Panda AGT4000 PVMV-N Book.prn · This alternator replaces a separate shipboard generators (constant...

Pan

da_A

GT

4000

_PV

MV

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ook_

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_s00

670

29.1

2.04

Generator type:Panda AGT 4000 PVMV-N

24V/140A - 4kW

Icemaster Fischer Panda

ii

Fischer Panda

FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel gene-rators with especially effective sound-insulation.

Fischer has been one of the leading manufacturers in respect of quality and know-how during this period.

FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series forexample and produced a GFK sound-insulated capsule as early as 1979 and the basis for new generator technology.

The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concentrateon the development of new products. Production was moved to Paderborn.

The amalgamation of the two qualified companies led to the development of a complete new programme within a shortspace of time. The aggregates developed at that time set new technological standards worldwide.

The aggregates became more efficient and powerful than other aggregates in the same nominal performance range,because of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institutesand magazines during the past years. The patented VCS (voltage Control System) means it can meet all demandsincluding motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect ofvoltage stability and starting values A Panda generator, with the same drive motor, produces 15% more effective outputthan the majority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same extent.

The 100% water-cooled Panda Aggregate are currently manufactured in the performance range from 2 to 100 kW invarious versions. Fast running motors are preferred for performances up to approx 30 kW (Nominal speed 3000 rpm).The heavier slow runners are preferred for the higher range. The fast running aggregates have proved themselvesmany times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weightsaving of 50% compared to slow running generators.

In addition to the Panda series, Icemaster also supply the super compact high-tech sound-insulated battery chargingaggregate from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile power.

The new HTG-alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible forthis compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to3500 kW from the main machine).

ICEMASTER GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best ofour knowledge. No liability is accepted for correctness. Technical modifications for improving the product without pre-vious notice may be undertaken without notice. Before installation, it must be ensured that the Pictures, diagrams andrelated material are applicable to the aggregate supplied. Enquiries must be made in case o doubt.

since 1972Established in theMarine technology

since 1978Fischer Marine

Generators

since 1988Conclusion Fischer -

Icemaster GmbH

since 1988100 % water cooled Pan-

da generators

since 1988Panda Vehicle Genera-

tors

30 20 10 10 10

iii

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,

birth defects, and other reproductive harm.

Attention, Important Directions regarding Operation!

1. The installation certificate must be completed when taken into use, and certified by a signature.

2. The installation certificate must be despatched within two weeks of use to ICEMASTER.

3. The official guaranty confirmation will be completed by ICEMASTER after receipt and sent to the customer.

4. A guaranty must be shown to make any claims.

Claims against the guaranty will not be accepted of the above said instructions are not, or only partially, carried out.

Manufacturer declaration in terms of the machine guideline 98/37/EG .

The generator is in such a way developed that all assembly groups correspond to the CE guidelines. If machine gui-deline 98/37/EG is applicable, then it is forbidden to bring the generator into operation until it has been determinedthat the system into which the generator is to be installed in also corresponds to the regulations of the machine gui-deline 98/37/EG. This concerns among other things the exhaust system, cooling system and the electrical installa-tion.

The evaluation of the "protection against contact" can only be accomplished in connection with the respectivesystem. Likewise among other things responsibility for correct electrical connections, a safe ground wire connection,foreign body and humidity protection, protection against humidity due to excessive condensation as well as the over-heating through appropriate and inappropriate use in its installed state on the respective machine lies within theresponsibility of those who undertake installation of the generator in the system.

Use the advantages of the customer registration:

• Thus you receive to extended product informations, which are sometimes safety-relevant

• you receive, if necessarily free Upgrades

Far advantages:

By your full information Fischer Panda technicians can give you fast assistance, since 90% of the disturbances resultfrom errors in the periphery.

Problems due to errors in the installation can be recognized in the apron.

Technical Support by Internet: [email protected]

iv

Safety Instructions

The electrical Installations may only be carried out be trained and

tested personnel!

The generator may not be taken into use with the cover removed.

The rotating parts (belt-pulley, belts, etc) must be so covered and protected do that there is no danger to life andbody!If a sound insulation covering must be produced at the place of installation, then well-placed signs must show thatthe generator can only be switched on with a closed capsule.All servicing-, maintenance or repair work may only carried out, when the motor is not running.

Electrical voltages above 48 volts ( battery chargers greater than 36 volts) are always dangerous to life). The rules ofthe respective regional authority must be adhered to. Only an electrician may carry out installation of the electricalconnections for safety reasons.

General safety references for the enterprise of a AGT generator.

With all energized systems, with which the current is more than 50 Ampère, special safety precautions must bemade, in order to protect the environment of the components against fire.

It is to be ensured absolutely that at the battery a main switch in well accessible place is accommodated, so that withdanger of the main switches can be separated immediately. The main switch must be however also directly at thebattery installed. If this place is not well accessible, a power relay must be used instead of the main switch which canbe served manually, which can be served then if necessary from different places. The switches for the power relayare to mark accordingly as main switches DC battery "with danger switch off!".

Cooling of the diode block.

The diode block is cooled with fresh water. A normal cooling of the diode block is therefore only possible, as long asthe cooling water supply of the generator functions duly. The cooling water supply of the generator must be so furnis-hed therefore that by a wide dirt deflector it is guaranteed that from outside no dirt can be sucked in into the linesystem. If this is not attainable, the supply must be secured by a flow switch or a negative pressure switch. Thegenerator must be switched off, if the cooling water supply is impair.

The temperature safety device on the diode block can be regarded only as additional safety device. The temperaturerise at the diodes is so fast that the diodes can be damaged during a unique interruption of the cooling water supply.A safe protection from damage of the diodes is not possible by the temperature monitoring on the diode radiator box.Thus this can take place only by means of an appropriate external monitoring of the cooling system.

ATTENTION!

Do not connect the minus pole of the starter battery to the ground of the boat because of galvanic reason.

Warning!

Never start the generator with the battery disconnected, the diodes will be damaged!

CAUTION!

Contact of the electrical contacts may be DANGER TO LIVE!

v

CAUTION!

The AGT-generator is not allowed to be connected to an inverter (without batteries)!

The Inverter generates voltage peaks, which can destroy the rectifier diodes of the generator!

A battery must always be connected to the inverter as a capacity!

Recommended capacity at 12V ≥ 240Ah at 24V ≥ 120Ah

The screws at the electric rectifier may be pulled tight only with a torque wrench. Torque 4Nm.

The battery cable must be secured at the generator and at the batteries with appropriate safety devices.

The generator is also include into the CO2 - fire-extinguishing system.

vi

Measures to the fire protection.

All construction units in the environment of energized parts, which carry more than 50 Amp., must be fire protection-moderately secured.

All junction points at the energized parts must be examined regularly on heating up (infrared thermometers).

Safety Instrictions for the Handling with Batteries

These instructions must be noticed additionally to the instructions of the battery manufacturer:

• If the batteries are working, someone should be in your near area to help you in a case of emergency.

• Water and soap must be hold ready if battery acid corrode your skin.

• Wear eye protection and protective clothing. During working with the batteries don´t touch the eyes.

• If you got a acid splash on your skin or clothing grow it with much water and soap out.

• If you got acid in your eyes rinse them immediately with clear water until no cauterization is noticeable. Visit imme-diate a doctor.

• Don´t smoke in the near of the batteries. Avoid naked flames or open fires. In the area of batteries exists danger of explosions.

• Pay attention that no tools fall on the battery poles, if necessary cover them.

• During the installation don´t wear a wrist watch or arm jewels, you can create under these circumstances a battery short-circuit. Burning of the skin could be the result.

• Protect every battery contact against unintentional touch.

• Use only cyclical profoundly dischargeable batteries. Starter batteries are not appropriate. Lead-gel batteries are commended. They are maintenance-free, profoundly dischargeable and not produce gas.

• Do not charge a frozen battery.

• Avoid a batterie short-curcuit.

• Take care of a good ventilation of the battery to drain off developing gas.

• The battery connection terminals must be checked of a tight contact at least before operating.

• The battery connection cable must be carefully mounted and checked about incorrect heating at operation with load. The vibrating devices must be regulary checked about scour points and flaw in the isolation.

