Unitor HPC Extreme 520 Specifications

User and maintenance manual for generating sets R230U 33504078701NE_0_1

1.3. Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in

Maintenance26Coolant. MixtureWARNING! All glycol is hazardous and harmfulto the environment. Do not consume!Glycol is flammable.IMPORTANT! Ethylene gl

27MaintenanceCoolant. Checking and fillingWARNING! Do not open the filler cap when theengine is warm, except in emergencies. Steamor hot fluid could s

Maintenance28Coolant. Draining.The engine must be stopped before draining, andthe filler cap unscrewed.WARNING! Do not open the filler cap when theeng

29MaintenanceCooling system FlushingCooling performance is reduced by deposits in the ra-diator and cooling galleries. The cooling systemshould be flu

Maintenance30Fuel systemOnly use the grades of fuel recommended in the fuel specification below. Always observe the greatest cleanlinessduring re-fuel

31MaintenanceFuel system. VentingThe fuel system must be vented after a filter change,if the fuel tank has been run dry, after a long-termstoppage etc

Maintenance32WARNING! Before any work is done on the electrical system, the engine must be stopped and the currentcut by switching off the main switch

33MaintenanceBattery. MaintenanceWARNING! Fire and explosion hazard. Batteriesmust never be exposed to open flames orsparks.WARNING! Never confuse the

Maintenance34Batteries, chargingWARNING! Explosion risk! Hydrogen is given offwhen batteries are charged. This forms an explo-sive mixture with air. A

35MaintenanceComponent location1. Speed sensor, camshaft2. Speed regulator / Actuator3. Coolant temperature sensor4. Charge pressure sensor, 3 pin*5.

Environment  The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be maintained

Skötsel36Laying upThe engine must be laid up to prevent damage if it is not used for two months or more. It is important that this isdone in the corre

37Fault tracingA number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-tact your Volvo Penta deal

38Diagnostic functionThe diagnostic function monitors and checks thatthe EDC 4 system functions normally.Diagnostic functionThe diagnostic function ha

39During operationIf the diagnostic lamp starts to flash during operation:1. Reduce engine speed to idling.2. Press the diagnostic button (for 1-3 sec

Diagnostic function40Fault codesPID 91, Code 2.2.1 Accelerator pedal sensorReason: Faulty sensor, connector or cable.Reaction: The engine goes into “l

41Fault codesPID 174, Code 2.2.7 Fuel temperature sensorReason: Faulty sensor, connector or cable.Reaction: A fault code is generated.Action:•Check th

Fault codes42PID 174, Code 2.3.7 Warning, fuel temperatureReason: Excessive fuel temperature.Reaction: A fault code is generated. The fault codedisapp

43Fault codesSID 23, Code 2.5.1 Control rod position sensor,differenceReason: Injection pump/actuator has got stuck or isnot connected. Difference bet

Fault codes44SID 252, Code 2.8.1 Parameter programmingReason: Memory faultReaction: The engine is emergency stopped and cannot be re-started until the

45PID 48, Code 2.9.2 Atmospheric pressureReason: Air pressure is outside permissible values.Reaction: A fault code is generated. The fault codedisappe

1.3.3 Risks related to toxic products The corrosion inhibitor contains alkali. Do not swallow it. This substance should not come into contact w

Felkoder46GeneralType designation ... TD420VE TAD420VE TAD620VEDirection of rotation (seen from flywh

Technical data47Type designation ... TAD720VE TAD721VE TAD722VEDirection of rotation, seen from flywheel: ..

48Technical dataTAD732GEAnti- clockwise6108 (4.25”)130 (5.12”)7,15 (436)1218,0:11-5-3-6-2-4201 (273)1)225 (306)1)1280 (944)15001193 (880)1800800 – 950

Technical data49Lubrication systemOilChange volume, including filter change,TD420VE/TAD420VE: ... 10 liter (

50Technical dataFuel systemInjection sequenceTD420VE/TAD420VE/TD520GE/TAD530/531GE/TAD520VE,TAD532GE: ... 1-3-4-2TAD620VE/TD720GE/TAD730/

Technical data51Cooling systemType ... Pressurized, sealedPressure cap, max. op

Notes...

Notes...

Notes...

