and number (sector, accessories, low voltage central
control panels etc.)
apply voltage to the accessories to check the following components (non comprehensive list) :
fuel pump (consumption and direction of rotation)
water preheating (intensity and voltage)
battery charger
etc.
carry out the mechanical checks (oil pressure, water temperature, absence of noise etc.)
carry out the electrical checks (voltage and frequency)
carry out the safety checks (emergency stop, oil pressure, water temperature etc.)
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33522903401_5_1
7.2.Cover sealing
A seal is used between the cover and the chassis, and between the chassis and the retention cover to ensure
leaktightness. This seal must always be replaced whenever the cover is removed.
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33522903401_5_1
Consequently, using any supercharged engine at low load (< 30%) can only have negative implications for engine
operation and service life. Maintenance will have to be stepped up in order to cope with the severe operating
conditions. Reducing the time between oil changes will allow for oil with a tendency to clog with unburned residue
and to pollute fuel, to be replenished more frequently. The main purpose of attaching a charging bank is to reduce
periods of low load operation and to enable full load to be reached periodically, which is necessary to unclog the
engine.
Finally, when operation is taking place under load we recommend that you pay close attention to the oil venting
system, especially for engines whose sump air vent is located at the turbocharger inlet (risk of oil or oil vapour
uptake and engine racing).
Tests under load:
It is recommended that the generating set be tested every month under load for approximately 1 hour after
conditions have stabilised.
The load should be over 50% (ideally 80%) to ensure the engine is de-coked and to give a reliable indication of the
operation of the generating set.
Off-load test (without load):
This test is not recommended; it should not last longer than 10 minutes and should not be repeated without the
monthly test under load. This test serves only to check that the engine starts correctly. It does not check that the
generating set is operating correctly.
8.1.Specifications
8.1.1 Oil grades
Engine
Make
Cummins
Type
All
John Deere
All
MTU
MITSUBISHI
Perkins
Volvo
43/59
396/2000/4000
183
All
Fuel
Gas
All
Make
SDMO
John Deere
SDMO
SDMO
SDMO
SDMO
SDMO
MOBIL
SDMO
33522903401_5_1
Type
GENLUB TDX 15W40
John Deere PLUS-50
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W40
GENLUB TDX 15W40
PEGASUS 705
GENLUB TDX 15W40
15W-40
0.883
Density at 15C
Cinematic viscosity at 40 C
Cinematic viscosity at 100 C
Viscosity index
Dynamic viscosity at -15 C
Pour point
Flash point
Sulphated ash content
(Values given as examples only)
105
14.1
mm2/s (cSt)
mm2/s (cSt)
140
3000
- 30
220
1.4
mPa.s(cP)
C
C
% weight
Type
All
All
All
MITSUBISHI
All
Perkins
Volvo
All
All
44/59
Make
SDMO
SDMO
SDMO
MITSUBISHI
SDMO
SDMO
SDMO
33522903401_5_1
Type
GENCOOL PC -26C
GENCOOL PC -26C
GENCOOL PC -26C
LLC
GENCOOL PC -26C
GENCOOL PC -26C
GENCOOL PC -26C
GenCOOL PC -26
High-protection coolant, approved by manufacturers.
GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by
the majority of European manufacturers.
y It is made from antifreeze and G 48 inhibitors.
y It protects up to -26C.
y It is free from nitrates, amines and phosphates.
y It is a clear, fluorescent orange liquid.
REFERENCES/APPROVALS (for the antifreeze):
HEAVY GOODS VEHICLE
LIGHTER VEHICLES
Approved by MTU, MERCEDES BENZ, MAN, Approved by BMW, VOLKSWAGEN,
KHD, GENERAL MOTORS
MERCEDES, PORSCHE
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33522903401_5_1
PACKAGING/STORAGE:
y GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings.
y It can be stored for 2 years in its original container and packaging.
y Avoid zinc coated containers.
RECOMMENDATIONS FOR USE:
y Compatible with the original fluid.
y It is recommended that the cooling system is completely drained when replacing the fluid.