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Table of contents - Page 1

A The Panda Generator .........................................................................................................3

A.1 Description of the Generator ................................................................................................ 3A.1.1 Front View ................................................................................................................................. 3A.1.2 Back View.................................................................................................................................. 4A.1.3 View from Above ....................................................................................................................... 5A.1.4 Right side View.......................................................................................................................... 6A.1.5 Left side View ............................................................................................................................ 7A.1.6 Radiator View ............................................................................................................................ 8

A.2 Details of functional units .................................................................................................... 9A.2.1 Remote control panel ................................................................................................................ 9A.2.2 Components of the cooling system ......................................................................................... 10A.2.3 Components of the fuel system............................................................................................... 17A.2.4 Components of the combustion air.......................................................................................... 19A.2.5 Componenta if the electrical system ....................................................................................... 21A.2.6 Sensors and switches for operating surveillance .................................................................... 24A.2.7 Components of the lubircation system .................................................................................... 27A.2.8 External components............................................................................................................... 29

B Generator Gebrauchsanweisung ...................................................................................31

B.1 Safety instructions .............................................................................................................. 31

B.2 Generator operation instruction ........................................................................................ 31B.2.1 Daily routine checks before starting ........................................................................................ 31B.2.2 Starting - Preliminary remarks................................................................................................. 32B.2.3 Overloading of engine during longer operation ....................................................................... 33B.2.4 Starting the Generator ............................................................................................................. 33B.2.5 Stopping the Generator ........................................................................................................... 34B.2.6 Operating control system on the Panda Generator ................................................................. 34

C Maintenance Instructions ................................................................................................37

C.1 Maintenance Requirements ................................................................................................ 37C.1.1 Checks before every start ....................................................................................................... 37C.1.2 Hose elements and rubber formed component in the sound cover......................................... 37

C.2 Intervalle für den Ölwechsel ............................................................................................... 37

C.3 De-aerating of the cooling water circuit ............................................................................ 40

C.4 De-aerating the fuel system ............................................................................................... 41

C.5 Exchange the air filter ......................................................................................................... 43

C.6 Additional maintenance ...................................................................................................... 43

D Generator Failure .............................................................................................................47

D.1 Overloading the Generator ................................................................................................. 47

D.2 Adjusting the nominal charge current .............................................................................. 47D.2.1 Lubrication of the spiral thread spindle.................................................................................... 48D.2.2 Effects of a overload to the actuator........................................................................................ 49D.2.3 Low Generator-Output Voltage ............................................................................................... 51

D.3 Testing Generator Stator Windings ................................................................................... 52D.3.1 Testing Generator Stator Winding for "Shorts" to Ground....................................................... 52D.3.2 Coil Resistance Measurements in Stator Windings ................................................................ 53D.3.3 Measuring the Coil Inductive Resistance ................................................................................ 54

Page 2 Panda AGT-DC 4000 PVMV-N s00670 - Table of contents 29.12.04

D.4 Starting Problems ................................................................................................................55D.4.1 VCS does not work................................................................................................................. 55D.4.2 De-aerating the fuel system.................................................................................................... 56D.4.3 Fuel Solenoid Valve................................................................................................................ 57

D.5 Troubleshooting Table ........................................................................................................57

E Installation Instructions .................................................................................................. 59

E.1 Generator Connections .......................................................................................................59E.1.1 General Instructions ............................................................................................................... 59E.1.2 Connections............................................................................................................................ 59E.1.3 Fuel System Installation ......................................................................................................... 60E.1.4 Connection of the starter battery ............................................................................................ 62E.1.5 Installation electronic components ......................................................................................... 63

E.2 Voltage Control System ......................................................................................................64

E.3 The battery monitor .............................................................................................................65E.3.1 Adjustments............................................................................................................................ 65E.3.2 Installation of the remote control panel................................................................................... 67E.3.3 Remote control panel for AGT-Generators............................................................................. 67

E.4 Cooling system ....................................................................................................................72E.4.1 Connection of the external radiator ........................................................................................ 72

E.5 Exhaust installation .............................................................................................................75

F Appendix ............................................................................................................................. I

F.1 Maintenance intervals ............................................................................................................ I

F.2 Operating resources ............................................................................................................. IIF.2.1 Engine oil specification ............................................................................................................. IIF.2.2 Coolant specification ............................................................................................................... III

F.3 Troubleshooting .................................................................................................................. IV

F.4 Technical data engine ......................................................................................................... IX

F.5 Technical data generator .................................................................................................... IX

F.6 Measurements ..................................................................................................................... XI

The Panda Generator

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 3

A. The Panda Generator

A.1 Description of the Generator

A.1.1 Front View

13

01 02 06

14 15

03 04 05 07 08 09 10 11 12

16 17 18

01. Water-cooled pre-silencer02. Ventilation screw on the pre-silencer03. Air suction socket04. Air suction housing with air filter insert05. Protection resistor for thermo-switch 75°C/70°C06. Starter motor07. Adjusting nut08. Oil pressure switch09. Electrical fuses (white=25A; blue=15A; 2x red=10A)

10. Starter relay Ks11. Pre-glow relay Kp12. Cooling water pump relay Kf213. Fuel pump relay Kf14. Fuel solenoid valve15. Engine oil filler16. Oil dipstick17. Actuator for speed regulation18. Passage for oil drain hose

The Panda Generator

Page 4 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04

A.1.2 Back View

10 12

03

1817

050201 04 08

09 13 14 1615

06

11

07

01. Cooling waterpump02. Cooling water connection block for diode block03. Generator housing with coil04. Generator front cover05. Bracket for silencer06. Cooling water hose07. Compensator under heat isolation08. Water-cooled pre-silencer09. Cable for DC/DC converter

10. Socket for remote control panel11. Drive shaft12. Socket for external VCS13. Fuel OUT14. Fuel IN15. Thermo-switch at exhaust manifold 98°C/83°C16. Water-cooled exhaust manifold17. Cooling water back-flow18. Exhaust output

The Panda Generator


A.1.3 View from Above

03

17

0201

11

12

13

15

060504 0807 09 10

18 19 20 21 22

1416

01. Water-cooled pre-silencer02. Exhaust output03. Compensator under heat isolation04. Cooling water hose05. Water-cooled exhaust manifold06. Thermo-switch at exhaust manifold 98°C/83°C07. Ventilation vlave on the exhaust manifold08. Generator front cover09. Generator housing with coil10. Cooling waterpump11. Thermo-switch 75°C/70°C

12. Thermo-switch 82°C/77°C13. Thermo-switch 98°C/83°C14. Thermo-switch at engine 98°C/83°C15. Ventilation screw engine16. Schottky diode under protection cover17. Ventilation screw on the silencer18. Air suction socket19. Air suction housing with air filter insert20. Protection resistor for thermo-switch 75°C/70°C21. Starter motor22. Terminal block

The Panda Generator


A.1.4 Right side View

01 02 03

06 0807 09

04 05

01. Terminal block02. Schottky diode under protection cover03. Cooling water pump04. Earth switch relay05. Engine Kubota EA 300

06. Connection cooling water flow to the radiator07. Connection cooling water flow from radiator08. Cable for fan09. Non-return valve

The Panda Generator


A.1.5 Left side View

0201 03

04

01. Water-cooled pre-silencer02. Starter motor

03. Ventilation screw on the pre-silencer04. Exhaust output

The Panda Generator


A.1.6 Radiator View

03

02

01 04

05

06

01. Connection for cooling water overflow02. Fan03. Connection cooling water in-flow (cold side)

04. Cooling water filler05. Radiator06. Connection cooling water back-flow (hot side)

The Panda Generator


A.2 Details of functional units

A.2.1 Remote control panel

The remote control panel is necessary for the controlling of the genset and for the interpretationthe engine/generator monitoring. In the case of deviation of the operational data from the desiredvalues the generator is switched off automatically. The operation of the generator without remotecontrol panel is not permissible.

Fig. A.1: Remote control panel

Automatic Start Option

An automatic start option is available as an accessory. This includes a separate control board,which is connected to the main remote control board panel. The Automatic Start Option allowsthe generator to be started by means of an external signal (i.e Battery Monitor). A speed gaugeand a sensor for speed pick-up are additionally necessary in addition to the automatic startoption.

01

06

02 03 04 05

07

01) Display operating hours02) Control light for engine temperature03) Control light for oil pressure04) Control light for battery charge voltage

05) Control light for operating status06) Generator „Start“-button07) Panel „Stand by“-button

The Panda Generator


A.2.2 Components of the cooling system

Cooling water filler neck

Fig. A.2: Cooling water filler neck

Output of radiator

The cooling water (cold side) flows fromhere to the generator.

Fig. A.3: Output of radiator

Cooling water in-flow

This connection is connected with theexternal radiator. From here the cold coo-ling water flows into the cooling water-pump.

Fig. A.4: Cooling water in-flow

The Panda Generator


Cooling waterpump

The cooling water is conducted by thewaterpumpe into the diode block.

Fig. A.5: Cooling water pump

Cooling water pipe into diode block

The diode block is cooled with coolingwater.

Fig. A.6: Cooling water pipe

Cooling water pipe

After the cooling water flows through thediode block it is conducted into theengine.


The Panda Generator


Engine input

Fig. A.8: Engine input

Ventilation screw engine

The ventilation screw on the engine maynot be opened, while the generator runs. Ifthis happens inadvertently, by the openingair is sucked in. A very complex ventilationof the entire system is necessary thereaf-ter.

Fig. A.9: Ventilation screw

Bypass for preheating unit

Fig. A.10: Bypass

The Panda Generator


Preheat pump

Fig. A.11: Preheat pump

Inlet into engine

Fig. A.12: Inlet into engine

Water-cooled exhaust manifold

The exhaust manifold is cooled by thewater withdrawing from the engine.

Fig. A.13: Water-cooled exhaust manifold

The Panda Generator


Ventilation valve exhaust manifold

The ventilation valve on the housing of theexhaust manifold may not be opened,while the generator runs. If this happensinadvertently, by the opening air is suckedin. A very complex ventilation of the entiresystem is necessary thereafter.

Fig. A.14: Ventilation valve exhaust manifold

Cooling water pipe

Cooling water pipe from the water-cooledexhaust manifold to the water-cooled pre-silencer.

Fig. A.15: Coolng water pipe

Water-cooled pre-silencer

Fig. A.16: Water-cooled pre-silencer

The Panda Generator


Ventilation screw pre-silencer

Die Entlüftungsschraube am wasserge-kühlten Vorschalldämpfer wird bei Erstbe-füllung oder nach Reperaturarbeitenbenutzt.

Fig. A.17: Ventilation screw pre-silencer

Rücklauf externer Kühler

From here the heated up cooling waterflows into the radiator.