Please note that this offer is valid for 12 months from the date of deliveryof the engine, after this it is subject to availability.Post or fax this c

1.3.5 Risks related to electrical networks  The electrical equipment supplied with the generating set complies with standard NF C15.100 (France

Notare che la validità dell’offerta è garantita solo per 12 mesi dalla consegna delmotore, dopodiché si procederà fino ad esaurimento scorte.Spedire i

Denk eraan dat de aanbieding geldt tot 12 maanden na levering van demotor, daarna nog slechts indien beschikbaar.Stuur of fax de coupon naar:Document

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7745131 English 06-2007132/209

9.2. Appendix B - Alternator user and maintenance manual 133/209

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User guide and maintenance manual LLEERROOYY SSOOMMEERR AAlltteerrnnaattoorr LLSSAA4466..22 LL66 -- LL99 LLSSAA4466..22 MM33 -- MM55

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2011.01 / h783779349709036512213632332232532015321344482841371198 36451301243133466 177 911203674921537172343100347This manual is to be givento the en

1.4. Identifying sets Generating sets and their components are identified by means of identification plates. The precise rules for identifying ea

2LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -SAFETY MEASURESBefore using your machine for the rst time, it

3LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -CONTENTS1 - RECEIPT ...

4LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -1 - RECEIPT1.1 - Standards and safety measures Our alternator

5LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -2 - TECHNICAL CHARACTERISTICS1.1 - Electrical characteristics

6LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -3 - INSTALLATIONPersonnel undertaking the various operation

7LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -There are 2 possible methods for restoring the above minimum v

8LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -Connection codes Voltage L.L Factory connection L2(V)L3(W)In

9LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -3.3.2 - Terminal connection: 6 wire (not possible with the R 2

10LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -3.3.4 - Connection checksElectrical installations must comply

11LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -4 - SERVICING - MAINTENANCE4.1 - Safety measuresServicing or

Alternator Cabinet Figure 1.4 : Examples of identification plates 13/209

12LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -4.4 - Mechanical defectsFault ActionBearingExcessive tempera

13LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -4.5.1 - Checking the windingYou can check the winding in

14LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -4.6 - Dismantling, reassembly(see sections 5.4.1. & 5.4.2

15LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -- Slide the threaded rod into the shield hole to make it e

16LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -If using a single-bearing or double-bearing machine with th

17LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -4.8 - Table of characteristicsTable of average valuesAlternat

18LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -5 - SPARE PARTS5.1 - First maintenance partsEmergency repair

19LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -5.4 - Exploded view, parts list and tightening torque5.4.1 -

20LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -5.4.2 - LSA 46.2 double-bearing377934970903651221361542851319

21LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -Ref. Qty DescriptionScrewØTorqueN.mRef. Qty DescriptionScrewØ

2. General description 2.1. Description Overview 1 Circuit breakers 2 Control unit 3 External emergency stop

22LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en - Electric Power Generation Division

23LEROY-SOMER2011.01/ hInstallation and maintenanceLSA 46.2 - 4 POLESALTERNATORS3856 en -159/209

LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE338 567 258 RCS ANGOULÊMEwww.leroy-somer.com160/209

This manual is to be given to the end user 4067 en - 2009.05 / bR250A.V.R.Installation and maintenance 4 x holes Ø 5.8 x 50 x 115 mm 140 mm 7

Installation and maintenanceR250A.V.R.2LEROY-SOMER4067 en - 2009.05 / bBefore using your machine for the rst time, it is important to read the

Installation and maintenanceR250A.V.R.4067 en - 2009.05 / bLEROY-SOMER3SUMMARY1 - SUPPLY ...

Installation and maintenanceR250A.V.R.4LEROY-SOMER4067 en - 2009.05 / b1 - SUPPLY1.1 - SHUNT excitation system The SHUNT excitation alternator is

Installation and maintenanceR250A.V.R.4067 en - 2009.05 / bLEROY-SOMER52 - R250 A.V.R. 2.1 - Characteristics- Storage: -55°C; +85°C- Operation: -40°C;

Installation and maintenanceR250A.V.R.6LEROY-SOMER4067 en - 2009.05 / b2.3 - R250 A.V.R. optionPotentiometer for voltage setting, 1000 W / 0,5 W min:

Installation and maintenanceR250A.V.R.4067 en - 2009.05 / bLEROY-SOMER72.5 - Typical effects of the LAM with a diesel engine or without a LAM (U/F onl

8 Circuit breaker 10 Connection termination box 9 Starter battery 11 Chassis Figure 2.1 (continued) : General description of the genera

Installation and maintenanceR250A.V.R.8LEROY-SOMER4067 en - 2009.05 / b3 - INSTALLATION - COMMISSIONING3.1 - Electrical checks on the AVR- Check tha

Installation and maintenanceR250A.V.R.4067 en - 2009.05 / bLEROY-SOMER93.3 - Electrical faultsWarning: after setting-up or trouble-shooting, repl