SPECIFICATIONS
UNITS
SPECIFIED
VALUES
TRIAL
METHODS
kg/m3
1,059 +/- 3
R 15-602-1
pH
pH
7.5 to 8.5
NF T 78-103
Alkalinity reserve
ml
>=10
NF T 78-101
Boiling point
105 +/- 2
R 15-602-4
Freezing point:
Glassware corrosion :
(test with antifreeze)
-26 +/- 2
NF T 78-102
Density at 20C
mg/test piece
R 15-602-7
- Copper
+/- 2.6
- Weld
+/- 0.5
- Brass
+/- 2.3
- Steel
+/- 1.6
- Cast iron
+/- 0.8
- Cast aluminium
Corrosion on warm plate
(test with antifreeze)
+/- 1.0
46/59
mg/(cmweek)
+/- 0.17
33522903401_5_1
R 15-602-8
TAD 1242
TAD 1640
TAD 1641
TAD 1642
FUEL
(in litres)
EX II
ENCLOSURE
M 227
ENCLOSURE
M 228
ENCLOSURE
M 229
ENCLOSURE
M 230
TAD 1241
LUBRICATION
(in litres)
COOLING
(in litres)
TAD 941
CIRCUIT
AND TANK
CAPACITY
TAD 740
ENGINES
TWD 740
29
29
33
35
35
48
48
48
41,9
36,9
41
44
44
60
60
60
390
390
470
470
470
500
500
610
390
390
470
470
470
500
500
610
47/59
S4L2-SD (srie SL
FUEL
(in litres)
LUBRICATION
(in litres)
COOLING
(in litres)
L3-SDH (srie L)
CIRCUIT
AND TANK
CAPACITY
L3-SD (srie L)
ENGINES
4.1
4.1
4.2
4.2
5.9
5.9
6.5
10
180
230
3,7
3,7
4,2
4,2
4,9
4,9
8,1
8,9
300
345
50
50
50
50
100
100
100
100
ISO 20
500
ISO 40
500
33522903401_5_1
3029DF120
3029TF120
3029TF270
4045DF120
4045DF270
4045HF120
4045HF150
4045TF120
4045TF270
4045TF220
4045TF250
4045HF275
6068HF120
(153kW @ 1500 rpm)
6068HF120
(183 kW @ 1500 rpm)
6068HF150
(187kW @ 1800 rpm)
6068TF220
6068HF475
6068TF250
6068HF150
(210kW @ 1800 rpm)
6068HF275
(187kW @ 1800 rpm)
6081 HF 001
6081HF070
(318kW @ 1800 rpm)
6081HF070
(260kW @ 1800 rpm)
6125HF070
(387 kW @ 1500 rpm)
LUBRICATION
(in litres)
13,5
13,5
13,5
13,5
13,5
13,5
13,5
13,5
13,5
21,5
31,5
21,5
21,5
33
21,5
31,5
33
32
32
32
42
COOLING
(in litres)
16,1
16,1
16,1
18,9
18,9
20,2
20,2
23,6
23,6
23,6
23,6
20,2
25,8
25,8
25,8
27,3
30
27,3
25,8
25,8
40
40
40
43,8
100
100
100
180
180
190
190
180
180
180
180
340
340
340
340
340
340
340
340
340
390
390
390
470
180
180
180
180
180
180
340
340
340
390
390
390
ENGINES
CIRCUIT
AND TANK
CAPACITY
EX
II
ENCLOSURE
M 128
FUEL
(in litres)
ENCLOSURE
190
M 129
ENCLOSURE
M 107
100
100
190
100
ENCLOSURE
340
M 226
ENCLOSURE
M 227
ENCLOSURE
340
340
340
340
340
470
M 228
48/59
340
33522903401_5_1
49/59
33522903401_5_1
12V4000G61
12V4000G81
16V4000G21
16V4000G61
16V4000G81
LUBRICATION
82
82
82
82
82
82
110 110 110 130
(in litres)
COOLANT
180 180 180 212 180 212 261 261 261 268
(in litres)
ISO 20
500 500 500 500 500 500 500 500 500
CIR 20
500 500 500 500 500 500 500 500 500 500
CIR 20 with fuel
2020 2020 2020 2020 2020 2020 2020 2020 2020 2020
FUEL
option
(in litres)
ISO 40
500
EUR 40
CAPOT M 127
930 930 930 930 930 930 930 930 930 930
12V4000G21
18V2000G23
16V2000G83
16V2000G43
16V2000G23
12V2000G83
12V2000G63F
12V2000G63E
12V2000G43
CAPACITY
OF CIRCUITS
AND TANKS
12V2000G23F
ENGINES
12V2000G23E
260
260
260
290
290
290
200
200
200
215
215
215
500
500
500
500
500
500
500
500
500
500
GMC
430
GMC
643
GMC
857
GMC
874 T
GMC
881
GMC
881 T
4.3
4.76
5.24
8.1
8.1
8.1
3.78
6.9
6.9
13.7
20.6
20.6
CIRCUIT
AND TANK
CAPACITY
LUBRICATION
(in litres)
COOLING
(in litres)
FUEL
(in litres)
50/59
2806
E16
TAG2
2806
E18
TAG2
3012
TAG
4006
TAG3
4012
TAG
68
55,5
73.8
113,4
178
105
4012 TAG
200
4012TAG2
231
50
61
122.7
500
610
ENCLOSURE ENCLOSURE
M229
M230
33522903401_5_1
930
ENCLOSURE
M427
Use
EZ 254
HT 254
Hydrocarbons
Max viscosity 300 cst
Composition
Base block
Zamak piston, seat and valves