Fig. A.18: Cooling water back-flow

Cooling water pipe


The Panda Generator


Input into radiator

Fig. A.20: Input into radiator

Cooling water overflow

Fig. A.21: Cooling water overflow

The Panda Generator


A.2.3 Components of the fuel system

External fuel pump

Fig. A.22: External fuel pump

Fuel connections

1. Fuel IN

2. Fuel OUT

Fig. A.23: Fuel connections

Fuel solenoid valve

The fuel solenoid valve opens automati-cally if „START“ is pressed on the remotecontrol panel“. The solenoid closes, if thegenerator is switched to „OFF“ position. Ittakes a few seconds before the generatorstops. If the generator does not start ordoes not run smoothly (i.e. stutters), ordoes not attain full speed, then the causeis fore-mostly the solenoid.

1) Fuel solenoid valve2) Magnetic coil

Fig. A.24: Fuel solenoid valve

1

2

2

1

The Panda Generator


Injection nozzle

Fig. A.25: Injection nozzle

Glow plug

The glow plug heats up the pre-chamber.

Fig. A.26: Glow plug

Additionnal glow plugs

Glow plugs for cooling water preheatingunit.

Fig. A.27: Glow plugs

The Panda Generator


A.2.4 Components of the combustion air

Combustion air intake at sound cover

The sound cover is provided at the uppersurface with drillings, through which thecombustion air can influx.

It must be consistently paid attention thatthe generator is installed in such a waythat from no water can arrive into the pro-ximity of these air openings.

Fig. A.28: Combustion air intake

Air suction housing

Remove the cover to look inside the hou-sing. There is a filter element. This mustbe checked from timt to time.

Fig. A.29: Air suction housing

Air filter insert

The figure shows the air filter element inthe air suction housing. A check is advi-sable once in a while.

Fig. A.30: Air filter insert

The Panda Generator


ater-cooled exhaust manifold

After the combustion air was led throughthe engine it occurs into the water-cooledexhaust manifold.

Fig. A.31: Water-cooled exhaust manifold

Compensator under heat isolation

This part is because of the internal con-struction elastic and comensates vibrati-ons.

Fig. A.32: Compensator under heat isolation

Exhaust output

Connect the exhaust pipe with thesilencer.

Fig. A.33: Exhaust output

The Panda Generator


A.2.5 Componenta if the electrical system

Main connection

1. Pasage for battery plus cable

2. Pasage for battery minus cable

Fig. A.34: Main connections

Electrical connection for control

1. Remote control panel

2. VCS

Fig. A.35: Electrical connections

Cable for DC/DC converter

1. Cable for DC/DC converter

Fig. A.36: Cable for DC/DC converter

1 2

1 2

1

The Panda Generator


Cable for Radiator fan

1. Cable for radiator fan

Fig. A.37: Cable for radiator fan

Starter motor

1. Starter motor and

2. Solenoid switch

The Diesel engine is electrically started.On the top of the engine is accordingly theelectrical starter with the solenoid switch.

Fig. A.38: Starter motor

Actuator for speed regulation

The generator voltage is determined byprogressive speed control through "VCS"in conjunction with the speed actuator.Speed increases with increasing load.

Fig. A.39: Actuator

1

1

2

The Panda Generator


Diode block

1. Schottky diode

2. Schottky diode

3. Schottky diode

4. Main connection plus

5. Main connection minus

6. Shunt for VCS-regulation

Fig. A.40: Diode block

DC/DC converter

24V/12V

Fig. A.41: DC/DC converter

Earth-switch relay

Fig. A.42: Earth-switch relay

1

5

32

4

6

The Panda Generator


A.2.6 Sensors and switches for operating surveillance

Thermo-switch at engine

The thermo-switch at the engine is usedfor monitoring the engine temperature.

98°C/83°C

Fig. A.43: Thermo-switch at engine

Thermo-switch at exhaust manifold

98°C/83°C

Fig. A.44: Thermo-switch at exhaust manifold

Thermo-switch at pre-silencer

The cooling water have here the hotestvalue. The cooling water flows from hereback to the radiator.

1. 98°C/83°C

2. 82°C/77°C (fan fast)

3. 75°C/70°C (fan slow)

Fig. A.45: Thermo-switch at pre-silencer

1 32

The Panda Generator


Protection resistor

This protection resistor is connected inseries with the thermo-switch 75°C/70°C.

Fig. A.46: Protection resistor

Thermo-switch coil

01. Thermo-switch 125°C

02. Generator housing

03. Thermo- sensor NTC 981S

(for measuring)

Fig. A.47: Thermo-switch coil

Oil presuure switch engine

In order to be able to monitore the lubrica-ting oil system, an oil pressure switch isbuilt into the system.

Fig. A.48: Oil pressure switch

1

2

3

The Panda Generator


Thermo-switch on the (+)-bar

Fig. A.49: Thermo-switch of the (+)-bar

Thermo-switch on the (-)-bar

Fig. A.50: Thermo-switch on the (-)-bar

Terminal block for remote control panel, fuses and relays

Ks relay for starter motor

Kp relay for plw plug

Kh relay for cooling water preheat unit

Kf relay for fuel pump and water pump

Fig. A.51: Terminal block - relays

Ks Kp Kh Kf

The Panda Generator


Terminal block for remote control panel, fuses and relays

F1 fuse 10A for DC

F2 fuse 15A for cooling water preheat unit

F3 fuse 10A for AC

F4 fuse 25A for starter motor

Fig. A.52: Terminal block - fuses

A.2.7 Components of the lubircation system

Oil filler neck with cap

Please pay attention tht the filler necksare always well locked after filling inengine oil.

Consider also the references to theengine oil specification.

Fig. A.53: Oil filler neck

Oil dipstick

At the dipstick the permissible level is indi-cated by the markings "maximum" andminimum". The engine oil should be neverfilled up beyond the maximum conditions.

Fig. A.54: Oil dipstick

F4 F2 F3 F1

The Panda Generator


Oil strainer

The oil strainer should be cleaned every500 operating hours.

Fig. A.55: Oil strainer

Oil drain hose

The Panda generator is equipped that theengine oil can be drained over an drainhose. The generator should be alwaysinstalled therefore that a collecting basincan be set up deeply enough. If this is notpossible, an electrical oil drain pump mustbe installed.

Note: Lubricating oil should be drained in the warm condition!

Fig. A.56: Oil drain hose

The Panda Generator


A.2.8 External components

VCS

The voltaget is regulated by the VCS inconnection with the actuator. The drivingpoints serve only as security for the factthat on disturbances of the VCS the upperand lower point cannot be exceeded.

For the automatic start of the "AGT" gene-rator a battery monitor is necessary.

The figure shows the control box in thatthe VCS and the battery monitors areinstalled.

Fig. A.57: VCS

Remote control panell

The remote control panel is necessary forthe controlling of the aggregate and forthe evaluation of the engine/generatormonitoring. In the case of deviation of theoperational data from the desired valuesthe generator is switched off automati-cally. The operation of the generator wit-hout remote control panel is notpermissible.

Fig. A.58: Remotr control panel

Electrical fuel pump

The Panda generator is always suppliedwith an external, electrical (12 V of DC)fuel pump. The fuel pump must be alwaysinstalled in the proximity of the tank. Theelectrical connections with the lead plan-ned for it are before-installed at the gene-rator. Since the suction height and thesupply pressure are limited, it can besometimes possible that for reinforcementa second pump must be installed.

Fig. A.59: External fuel pump

The Panda Generator


Generator Gebrauchsanweisung

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter B: Generator Gebrauchsanweisung Page 31

B. Generator Gebrauchsanweisung

B.1 Safety instructions

Do not run the generator with an open capsule!

There are dangerous rotating machine components which could cause injury.

All servicing, maintenance and repair work must be carried out with the generator switched off.

High Voltage DANGER !

The genset output voltages can be lethal.

Ensure that all electrical installations comply with all required regulations of the regional authori-ties.

The electrical installation should only be maintained by a qualified technician.

The battery must be always clamped (first minus then positive terminal), if work on the generatoror on the electrical system of the generator is made, so that the generator cannot be started unin-tentionally.

B.2 Generator operation instruction

B.2.1 Daily routine checks before starting

1. Check engine oil level and top up to MAX.

LOW OIL PRESSURE WARNING LIGHT!The generator switches off automatically in the case of insufficient oil-pressure. Do not run the generator with theoil at the lowest level in the crankcase. (A smaller volume of oil will become contaminated considerably quickerthan a larger volume and there is the possibility that small air bubbles will get in the oil.) Therefore daily oil-checksare required. The oil-level should always be refilled to MAX. Check oil level prior to starting motor or at least 5minutes after the motor has stopped.

Engine oil should have properties of API classification CF grade or higher. Change the type ofengine oil according to the ambient temperature. See Table F.2.1, “Engine oil specification,” onPage II. For Oil-Quantities see Table F.4, “Technical data engine,” on Page IX.