Installation and maintenanceR250A.V.R.10LEROY-SOMER4067 en - 2009.05 / b4 - SPARE PARTS4.1 - DesignationDescription Type CodeA.V.R. R 250 AEM 110 RE

Installation and maintenanceR250A.V.R.4067 en - 2009.05 / bLEROY-SOMER11171/209

MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE338 567 258 RCS ANGOULÊMES.A. au capital de 62 779 000 ¤www.leroy-somer.com172/209

R 450VOIR NOT ICESE E NOTI CEVOLT. STAB. I EXC STAT.FUSIBLES / FUSES 1k3PH.S1 S250 Hz60 HzEXT FREQSETTING7LAMOFFLAMONONLY FORSPECIALCON

22012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -SAFETY MEASURESBefore using your machine for the rst time, it is important t

2012.03 / eLEROY-SOMER3Installation and maintenanceR 450AVRs 4531 en -CONTENTS1 - GENERAL INFORMATION ...

42012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -1 - GENERAL INFORMATION1.1 - DescriptionThe R450 AVR is supplied in a cas

2012.03 / eLEROY-SOMER5Installation and maintenanceR 450AVRs 4531 en -2 - POWER SUPPLYBoth the SHUNT/AREP & PMG excitation systems are controlled

Sockets ( voltage 208/120V ) 16/209

62012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -2.2 - PMG excitation systemWith PMG excitation, a permanent magnet generator (P

2012.03 / eLEROY-SOMER7Installation and maintenanceR 450AVRs 4531 en -2.3 - SHUNT or separate excitation systemWith SHUNT excitation, the AVR is power

82012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -3 - TECHNICAL CHARACTERISTICS3.1 - Electrical characteristics- maximum power sup

2012.03 / eLEROY-SOMER9Installation and maintenanceR 450AVRs 4531 en -WARNINGThe limitation threshold must be adjustable between 1 and 5.5 A.

102012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -One red LED:- Lights up simultaneously with the green led when the continuous o

2012.03 / eLEROY-SOMER11Installation and maintenanceR 450AVRs 4531 en -3.2.2 - Rotating switch selection: LAM and U/F7LAMOFFLAMONONLY FORSPECIALCONFIG

122012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -3.3 - U/F and LAM function3.3.1 - Frequency variation compared with voltage (wi

2012.03 / eLEROY-SOMER13Installation and maintenanceR 450AVRs 4531 en -3.4.3 - Power3.5 - AVR options - Current transformer for parallel opera-tion of

142012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -4 - INSTALLATION - COMMISSIONING4.1 - Electrical checks on the AVR- Check t

2012.03 / eLEROY-SOMER15Installation and maintenanceR 450AVRs 4531 en -i) Vary the frequency (speed) around 48 or 58 Hz according to the operating fre

2.2. Technical specifications Range / Generating set type RENTAL POWER / R230U Weights and Dimensions Dimensions with standard tank Dimen

162012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en - When the excitation current is set to the rated

2012.03 / eLEROY-SOMER17Installation and maintenanceR 450AVRs 4531 en -4.3 - Electrical faultsFault Action Measurements Check/CauseNo voltage at no l

182012.03 / eLEROY-SOMERInstallation and maintenanceR 450AVRs 4531 en -5 - SPARE PARTS5.1 - DesignationDescription Type CodeVoltage regulator (AVR)R

2012.03 / eLEROY-SOMER19Installation and maintenanceR 450AVRs 4531 en -191/209

www.leroy-somer.com192/209

9.3. Appendix C - Common spare parts R230U Rental Power VOLVO TAD733GE ENGINE Starter relay 330052259 X 1 Radiator cap 31802

GENCOOL x 20 L 330910098 X 1 x 60 L 330910099 x 210 L 330910100 330570107 + 330570108 X 1 330560196 + 3305

9.4. Appendix D - List of John Deere - Volvo and Perkins fault codes SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 28

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 100 100 100 Oil pressure sensor 1 Engine oil pressure ext

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 108 274 108 Barometric pressure sensor Not use with EDC III and

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth de

Fuel Fuel type Diesel Standard fuel tank 340 L High autonomy fuel tank 868 L Lubrication Oil capacity with filter 34 L Min. Oil pressure 2

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 172 172 172 Ambient air temperature sensor Inlet air temperature s

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 282 282 Overspeed output status 3 Overspeed output open/short

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 626 45 Start enable device (intake heater and ether) 3 Star

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 639 247 231 Communication status 2 Bus Off error 9

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 653 3 3 653 Cylinder #3 injector status 0 Injector outsi

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 656 6 6 656 Cylinder #6 injector status 0 Injector outsi