Steel shaft against mounting clamps and
lugs
O ring
Base block
Brass piston, seat and valves
Steel shaft against mounting clamps and
lugs
O ring
1
2
3
4
5
6
7
8
9
10
Pump body.
Cover.
Lever.
Piston.
Seat.
Lever nut.
O ring
Suction or discharge clamp.
Clamp joint.
Screw with nut for cover or
bracket (to be specified).
11 Piston valve.
12 Seat valve.
13 Valve split pin.
9.1.2 Description
Suction:
Suction capacity is completely independent of the size of the pump.
These pumps can attain 7m to 7.50m of pressure suction with cold water at sea level.
The suction pipes should always face on an upwards slope from the fluid suction pump to the pump installation
point with no top section and with as few bends as possible with a large radius.
For any suction over 2 metres, a foot valve must be installed (suction valve) to hold the fluid in the pipes which
should have no cracks or leaks.
The suction manometric height should not be confused with the vertical distance of the expanse of water to the
pump.
Losses of pressure are inevitable and are related to:
- the length and diameter of the pipes used according to the flow,
- the presence of a non-return valve or elbows in the pipes.
A non-return valve or elbow causes a loss of pressure equivalent to what 5 metres of straight pipes would give.
When there is a certain length of pipework or high suction (or discharge), a larger diameter pipe than usual should
be used.
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33522903401_5_1
Discharge:
The pumps have been tested at a pressure of 1,500 kg to 2 kg and can therefore handle a 15m discharge. However,
the force developed by the person handling the pump, will increase according to the flow and elevation height
(suction + discharge). Therefore with a low flow, the fluid can be raised higher than with a large flow pump.
Draining:
A small tap or bolt, about 0.70m above the pump is indispensable.
Fitting:
The pump should be installed on a strictly vertical plane, with Japy marque on the discharge side. Check that the
mounting has a flat surface and that the nuts are tightened moderately and alternately to prevent distortion of the
body.
33522903401_5_1
In general, when pistons and seats need to be replaced we recommend a standard replacement pump.
To remove the lid and to check inside, begin by unscrewing the 6 bolts that attach the lid to the chamber . Then, to
undo the lid, hit it preferably with a piece of wood, alternately on the discharge and suction manifolds, while
keeping the other hand on the piston rod and the valve gland clamp. Do not carry out these removal procedures
often.
Before refitting, carefully clean the whole of the inside with a cloth, lightly lubricate the internal parts of the
chamber with liquid paraffin, put the piston back in place by pushing down slowly with a semicircular motion.
Check that the suction seat is held in place and that the felt pad is properly positioned.
Put the bolts back in position, retighten the blocks moderately and alternately until the cover is locked down.
53/59
Corresponding dangers
Fire, explosion
Fire, explosion
Pollution of the fluids
Pump corrosion
Damage to linings and joints
33522903401_5_1
9.2.5 Maintenance
The pumps do not require any specific maintenance.
Possible checking for leaks at the joints.
Actions
Check the connections
Take apart the engine pump.