2. Check engine cooling system: coolant level in radiator, all hoses and hose connections forleaks or deterioration.

3. Check thermal switches and all cables and terminal connections

a.Thermo-switch pre-silencer

b.Thermo-switch engine

c.Thermo-switch exhaust

d.Oil pressure switch

4. Check tightness of all retaining and connection bolts on the engine & generator and generatorbase mount bolts.

5. Switch main battery switch "ON" (if installed).

6. Open fuel inlet valve (if installed).


Page 32 Panda AGT-DC 4000 PVMV-N s00670 - Chapter B: Generator Gebrauchsanweisung 29.12.04

B.2.2 Starting - Preliminary remarks

Damage to Starter Motor

The starter is fitted with a free rotating spring cog, which prevents the starter being driven exter-nally by means of the motor. The free wheel will be damaged, if the starter still operated while theengine is running and in some circumstances it could lead to complete destruction of the starter.

It is important that every person who operates the generator is aware of this situation.This is the only operating error that can lead to generator failure and possibly operatorinjury.

Pre-heating the diesel motor

The motor must be pre-heated, if the diesel motor is designed as a "pre-combustion chambermotor" for indirect fuel injection. A quick glow fitting is used for all Kubota-diesel motors. This glowfitting may only be used for a maximum of 20 seconds without a pause. A pre-glow period of 5 - 6seconds suffices for ambient temperatures above 20°C (plus). For lower temperatures thepreglow period should be increased.

The motor can be started for temperatures up to minus 20°C, as long as running conditions aresuitable. The fuel must be suitable for such conditions, as conventional diesel fuel can produce aparaffin coating at temperatures lower than minus 8°C. so blocking all filters and pipes. It is nor-mal in Europe to use an additive, obtainable from gas stations to ensure use at temperatures aslow as minus 15°C. If a generator is to be used for temperatures below minus 8°C, then it must beensured the fuel is suitable for winter. By use of extra additive, the fuel can also be used at lowertemperatures. The appropriate regulations can be obtained from the fuel suppliers. The mineraloil trade have stocks of fuel, which are suitable for use for temperatures below minus 20°C.

Starter Battery

Adequate batteries are installed for extreme winter conditions. Unless the generator is being runfrequently for extended (over 1 hour) periods, it is recommended that the starter battery is regu-larly charged by a suitable external battery-charging device, at least every 2 months. A correctlycharged battery is essential for low temperature starts.

Motor Oil Quality during extreme Winter Conditions

Motor oil of the correct grade for the temperatures anticipated should be used. There is adviceelsewhere in this handbook on the grades which are suitable for various environmental conditi-ons.



B.2.3 Overloading of engine during longer operation

Please ensure that the genset is not overloaded. Overloading occurs when the electrical load(demand) induces a load torque in the generator which is higher than that which the diesel drivemotor can provide. Overloading causes the engine to run rough, burn oil, creates excessiveexhaust (environmentally unfriendly) and even to stall. Extra caution should be practised withmulti-power units (single and 3-phase current generation) to avoid overloading the diesel driveengine.

The generator should only be loaded at the peak rated power for short periods only! A high peakcurrent is required to start many electrical devices, especially electric motors and compressors(from a still stand state).

The height of the rated output (P) can taken from the identification plate attached on the engine.

In order to guarantee a long life span, the continuous load should not exceed 80% of the nominalload. By continuous output we understand the continuous operation of the generator over manyhours. It is harmless for the engine to supply for 2-3 hours the full rated output.

The total conception of the Panda generator guarantees that the continuous load operation doesnot release superelevated temperatures of the engine also with extreme conditions. It is to beconsidered that the exhaust gas values in the full load operation become more unfavorable (sootformation).

B.2.4 Starting the Generator

1. If necessary, open the fuel valve..

2. If necessary, close the main battery switch.

3. Check if all the load have been switched off.

The load is switched off, before the generator is switched off. The generator is not to be started with load connec-ted. If necessary, the main switch or fuse should be switched off or the load should be individually switched off.

4. Press „ON“ button.

If an automatic start is requested during the switching on process, the generator is started and the panel switchesto automatic mode; if there is no automatic start request, the panel switches to delay mode.

5. Press „START“ button.

Press the "START"-button for a short period. The generator is started automatically. As soon as the motor turnsover, the starter switches off automatically. It must be monitored every time it is started. The generator must beimmediately switched off if the starter is still audible after the engine revs up.The "START"-button fulfills several functions in the different operation modes of the panel:If the panel is in delay mode, the generator is started and the panel switches to manual mode, that means theautomatic stop functions are not carried out. If the "AGT"-generator is started manually, it must be stoped manually,too. In this case there is no automatic stop!In the manual mode, the generator continues to run and the panel switches to automatic mode, that means if thelast automatic start programm is dispensed with, the generator is stopped and the panel switches to delay mode; ifthere is no automatic start programm, the generator is stopped and the panel switches to delay mode.

6. Check coolant flow.

Immediately after starting it must be checked whether sufficient coolant flows out at the exhaust.

7. Check with voltmeter if electrical voltage is in the range of tolerance.

8. Switch on load.



B.2.5 Stopping the Generator

1. Switch off load.

2. If the running load has been higher than 70% of the nominal load, then generator temperatureshould be stabilised by running the generator for at least 5 minutes after switching off the load.

At higher ambient temperatures (more than 25°C) the generator should always be run for at least 5 minutes wit-hout load, before it is switched off, regardless of the load.

3. Press „ON/OFF“ button and switch off the generator.

4. Activate additonal switches (Battery switch, fuel stop valve etc.).

B.2.6 Operating control system on the Panda Generator

Panda generators are equipped with various sensors. One of these sensors is to stop excitationshould a short circuit occur. The combustion engine is further equipped with a oil pressure controlswitch, which switches the motor off, if the oil pressure sinks to a particular level. Apart from this,all generators are equipped with four temperature switches.

The thermo-switches are placed at the following locations:

1. Thermo-switch at exhaust elbow

2. Thermo-switch at engine

3. Thermo-switch at pre-silencer

4. Thermo-switch coil

5. Oil pressure switch

Thermo-switch at exhaust manifold

98°C/83°C

Fig. B.1: Thermo-switch at exhaust manifold



Thermo-switch at engine

The thermo-switch at the engine is usedfor monitoring the engine temperature.

98°C/83°C

Fig. B.2: Thermo-switch at engine

Thermo-switch at pre-silencer

The cooling water have here the hotestvalue. The cooling water flows from hereback to the radiator.

1. 98°C/83°C

2. 82°C/77°C (fan fast)

3. 75°C/70°C (fan slow)

Fig. B.3: Thermo-switch at pre-silencer

Thermo-switch coil

01. Thermo-switch 2x130°C

02. Generator housing

03. Thermo- sensor NTC 981S

(for measuring)

Fig. B.4: Thermo-switch coil

1 32

1

2

3



Oil presuure switch engine

In order to be able to monitore the lubrica-ting oil system, an oil pressure switch isbuilt into the system.

Fig. B.5: Oil pressure switch

Maintenance Instructions

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter C: Maintenance Instructions Page 37

C. Maintenance Instructions

C.1 Maintenance Requirements

C.1.1 Checks before every start

• Oil level

• Cooling system leaks

• Visual check for any changes, leaks oil drain system, v-belt, cable connections, hose clips, airfilter, fuel lines

Once a month

• Lubrication of actuator-trapezoid thread spindle

For maintenance intervales see Table F.1, “Maintenance intervals,” on Page I.

C.1.2 Hose elements and rubber formed component in the sound cover

Check all hoses and hose connections for good condition. The rubber hoses are very sensitiveenviromental influences. They can season fast with dry air, in which environment of muted oil andfuel steams and increased temperature. The hoses must be checked regularly for elasticity.There are operating situations, at which the hoses must be renewed once in the year.

Additionally to usual tasks of maintenance (oil level check, oil filter control etc.) further mainte-nance activities are to be accomplished for marine aggregates.

C.2 Intervalle für den Ölwechsel

The first oil change is to be accomplished after a period of operation from 35 to 50 hours. After-wards the oil is to be changed after 100 hours. For this the oil SAE30 for temperatures over 20°Cand SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5°C oilof the viscosity SAE10W or 10W-30 is prescribed.

Type and amount of required oil:

see Table F.2.1, “Engine oil specification,” on Page II,

see Table F.4, “Technical data engine,” on Page IX.


Page 38 Panda AGT-DC 4000 PVMV-N s00670 - Chapter C: Maintenance Instructions 29.12.04

Oil drain hose

For the oil change an oil drain hose mustbe lead through the sound cover. Openthe sound cover passage and pull out thedrain hose.

Oil drain screw

The oil can be drained by opening the oildrain screw. For countering use a secondwrench.

Oil drain pump

If draining of the oil is not possible, werecommend the employment of a handpump, which can be attached to the oildrain hose.

Afterwards the oil drain screw is closedagain.

17



Oil strainer

The oil strainer must be cleaned every500 opeatiing hours.

Open the oil filler neck

After opening the cap of the oil filler neckthe new oil is refilled.

Please wait instant, before measure theoil level, the oil must set off in the sump.

Oil dipstick

With the help of the engine oil dipstick theoil level is to examined. The prescribed fil-ling level may not exceed the „Max“ mar-king.

We recommend 2/3 oil level.

17



C.3 De-aerating of the cooling water circuit

Special notes for the ventilation of the cooling system

If the cooling water is drained or if other air should have arrived into the cooling system, it isnecessary to de-aerate the cooling system. This de-aerate procedure must be repeated severaltimes:

ATTENTION ! Before opening the de-aerating points the generator must be stagnant !!!

Open the ventilation screw on the engine.

Open the ventilation screw on the water-cooled silencer.

Pour in coolant through the cooling waterfiller cap. The coolant flows in very slow.