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 1069 Tire size status 2 Tire size error Not possible with

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 1172 Input temperature of the TGV compressor 3 Input voltag

SPN CID SID PID PPID FMI John Deere Volvo Perkins Description Comment 2659 Flow level of the EGR valve 2 Calculated EGR flow

SAE J1939-73 : March 2004 FMI and Description FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL The signal communicating

2.3. Fuel and consumables All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manua

FMI=11—ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not kn

FMI=20-30—RESERVED FOR SAE ASSIGNMENT FMI=31—CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no mo

2.3.1.2. Specifications of coolants Engine Coolants Make Type Make Type John Deere All GenPARTS GENCOOL PC -26°C MITSUBISHI All Mitsubish

RECOMMENDATIONS FOR USE:  Compatible with the original fluid.  It is recommended that the cooling system is completely drained when replacing

3.1.2.2. Fork lift truck  Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets"

Figure 3.3 : Offset fluid retention container underneath the generating set chassis. Figure 3.4 : Offset fluid retention container integrated

3.3. Choice of location It should be determined on the basis of use. There are no specific rules governing the choice of location, other than pr

3.4. Electricity a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NF

d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54 In order to protect personnel against electric shocks, this generati

3.5. Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvr

1. Preface ...

4.3. Operation "On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow fo

4.5. Implementation for installation Operations to be carried out:  Ensure that the ground is strong enough for the assembly not to sink into

Figure 4.3 : Braking transmission Figure 4.4 : Cross bar fitting Figure 4.5 : Tandem bearing fitting 30/209

4.7. Faults and repairs Fault observed Origin SolutionsErratic braking of trailer - Faulty shock absorber Replace the shock absorber Braking

4.8. Electrical connection diagram Figure 4.6 : Electrical connection diagram 4.9. Complete wheels technical information TYRES COMPLETE WHEE

5. Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate. Specific skil

Coolant level, check Do not open the filler cap when the engine is hot, except in an emergency. Boiling liquid or vapour may be ejected. Warnin

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

6.2. Generator set with NEXYS control panel 6.2.1 Control panel presentation Figure 6.1 : View of the front side  Emergency stop button f

Figure 6.2 : Description of the LEDs A lit LED indicates:  Module being supplied (green, lights up and remains lit)  Emergency stop activat

6. Using the generator set ...

6.2.2 Manual starting Check that the generating set circuit breaker has triggered. Danger  Connect the generating set battery.  Turn the key

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 minute

6.2.5 Faults and alarms - Details List of faults which will cause the generating set to stop and generate a pictogram Oil pressure fault: Indic

List of faults which will cause the generating set to stop and generate a fault code Low coolant level fault: indicates that the level of coolan

List of alarms associated with a pictogram Low fuel level alarm: Indicates the need to fill up with fuel. Associated pictogram "Alt

6.3. Generator set with TELYS control panel 6.3.1 Control panel presentation 6.3.1.1. View of the front panel Figure 6.4 : View of the

Figure 6.5 : Description of the LEDs A lit LED indicates: 1 Alarm activated (flashing yellow). 2 Fault found (flashing red). 3 Module on (

6.3.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones.   

6.3.1.3. Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms DisplayActivation conditions "MANU" Mode Fixed TELY

6.3.1.4. Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS i

1. Preface 1.1. General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to

6.3.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised

Generating set started Screen no. Pictograms Data displayed P3 Default screen in operation Fuel Level Indicator Alternator composite Voltage In

Screen no. Pictograms Data displayed P8 Single phase Alternator current indicator Two phase Alternator current indicator Three phase Alternator

6.3.1.6. Display of messages in zone 4 The display (zone 4), among other things, displays messages relating to the operation of the generating se

Generating set stopped Screen no. Screen Data displayed G 3 OPERATION MANUAL Press START to start 24/08/2005 13:12 Operatin

Generating set start-up Screen no. Screen Data displayed G 6 START-UP IN PROGRESS 24/08/2005 13:12 Operating phase - gener

Generating setstop Screen no. Screen Data displayed G 11 OFF IN PROGRESS 24/08/2005 13:16 Generating set stop in progress

6.3.2 Starting Check that the generating set circuit breaker has triggered. Danger  Connect the generating set battery  Turn the key switch

6.3.3 Switching off  Open the circuit breaker  manually OR  by selecting menu 12 "CONTROL LOAD" The following display will disap

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:  th

1.2. Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician&apo

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)

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 s

6.3.4.4. Engine fault codes display Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the

In the event of a fault, the screen will display the following message: FAULT ALARM ENGINE GENERAL 110 18 25/12/2005 15:30 OK=HELP Engine