Look for a possible foreign body
Actions
Move the pump nearer to the fluid to be pumped
Clean or replace
Clean the filter
Increase the diameter of the pipes
Clean or replace
Check that they are sealed
Check the pipe connections.
Replace the seals
9.3.2 Composition
The majority of models are equipped with a low level threshold alarm or stop feature to warn operators of a low
supply of oil, a drop in the oil level in the sump and possibly an overflow of oil.
A built-in oil level threshold triggers an alarm or stops the engine to warn the user of a low supply of oil. The
engine still consumes oil.
54/59
33522903401_5_1
9.3.3 Operation
When the oil level falls in the sump, the float moves down and opens a valve.
When the valve opens, oil can flow from the tank into the sump via the regulator.
As the sump fills, the float moves up and eventually closes the valve when the required oil level is reached,
preventing oil from flowing into the sump.
The valve is designed to be able to clean itself and consequently cannot become clogged.
A 3 mm hole in the regulator is wide enough to enable the sump to be filled effectively.
Thumb ValveTM
Oil supply
HIGH
Movement
of float
LOW
9.3.4 Settings
After having fitted the unit as illustrated below, manually fill the engine to the "low" or "add" mark on the oil
gauge, without starting the engine. Position the oil level regulator so that the oil level is in the centre of the front
inspection window. Give the system some time to balance out the oil level between the regulator and the sump
before the sump is finally fixed into position. This level depends on the level of use. Start the engine and wait a
while for the regulator to replenish the measured oil circulating in the sump. When the engine is switched off, the
return of oil from the engine causes the oil level to rise and this can be seen through the front inspection window on
the regulator. This is normal and as soon as the engine is switched on again the oil level will return to the level
required for use previously mentioned.
VENTILATION DUCT
ALUMINIUM MOUNTING BRACKET
SUMP
55/59
33522903401_5_1
9.4.Battery maintenance
9.4.1 General information - Safety
Danger
56/59
33522903401_5_1
9.4.3 Commissioning
- Batteries filled with acid have a density of 1.28 g/ml and are charged.
- In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the
plates. Let the battery rest for 20 minutes.
- Before fitting the battery, stop the engine and any power consumer, clean the terminals and give them a light
coating of grease. When connecting, connect the positive terminal (+) first, and then the negative terminal (-).
9.4.4 Checks
Acid density
1.27
1.25
1.20
1.19
1.13
57/59
Charge status
100%
80%
60%
40%
20%
33522903401_5_1
From 50 % recharge
Risk of sulphation
Unusable
Battery charge
When several batteries are connected together, the following points should be checked:
Are the batteries connected in series ?
Is the voltage chosen exact? 1 x 12 V battery, 3 x 36V batteries
Adjust the charge current to the lowest battery.
The power difference between the batteries must be as low as possible.
Example of charge:
- Battery 12V 60 Ah = charging current 6 A
- Charge status: 50% (acid density 1.21/voltage when idle 12.30V)
- Battery lacks 30 Ah, recharging required
- Charge factor: 1.2
- Ah x 1.2 = 36 Ah to be recharged
- Charging current: 6A around 6 hours charging required.
Recharging is complete when the battery voltage and the acid density stop increasing.
The charging current must always be 1/10th of the nominal capacity of the battery
- The power of the charger must be suitable for the battery to be charged and the charging time available.
- You need to use an automatic charger able to provide a sufficient voltage and charging current, as well as a
compensation voltage to handle spontaneous battery discharge.
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33522903401_5_1
59/59
Probable origin
- Incorrect composition
- Incorrect storage
- Prolonged storage in a damp
place
- Battery overflow during filling
Measures or observations
- Cool
- Charge
- Check the acid density
- Battery empty
- Battery used up or faulty
- Capacity too low
- Battery sulphated
- Incorrect electrical connection
- Incorrect battery wiring
- Cell(s) faulty
- Charge status too low
- Short circuit in the current circuit
- High self-discharge (for example:
through
electrolyte
contamination)
- Sulphation (storage of discharged
battery)
- Incorrect battery part no.
- Too many
repeated
deep
discharges
- Battery stored too long without
charge
- Overload
- Charging voltage too high
- Spark after battery charging
- Short circuit
- Connection or disconnection
during charging
- Internal fault (for example:
interruption) and low electrolyte
level
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