If it is to be recognized that the coolingwater level does not sag any longer (withcold cooling water the cooling water levelmust cover the sheet metal in the exhaustelbow union), close the ventilation screwsand start the generator.

Run the generator to maximally 60.

Switch off generator.

10

10



Open cooling water filler cap and ventilation screws again.

Pour in cooling water again.

Repeat this procedure several times.

The generator can be started for 5 minutes, if there is no change. De-aerating must be thenrepeated two or three times.

To be sure that the coolant circulates it is very important that the hose pipe away from the gensetalso gets warm. After a short time the radiator and the reverse-flow pipe from the radiator to thegenset also get warm.

Please wait until the temperatures raise more and check if the fan will activate.

It makes sense to, once again, repeat the de-aerating procedure after a few days, in order ensurethat remaining air bubbles have been finally removed.

C.4 De-aerating the fuel system

Normally, the fuel system is designed to bleed out air itself i.e. as soon as the electric startermotor starts operation the fuel pump starts working and th

e fuel system will be de-aerated after some time automatically. It is nevertheless essential tobleed the system as follows prior to the first operation (as all hoses are empty):

1. Put a container under the fuel returnpipe to catch running out fuel to catch.

2. Take off the plug at the solenoid of the starter motor.



3.Switch the panel „ON“.

4. Press „START“-button. The fuel pump runs audible.

5.Switch the panel „OFF“.

6.Switch the panel „ON“.

7.Press again the „START“-button.

This procedure must be repeatedseveral times, until fuel (nonporously)withdraws perfectly at the fuel returnpipe.

8.Switch the panel „OFF“.

9.Attach the plug at the solenoid of the starter motor.



C.5 Exchange the air filter

Open the air suctin housing by loosen thesix hexagon head screws on the framecover.

Remove the cover.

Change the air filter mat and close thecover again.

Subsequently, close the cover againfirmly.

C.6 Additional maintenance

Furthermore in addition to the standards checks according to the manual following points of thegenerator have to be checked:

• automatic shut down of the generator in case off high heating temperature This shall be done bydisconnecting the thermo-switch of the heat sink. Next to the rectifier you will find a 2-pole con-nector. If you disconnect this connector from the opposite socket, the generator shall shutdown– or, when the generator is not running you will get a signal on the panel.

8



Temperatures of the rectifier and heating

• Apply a thermocouple meter to the heat sink and the copper bars and monitor the maximum tem-peratures of the rectifier.

• With the help of the infrared thermometer you can check all the temperatures on the rectifier.Check all the cable connections of the DC- wiring. The easiest is to touch them carefully withyour finger. If they are getting warm or getting hot, these connections are poor and shall be re-placed.

The temperature of the heat sink shall never exceed 95°C.

The temperature of the copper bars shall never exceed 120°C



Ensure, that a fuse next to the battery is installed in the battery line for the generator output cable.

Ensure that a battery switch is installed in the battery line. Never leave the generator behind wit-hout the cover mounted over the heat sink and capsule not closed.

Remind the customer

• to run the generator only with closed capsule.

• not to run the generator unattended

• to ask for regular service

SicherungFuse

Batterie-TrennschalterBattery switch

SicherungFuse



Generator Failure

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter D: Generator Failure Page 47

D. Generator Failure

D.1 Overloading the Generator

Please ensure that the genset is not overloaded. An overload in the long term can harm theengine. In addition the exhaust gases are soot-blackened (environment).

The full rated output of the generator is intended primarily for brief use. It is however needed, inorder to start electric motors or make special approach procedures possible.

As continuous load should be calculated in the interest of a long life span of the engine80% of the nominal load.

You should consider this when switching on the devices on. This calculation serves a long lifespan of the engine. By continuous power we understand the continuous operation of the genera-tor over many hours. It is harmless for the engine to supply occasionally over 2-3 hours the fullrated power. The total conception of the Panda generator guarantees that the continuous loadoperation does not release superelevated temperatures of the engine also with extreme conditi-ons. In addition, it is to be considered that the exhaust gas values in the full load enterprisebecome more unfavorable (soot formation).

Effects of Short Circuiting and Overloading on the Generator

The generator cannot be damaged by short circuiting or overloading. Short circuiting and over-loading suppress the magnetic excitation of the generator, thus, no current is generated and thevoltage will collapse. This condition is immediately offset once the short-circuit has been elimina-ted and/or the electrical overload removed.

D.2 Adjusting the nominal charge current

ATTENTION! Before working on the system read the section “Safety Instructions” onPage iv.

These adjustments may not be changed, they are sealed. The adjustments should be changedexpires the warranty.

The adjustments of the nominal charging current is made at the actuator. By the nuts on the leftand on the right at the spindle of the actuator the adjustment is limited.

The generator must be started and loaaded with the nominal dates. The engine adjusts the speedregulator lever after a short time in such a way that the generator supplies appropriate nominaldates. The adjusting nuts must be fixed to this point. This delimitation serves for the protection ofthe generator, so that it is not overloaded.

Generator Failure

Page 48 Panda AGT-DC 4000 PVMV-N s00670 - Chapter D: Generator Failure 29.12.04

01. Actuator

02. Spiral thread spindle

03. Adjusting nuts for min. speed

04. Spindle nut with speed regulator lever

05. Adjusting nuts for max. speed

This adjustment may not be changed,since otherwise the warranty expires.

During any operation at the generator all load have to be switched off to avoid damages at thequipments.

D.2.1 Lubrication of the spiral thread spindle

The spiral thread spindle must be lubricated carefully and regularly. Please only use a temperaturindependence lubricant (up to 100°C) witch is also equiped with "emergency run qualities".Spread also lubricant to the end of the nuts.

It is possible that the spindle could clamp if the spindle is not enough lubricated. Then the genera-tor can be switched off by over- or undervoltage.

All screws at the actuator and the spindle must be ensured "solveable" with a screw safetygrease.

01. Actuator

02. Spiral thread spindle

05 04 03 02 01

0102

Generator Failure


D.2.2 Effects of a overload to the actuator

If the generator is overloaded the voltage falls on account of a not adequate motor power underthe nominal value. The actuator stays at the upper keystroke and tries to rev up the diesel engine.An internal regulation limits the current to the actuator, nevertheless a longer overload candamage the winding of the actuator. (short of the winding). The motor gets not strictly inoperativebut it can happen that the cranking torque of the actuator is getting weak. This has the consecu-ence that the rev spindle can not be turned to all positions faultless. Therefore the voltage of thegenerator is regulated not good or sometimes not at all.

If you notice that the spindle of the actuator doesn´t run faultless, first check if the aggregate wasoverloaded for a short time and if thereby the winding of the actuator was damaged. Then theactuator has to be changed.

Check the electrical fuse (miniature slow-to-blow fuse 1,6A) on the control printed circuit board ifthe actuator will not turn at all.

Change this fuse (1,6A slow to blow)

The generator can’t be damaged by an overload because the winding is overload- and short-cir-cuit safety. But damages are possible in the periphery. Especially connected consumers areendangered because a lower voltage can damage them by order.

Possible disturbances in the area of the rev regulation "VCS"

Failure Cause

The spindle of the actuator jams • not regularly lubricated.

• surface is mechanical damaged.

• actuator is defect.

• defect of the VCS control (short of winding).

• signal DC missing.

• limiting nut jams the spindle.

Fuse on the printed circuit board of theVCS control is melted.

• constant overload of the generator.

Generator Failure


Steps to check the voltage control by a disturbance:

1. Switch off all electrical load.

2. Disconnect the plug of the actuator.

3. Turn the actuator with the hand to examine whether the adjusting nut is jammed at the limitingstops.

4. Turn the actuator up with the hand to examine whether the adjusting nut on the spindle runsperfectly. The spindle has a clockwise rotating thread, to the assistance take a spannerSW14.

If there is no result by these steps the actuator is working mechanically correct. After this theelectrical components must be checked:

1. Connect the plug of the actuator.

2. Start the generator.

3. Turn the actuator by hand and check if the spindle turns back by the motor.

4. If the motor react on the turn by manual strongly (the motor can normally hold with the fingers)the drive will be working faultless. If there are nevertheless faults in the voltage control there isa fault in the control VCS.

If the actuator is not moving the following points are necessary:

1. 1. The motor turns not strongly rather weak:

• The actuator has shorts in the winding and must be changed. (pay attention that the generatoris not overloaded anymore.)

2. 2. The actuator does not move but the spindle can be turned manually.

• Disconnect the plug of the actuator. Connect provisional an external voltage source 12V-DC tothe motor. The actuator don’t turns with the external voltage source. The actuator is defect andhave to be changed.

Actuator does not turn The actuator is defect and have to be changed.

the actuator turns und worksfaultless

1. Check the fuse on the VCS printed circuit board.

2. Check if the sense voltage is wired to the VCS printed circuitboard.

3. Check if the VCS supply voltage is wired to the VCS.

4. Check if the VCS outlet signal for the actuator is wired.

Change the VCS printed circiut board if the points above carries no clearance.

Generator Failure


Checking the limitation of the generator voltage

The mechanical voltage limitation must be checked regularly. The following steps have to bedone:

1. Disconnect the plug of the actuator.

Lower suspension point:

2. Switch off all load.

3. Connect an electrical ammeter.


5. Turn the actuator manually to the lower suspension point.

6. Charge current must be <10 A, at U=UNenn.

Upper suspension point:

7. Connect the load.

8. Turn the actuator by hand gradually the insertable load up to the upper susoension point.Charge current must not lay over 140A, at U=UNenn

9. If deviations are determined, a new adjustment is necessary.

D.2.3 Low Generator-Output Voltage


Panda generators are designed such that even high electrical variations will not cause seriousdamage to the generator.