7. Maintenance schedule 7.1. Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the mainten

8. Battery Fit the battery so that it is properly ventilated. Maintenance should only be carried out by qualified personnel. If replacing the ba

8.2. Battery setting into service  Batteries filled with acid have a density of 1.28 g/ml and are charged.  In the case of dry batteries, fi

8.4. Load preconization  Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard

8.5. Faults and remedies Fault observed Probable origin Measures or observationsThe acid heats up when a new battery is filled - Incorrect comp

9. Appendix 9.1. Appendix A – Engine user and maintenance manual 67/209

WARNING: DANGER This symbol warns of a safety hazard. The presence of this symbol indicates a risk of injury. Observe the safety instructions

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User's guide and maintenance manual VVOOLLVVOO DDIIEESSEELL EENNGGIINNEE TTAADD 773333 33522077701_0_1 69/209

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Generating set and industrial engines4-7 liter (EDC 4)OPERATOR’S MANUALp71/209

Engine dataEngine designation ... Product number ...Serial number ...

1Safety information ... 2Safety rules for operation and maintenance ... 3Introduction ...

2Safety informationIncorrect operation can lead to personal injury and damage to products or property. So read theinstruction book through very carefu

Safety information3Safety rules for operation and maintenanceDaily checksMake it a habit to give the engine and engine bay a vi-sual check before oper

Safety information4Lifting the engineThe existing lugs on the engine should be used for lift-ing. Always check that the lifting devices are in goodcon

Safety information5Cooling systemAvoid opening the coolant filling cap when the engineis hot. Steam or hot coolant can spray out at thesame time as th

WARNING: DANGER  Hot coolant can cause serious burns.  Switch off the engine. Do not remove the filler cap until it is completely cold. 

6IntroductionThis instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrialengine. It contains the

Introduction7Certified enginesIf you own an emission certified engine, which isused in an area where exhaust emissions are regu-lated by law, it is im

8PresentationTD420VE, TAD420VE, TD520GE, TAD530/531GE and TAD520VE are in-line, direct injected, 4-cylinder industrialdiesel engines.TAD620VE, TD720GE

Presentation9TD420VE, TAD420VE, TAD620VETD520GE, TAD530GE, TAD531GE, TAD532GE, TAD520VETD720GE, TAD730/731GE, TAD732/733GETAD720VE, TAD721VE, TAD722VE

Presentation10Identification numbers 1. Engine model 2. Engine specification number 3. Engine series number (10 digits) 4. Engine power, peak, wit

Presentation11EDC 4EDC 4 (Electronic Diesel Control) and is an electronic system with CAN (Controller Area Network) or potentiome-ter communication f

12InstrumentsThe engines are not supplied with instruments andcontrols. The choice of instrument type and controlsis made by the customer.The function

13Starting the engineMake it a habit to check the engine and engine room before starting. This will help you to discover quickly if any-thing abnormal

Starting the engine14Starting in extreme coldCertain preparations must be made to facilitate enginestarting, and in some cases to make starting possib

Starting the engine15Never use start sprayWARNING! Never use start spray or similar prod-ucts as a starting aid. Explosions could occur inthe inlet ma

WARNING: DANGER  A poor earth connection can lead to serious injuries or death.  Always connect the earth terminal of the generating set

16OperationCorrect operation technique is very important for both fuel economy and engine life. Always let the engine warmup to normal operating tempe

17Stopping the engineDuring longer breaks in operation, the engine must be warmed up at least once every fortnight. This prevents cor-rosion damage in

18MAINTENANCE SCHEDULEWARNING! Before you start to do any maintenance work, read the “Maintenance”chapter carefully. This contains instructions for do

Maintenance schedule19Every 50-600 hours or at least every 12 months•Engine oil and oil filter, change 1)...

20MaintenanceThis chapter describes how the specified maintenance points should be done. Read them carefully before startingwork. The times when maint

21MaintenanceDrive belts. Inspection/adjustmentInspection and any adjustment should be done afteroperation, when the belts are hot.Loosen the screws (

Maintenance22Oil change intervals can vary from 40 to 500 hours, depending on oil grade and sulfur content of the fuel. Notethat oil change intervals

23MaintenanceOil level. InspectionMake sure that the oil level is between the MAX andMIN marks.IMPORTANT! In continuous operation, the oil le-vel sho

Maintenance24Oil and oil filters. ChangeAlways follow the recommended oil change intervaland always change the oil filter during oil changes. Onstatio

25MaintenanceCooling systemThe cooling system ensures that the engine operates at the correct temperature. It is a closed circuit system andmust alway