If the generator does not produce any voltage while the engine is running, the suspected causelies outside the generator capsule.

• electrical load not switched off prior to start

• short circuit somewhere in electrical system

• electrical overload

Generator Failure


D.3 Testing Generator Stator Windings


D.3.1 Testing Generator Stator Winding for "Shorts" to Ground

The generator stator windings can be tested as follows:

1. Ensure that the generator is "OFF" and cannot be accidentally started. Disconnect the battery.

2. Remove the cover of the power treminal box.

3. All terminal box connections are to be removed. (See appropriate circuit diagram.)

4. Remove all cables.

5. A check of the power terminal box is made by means of a multimeter to determine whetherthere is continuity between the individual windings connections.

If continuity is detected for any of the combinations, the generator must be sent to the factory forinspection and repair. If this is not possible, the stator can be rewound by a qualified tradesper-son/technician. Winding diagrams can be obtained from ICEMASTER GmbH, Germany.

This test, unfortunately, is carried out at very low voltage (9V) when a normal multimeter is used.Therefore only positive short circuits will be displayed. There is the possibility that a short circuitwill occur in spite of a negative test result (i.e. moisture). A reliable check can only be carried byusing an essentially higher voltage (approx 500V). This type of measuring instrument is normallyonly used by experts.

If in doubt an electrician must check the winding for a short circuit with an isolation meter.

Diode block at the Panda Generator

Generator Failure


Wiring diagram

D.3.2 Coil Resistance Measurements in Stator Windings

If the testing set determined no earthing, the coil windings of the generator must be controlledwith a resistance measuring instrument (ohm meter). To measure coil resistance a meter capableof measuring low resistances (Milli-Ohm resolution if possible) accurately. The measured resi-stance values should be close to the same between the following terminals:

U1-U2, V1-V2, W1-W2

Checking windings.

• Disconnect all connections from the power terminal box. Loose the nuts and deduct the cables.

• Remove all winding connections from the power terminal box.

• Switch your meter in resistance range. When you put the probes of you meter together, youshould get a reading of 0.00Ohm. When you isolate the probes, the reading will be Overflow.Please do this tests to check your meter.

• Measure of the resistance within the individual windings. The values should be very small. Itmainly depends on the relation between the values. Some measuring instruments operate veryinaccurately, if the measured values are very small.

• Resistance measure between different windings. If the value is in the Giga ohm area, the coilis correct.

If you find any anormality, when doing this test, please ask your Fischer Panda dealer.

If strong deviations are measured in the individual coil windings, there is a coil short-cut in onecoil. No voltage is induced.

The actual values between the coil windings are not determined so exactly. It depends on the factthat the values of all three measurements are as alike as possible. Deviations among themselvesrefer to a coil short-cut. In this case the generator must be newly wound by a specialist.

Generator Failure


D.3.3 Measuring the Coil Inductive Resistance

Unfortunately the checking of the ohmic resistance permits still no reliable statement about thecondition of the coil. If the ohmic resistance values arise inequalities between the coils, that is asafe indication for the fact that the coil is defective. To be exactly sure the inductive resistance ofthe coil have to be measured. For this a special measuring instrument is necessary, which mea-sures the inductance of a coil.

Inductance is measured in the same way as the ohmic resistance, i.e. the coils are compared.The value is indicated in mH (milli Henry).

Note: These values depends strongly from the measuring method (kind of the measuringinstrument).

An alternative test method to check the stator windings can be performed as follows:

1. Ensure that the connection to the circuit system is disconnected.

2. All electrical wires in the power terminal box must be disconnected.

3. Reconnect the battery connections.


5. Measure the voltages between the following terminals and compare for symmetry:

U1-U2, V1-V2, W1-W2

Generator Failure


D.4 Starting Problems

D.4.1 VCS does not work

For start problems one chief cause is that the VCS doen not work. Check:

Is the voltage sense connecttion ok?Check polatrity!

Is the shunt connection ok? Check pola-trity!

Is the main supply connection ok? Checkpolatrity!

Does DP+ (VCS ON) lie on clamp 6 of theplug with 6 pins?

Generator Failure


Checking the fuse on the VCS printed cir-cuit board.

D.4.2 De-aerating the fuel system

Normally, the fuel system is designed to bleed out air itself i.e. as soon as the electric startermotor starts operation the fuel pump starts working and the fuel system will be de-aerated aftersome time automatically. It is nevertheless essential to bleed the system as follows prior to thefirst operation (as all hoses are empty):

1. Put a container under the fuel return pipe to catch running out fuel to catch.

2. Take off the plug at the solenoid of the starter motor.

3. Switch the panel „ON“.

4. Press „START“-button. The fuel pump runs audible.

5. Switch the panel „OFF“.

6. Switch the panel „ON“.

7. Press again the „START“-button.

This procedure must be repeated several times, until fuel (nonporously) withdraws per-fectly at the fuel return pipe.

8. Switch the panel „OFF“.

9. Attach the plug at the solenoid of the starter motor.

Generator Failure


D.4.3 Fuel Solenoid Valve

For start problems the possibility of an error exists with the solenoid for engine stop or fuel sole-noid valve, which both effect affect simultaneous on the fuel system.

The fuel solenoid valve is located in front of the injection pump. It opens automatically, if the"START"-button is pressed on the remote control panel. The solenoid valve is CLOSED when thegenerator main power is switched "OFF". For this reason, it requires a few seconds before themotor comes to a full halt.

If the generator fails to start, runs rough, does not reach the proper RPM, or does not stop pro-perly, the first item to suspect in most cases is the fuel solenoid valve and should be inspectedfirst.

A check of the fuel solenoid valve by removing the plug from the fuel solenoid valve for a shortperiod whilst in operation (first remove the small retention screw) and replace it immediately. Themotor should "react immediately" by revving high.If the motor does not react sharply to the recon-nection of the solenoid wire, it is a sign that the solenoid valve could be faulty.

Fuel solenoid valve

D.5 Troubleshooting Table

For troubleshooting see Table F.3, “Troubleshooting,” on Page IV.

Generator Failure


Installation Instructions

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter E: Installation Instructions Page 59

E. Installation Instructions

E.1 Generator Connections

ATTENTION! Before working on the System read the “Safety Instructions” on Page iv

E.1.1 General Instructions

• It is important to pay attention to the fresh air intake.

• It must be guaranteed that the cooling air supply is sufficient.

• The radiator may not be covered.

• Untrained personnel should never open the generator.

E.1.2 Connections

04 05 0601 02 07 09 10

03 08

01. Passage for battery cable (+)02. Passage for battery cable (-)03. Cable for DC/DC converter04. Socket for remote control panel05. Socket for vcs cable

06. Connection fuel OUT07. Connection fuel IN08. Air suction intake09. Cooling water OUT10. Exhaust output


Page 60 Panda AGT-DC 4000 PVMV-N s00670 - Chapter E: Installation Instructions 29.12.04

E.1.3 Fuel System Installation

Generally fuel intake and fuel return must be attached with its own fuel intake at the Diesel tank.

If the generator is installed more highly than the tank, the return pipe should be led to the tank upto the same submergence into the tank as the sucking in line, in order to avoid that after the shu-toff the generator the fuel can run back into the tank, which leads to substantial initial problemsafter longer shut-off the generator.

If the return pipe cannot put as immersion tube into the tank, it should be absolutely ensured by anon-return valve in the sucking in line that the fuel cannot flow back after shut-off the generator.

Basically the Panda is airing out. After the first line-up or after longer downtime the notes "Venti-lation of the Fuel System" should be considered.

See Table C.4, “De-aerating the fuel system,” on Page 41.

The following components must be installed:

1. Fuel pre-filter

2. external fuel pump

3. non-return valve

Connection of the fuel system

0502

04

01

03

01. Generator02. Non-return valvel03. External fuel pump

04. External fuel filter05. Tank



Lead the return fuel pipe connected to the day tank to the floor

The return pipe connected to the tank must be dropped to the same depth as the suction pipe, ifthe generfator is mounted higher than the tank, in order to prevent fuel running back into the tankafter the motor has been switched off, which can lead to enormous problems if the generator isswitched off for a long period.

Non-return Valve in the Suction Pipe

A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back afterthe generator has been switched off, if it is not possible to use the return flow pipe as a submergepipe be placing it in the tank. The instructions "Bleeding Air from the Fuel System" must be readafter initial operation or after it has stood still for a long period, in order to preserve the starter bat-tery.

ATTENTION! Non-return valve for the fuel return pipe

If the fuel tank should be installed over the level of the generator (e.g. daily tank), then anon-return valve must be installed into the fuel return pipe to guaranteed that through thereturn pipe no fuel is led into the injection pump.



E.1.4 Connection of the starter battery

An own separate starter battery must be installed for the generator.

The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor(position 01). The negative cable (-) of the battery is attached underneath the starter motor at theengine mount (position 02).

ATTENTION!

It must be guaranteed that first the cables are attached at the generator and then at thebattery. To avoid large voltage drops the battery should be installed as near as possible tothe generator. The positive terminal of the battery is attached at the red cable, the negativepole at the blue cable.

0201

01. Connection starter battery plus cable 02. Connection starter battery minus cable

01

02

01. Generator 02. Starter battery



E.1.5 Installation electronic components

01

04

0302

01. Generator02. Radiator

03. Remote control panel04. VCS with battery monitor



E.2 Voltage Control System

The VCS control is used for the adjustment of the number of revolutions of the engine and thusthe voltage of the generator. It belongs to the accessories and is externally attached.

ATTENTION!

The cable for the measuring voltage must be attached directly at the battery, and may not atta-ched to the output of the electric rectifier. By the voltage drop between generator and battery theaccurate voltage can only recieved direct at the battery. A false link can lead to damage the bat-tery!

06

03

04

01

05

07

02

09

08

01. Voltage sense (+) (24V)02. Voltage sense (-) (24V)03. Actuator (+)04. Actuator (-)05. Battery voltage supply (+)

06. Battery voltage supply (-)07. Stop line (regulates the actuator back at shut-off the device)08. Terminal shunt measurement 0mV DC (-)09. Terminal shunt measurement608mV DC (+)



E.3 The battery monitor

For the automatic start of the "AGT" generator a battery monitor is necessary.

This battery monitor ensures that the unit starts automatically when the battery voltage dropsbelow a pre-set level. If the battery voltage exceeds the adjusted value, then the unit is stoppedautomatically. The two contacts of the battery monitor (7+ & 8 -) must connected with the appro-priate clamps of the automatic control panel (14+ & 13 -).

Responding the battery monitor is indicated by a red light emitting diode. That means if the bat-tery voltage dropped below the adjustable threshold value, an internal relay is switched on. Theconnection occurs with a time delay from approx. 1-3 minutes, voltage drops are ignored e.g.starting currents.

ATTENTION:

The shut down voltage depends on the battery type and on the battery temperature. Considernotes or technical data of the respective battery type.

ATTENTION:

Furthermore attention must be paid that the battery shut down voltage of the battery monitor liesbelow the synchronised voltage of VCS electronics. The generator runs constantly and cannot beautomatically stopped if the synchronised voltage should be less than the battery shut downvoltage.

The the battery monitor may only be connected directly to the terminals of the battery and not tothe output of the generator for example.

E.3.1 Adjustments

Direction of turning the potentiometer:

The battery monitor has three adjustment potentiometer screws labeld (OFF, ON,and td). For all,three, clockwise turns increase and anti clockwise will reduce the value, (with the assistance of ascrewdriver).

Battery charging shut down voltage: 'OFF potentiometer'

This adjusts the upper battery level at which the generator close down sequence will start (butremember there will be a time delay between the voltage level being reached and the actual shutdown). To adjust this upper shut down voltage connect a voltmeter between terminals 2 ground (-) and 3 of the battery monitor. The voltage measured will be of a single cell of the battery (i.e. thatthe entire battery multiplied by its six cells for a 12V system). Adjustment of this upper potentio-meter will set this level to between 2,308 and 2,475V (corresponding to 13,848 - 14,85V).

NOTE: This level must be set at a level lower than the generator voltage output level asmaintained by the VCS. Failure to do so would mean the generator would never shutdown.

Battery charging switch on voltage: 'ON potentiometer'

This adjust the lower battery level at which the generator start up sequence will start (but remem-ber the generator will not start until the voltage is below this level steadly for a period of 1-3 min.).To adjust this start up voltage connect voltmeter between terminals 2 ground (-) and 4 of thevoltage monitor. The voltage measured will again be that of a single cell of the battery. Themiddle potentiometer can adjust this level to between 1,98 and 2,15V (corresponding to 11,88 -12,9V).



Time delay: 'td potentiometer'

This lower potentiometer adjusts the time delay in the sequence between the upper level beingreached (as set by the 'OFF potentiometer') and the actual signal to shut down the generator.This time delay can be adjusted between 10 and 120 min. but can only be measured by timingthe actual delay.

Test button:

Underneath the extension terminals 1 - 2 is a hole which contains a switch that can be actuatedby a small screwdriver. You are able to simulate if the battery monitor will works correct even ifthe voltage differences have been reached. This will be signaled by illumination of the LED. Thetest could only be successfull if the extension terminals 1,2, 7 and 8 are being allocated.

Clamp Function Clamp Function

1 Battery positive pole (+) 5 not allocated

2 Battery negative pol (-) 6 not allocated

3 measuring connection shut down voltage

7 positive output of the sensor

4 measuring connection switch on voltage

8 negative output of the sensor

Batteriewächter

E.3.1 Adjustments

01

03

05

02 04

01. Connections 1-802. Test button03. Switch off potenttiometer

04. Switch on potentiometer05. Time delay potentiometer



E.3.2 Installation of the remote control panel

As standard a 12 core connection-cable,7m long, is included in the supply. Coresare numbered from 1 to 11 and the 12thcore is coloured (yellow/green). The con-trol cables are securely connected to thegenset. On the back of the control panelthere are terminals numbered from 1 - 12.Connect the cores of the controlcable inrespective order.

Please ensure that the remote controlpanel is installed in a protected, dry andeasily accessible place.

E.3.3 Remote control panel for AGT-Generators

1

2

6

7

3 4 5



1. Display operating hours

2. Control light - temperature

3. Control light - oil pressure

4. Control light - charge control

5. Control light - operating status

red glowing Generator is in „Stand-by“-mode

red blinking Generator is started manually

red blinking for more than 20 seconds Generator did not start when activated manu-ally

green blinking Generator runs in manual mode

green glowing Generator runs in automatic mode

6. Switch for Manual Start:

• Switch pressure in sleeping mode: Generator is started and the panel switches to manual mode, i.e. automatic cut off requirements are not carried out.

• Switch pressure in manual mode: If the generator starts automatically, the generator continues to run and the panel switches to automatic mode, i.e. when the last automatic start cuts out, the generator stops and the panel goes into sleeping mode; If the generator is not started automa-tically, the generator stops and the panel goes into sleeping mode.

• Switch pressure in automatic mode: The generator continues to run and the panel switches to manual mode.

7. Main switch:

If it is already in automatic mode when it is switches on, the generator starts and the panel swit-ches to automatic mode; If it is not in automatic mode, the panel switches to sleeping mode; If thegenerator is switched off, the generator will stop in every case.



8. Main terminal clamp - allocation:

1: Battery plus (+)

2: Battery minus (-)

3: Input temperature failure

4: Input charge control

5: Input oil pressure failure

6: Input generator voltage 1

7: Input generator voltage 2

8: Output pre-glow

9: Output fuel pump

10: Output starter motor

11: Output VCS-ON (voltage control for VCS)

12: Output operating voltage, maximum permissible load: 0,2A

9. Terminal clamp for battery monitor - allocation:


14: Input for battery monitor

The potential-free contact of a battery monitor can be connected to these two terminals, the star-ting sequence occurs automatically if the contact closes.

8

9

10

11

12

14

13



10.Terminal clamp for external automatic start - allocation:


16: Input for external start demand

The potential-free contact can be connected to these two terminal. The starting sequence occursautomatically if the contact closes.

11.Fuse 1,6A slow to blow

12.Switch for the starter motor cut-off voltage:

Switch 1: 12V - generator




Attention! Only one switch may remain switched „ON“, all others must be switched „OFF“,otherwise the complete generator could break down! An external voltage-cut-off-switch isneccessary for voltages exceeding 48 Volts.

13.Compensation potentiometer for (12)

Is set at the factory.

14.Soldering bridge for choice of pre-glow time

• Soldering bridge open - pre-glow time 8 sec.

• Soldering bridge closed - pre-glow time 4 sec.

Attention! The panel-circuit board voltage is dangerous if the battery voltage exceeds 60Volts. The panel must be mounted, that the voltage carrying points can not touched. Thisis also the case during testing.

1. Operating and starting the Generator will works with the Control Panel. This implementing theMain Switch (7) is effected for. By switching 'On' the Main Switch the Generator will be at first inoperaton modus. After pressing the button 'Start' (7) the Generator (Motor) will be aglow and star-ting. Pay attention, the button (7) will only be hold down for a second to ignitiate the start proce-dure.

2. Therefore with the panel it is possible, monitoring the operation modus. Hereto are beeing pla-ced four diodes ( LED), which are connected as a pair each other, so they have the possibility tolight up in green or red.

These are:

(3) for exhaust, cooling water temperature

(4) Control unit meter - oil pressure

(5) Control unit meter - operating status

(6) Control unit meter - charge control

If (2), (3) or (4) is been illuminated red, this lights will indicate the precise cause. Illuminate con-stant green the genset is in operation modus.

In the starting sequence, (2) is been illuminte green, (3,4,5) red,is there no fault all diodes beco-mes green or green flashing when the generator runs.



Discription of the illuminate diode (5) LED

all LED´s off Generator is off

red LED illuminates constant Generator is in „Stand-by“-mode

red LED blinks up to 20s Generator is in start mode

red LED blinks more than 20s Generator had not been started --> failure

green LED blinks The genset had been startet on the panel with6), runs, and can only be stopped by this but-ton. (Even if there is a battery monitor instal-led).

green LED illuminates constant The generator had been external startet by anextern switch. This could be the battery monitor(terminal 13 and 14 on the panel) which willstart the generator after a adjusted time of oneminute if there is the voltage drops down in aadjustable level, to reload the batteries.

On the panel at the terminal 15 and 16 is theallocation for extern switches like thermo-,time-, or ambient switches.

Every switch including the battery monitor willoverdrive each other. The shut down proce-dure will works with the switch that had beenswitched.

If there is no extern switch or battery monitorallocated, this LED becomes not constantflashing. (however green blinking)

If the external battery monitor is inbuilt to monitoring a battery-group, it will be advisable to switchit with an accessory (On/Off) switch. This battery monitor ensures that he will be activ while thevoltage of the batteries is on the pre-set level. Therefore there is a time delay available the gensetwill run until he reached the upper level. More information see battery monitor.



E.4 Cooling system

E.4.1 Connection of the external radiator

02

01

01. Generator 02. Radiator



Radiator position

The place and fitting position of the radiator must be carefully considered. It is especiallyimportant that the warm air can escape. For this reason, the best place for the radiator is in a ver-tical position on the vehicle roof (if one take into account that an obstruction could arise in narrowentrances).

The manufacturer is only too happy to give suggestions on how to install the radiator. It must,however, be expressively pointed out that all recommendations of this type are not binding. Itcontinually occurs that special influencing factors are not recognised from the start. The customeror the technician making the installation must always take changes to the position or radiator’splace of installation into consideration. The manufacturer cannot accept liability for the recom-mendations given to the best of his knowledge. As a precaution, attention should always be paidthat the air outlet for escaping warm is as large as possible. The vehicle paint sprayer is oftennot in agreement with this, but the person making the installation must make the aim clear. Thefitter must make his position clear.

Radiators which are installed vertically, and the warm air is blown downwards, must be twice thesize of such radiators, by which the warm air rises through its own thermal energy. It must also beconsidered that a build up of heat results through the emission of warm air in the direction of theground, whereby the warm air is once again forced to rise to the area of the radiator. Freely esca-ping warm air cannot be guaranteed in this case. Additional ventilators may be necessary shouldthe warm air need to be channelled through pipes. It must be ensured that warm air is extractedout of the radiator.

Permitted coolant temperatures

The performance of the radiator must be so measured that the coolant temperature of the Pandagenerator does not exceed more than 70°C. The coolant intake must be fitted direct to the coolantpump.

There must be a large amount of water circulating to ensure that the difference in temperaturewhen compared to the temperature of the water leaving the generator (full load) does not exceed12°C. The difference may also amount to 17K if a pre-silencer is installed.

The hoses must be so laid out that knots and other obstructions are avoided. If necessary, theamount of coolant must be measured. As a minimum the following values are necessary:

Distance from the radiator to the unit

The coolant water pump mounted on the generator is so laid out that a maximum distance of upto 5 mtrs length from the radiator is possible. The hose cross-section must be laid out accordin-gly. The minimal internal diameter amounts to 18mm (Panda 4500). A hose must be used forboth sides (forward and back flow) which is resilient to pressure and high temperatures (at least120°C).

Coolant Pump

This Is normally equipped with a independent impeller suction pump. This pump suffices if thecooling water pipes etc equate to the normal standard. ICEMASTER can give no guaranty. Itmust be determined whether the amount of cooling water circulating is sufficient. Considerationmust always be given to the fact that the water flow is supported by an external pump.



Antifreeze

The antifreeze concentration must be regularly checked in the interests of safety. The antifreezesolution supplied from the factory provides protection to -15°C. If lower temperatures are occasio-ned during transportation or storage, then the coolant must be drained. The cooling system is,however, so arranged that the draining of the coolant is only possible in the assembled state,when air under pressure is blown into the system. Air pressure of approx. 0.5b suffices, in orderto blow out the water.



E.5 Exhaust installation

Exhaust connection for roof outlet

Exhaust connection for mounting below the vehicle

03

02

01

04 05 06 07 08

01. Exhaust oulet02. Generator03. Dachdurchführung mit Winkel04. Vibration damper

05. External pre-silencer06. Exhaust pipe07. External series silencer08. End pipe

01 02 03 04 05 06 07 08

01. Generator02. Exhaust outlet03. Compensator04. External pre-silencer

05. Vibration damper06. Exhaust pipe07. External series silencer08. End pipe



Appendix

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix Page I

F. Appendix

F.1 Maintenance intervals

After operating hours:

35-5

0h

100h

200h

300h

400h

500h

600h

700h

800h

900h

1000

h

Check all coolant and water hoses X X X X X X X X X X X

Check waterpump X X X X X X X X X X X

Empty water separator / fuel filter (if installed) X X X X X X X X X X X

Change engine oil X X X X X X X X X X X

Check air intake suction & flow, air filter, etc. X X X X X X X X X X X

Change air filter X X*) X*) X*) X*) X*)

Check fuel lines X X X X X X X X X X X

Change fuel filter X X X X X X X X X X X

Inspection of the diode block X X X

Check all sensors & switches:

a) coolant thermo-switches

b) exhaust thermo-switch

c) oil pressure switch

X X X X X X X X X X X

Check all securing and fastening screws:

a) all base mount screws

b) exhaust manifold screws

c) starter fixing

d) connection screws engine/generator


Check all electrical cables X X X X X X X X X X X

Check batteries X X X X X X X X X X X

Idle run voltage (Volt) X X X X X X X X X X X

Voltage with load (Volt) X X X X X X X X X X X

Current with load (Ampere) X X X X X X X X X X X

Radiator fan under load at bridged thermo-switch/thermo-sensor


Uptake of the ambient temperature X X X X X X X X X X X

Water temperature IN/OUT at full load and maxspeed of radiator fan, bridged thermo-switch/thermo-sensor


Actuate all ventialtion vales/ventilation screws X X X X X X X X X X X

Pressure test the injection nozzle (every 2000h)

Appendix

Page II Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix 29.12.04

*) or every 12 month

The motor manufacturer’s regulations and instructions must be observed, especially operating and inspectioninstructions ! (See the motor manufacturer’s operating instructions.)

F.2 Operating resources

F.2.1Engine oil specification

Engine oil classification

Operating range:

The operating range of an engine oil is determined by SAE class. "SAE" is for the union of American engineers(Society of Automotives Engineers).

The SAE class of an engine oil only informs over the viscosity of the oil (larger number = more viscous, lowernumber = more highly liquidly) e.g. to 0W, 10W, 15W, 20, 30, 40. The first number shows the liquid of cold wea-ther, the second number refers to the fluidity with heat. Complete yearly oils have usually SAE 10W-40, SAE15W-40 etc.

Quality of oil:

The quality of an engine oil is specified by the API standard ("American Petroleum Institutes").

The API designation is to be found on each engine oil bundle. The first letter is always a C.

API C for diesel engines

The second letter is for the quality of the oil. The more highly the letter in the alphabet, the better the quality.

Examples for diesel engine oil:

API CC Engine oil for small demands

API CG Engine oil for highest demands, turbo-tested

ICEMASTER recommend the API-class CF !

Types of engine oil

over 25°C SAE30 or SAE10W-30

SAE10W-40

0°C to 25°C SAE20 or SAE10W-30

SAE10W-40

below 0°C SAE10W or SAE10W-30

SAE10W-40

Appendix

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix Page III

F.2.2Coolant specification

Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze concen-tration must be regularly checked in the interests of safety.

ICEMASTER recommend to use the product: GLYSANTIN PROTECT PLUS/G 48

Engine coolant automotive industry Product description

Product name GLYSANTIN ® PROTECT PLUS / G48

Chemical nature Monoethylenglykol with inhibitors

Physical form Liquid

Chemical and physical properties

Reserve alkalinity of 10ml ASTM D 1121 13 – 15 ml HCl 01 mol/l

Density, 20°C DIN 51 757 procedure 4 1,121 – 1,123 g/cm3

Water content DIN 51 777 part 1 max. 3,5 %

pH-value undiluted AST M D 1287 7,1 – 7,3

Mixture ratio coolant/antifreeze G48

Water/antifreeze Temperature

70:30 -20°C

65:35 -25°C

60:40 -30°C

55:45 -35°C

50:50 -40°C

Appendix

Page IV Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix 29.12.04

F.3 Troubleshooting

GENERATOR OUTPUT VOLTAGE TOO LOW

If the generator delivers less than 80V current ("undervoltage"), there can be various reasons for this:

Cause Solution

Generator is overloaded. Reduce the electrical load. (Switch off load)

Motor is not reaching the rated rpm. Refer to "motor faults" section.

Actuator is not in maximum position. Check actuator resp. renew.

VCS-voltage controller defective or wrong adjusted. Check resp. renew.

GENERATOR VOLTAGE TOO HIGH (MORE THAN 80V)

The following reasons may be the cause, if the generator delivers more than 80V ("overvoltage"):

Cause Solution

The engine is running at the wrong speed. Check the speed of the motor with a rev or frequencycounter, set the correct speed.

VCS-voltage controller defective or wrong adjusted. Check resp. renew.

Actuator defective. Check resp. renew.

GENERATOR VOLTAGE FLUCTUATES

Cause Solution

1. Fault or defect on the load side.

2. A motor fault.

1. Check if the power requirement of the load fluctua-tes.

2. See "Motor running irregularly".

MOTOR DREHT BEIM ANLASSVORGANG NICHT

Cause Solution

Battery main switch is switched off. Check the position of the battery main switch, if neces-sary switch on.

Battery voltage not sufficient. Check that connection is firm and whether corrosionhas occurred.

Starting current fault. The voltage of full batteries fall to a maximum of 11V.The wiring is severed if the voltage does not drop. Thebattery is discharged if the voltage drops further.

Appendix

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix Page V

MOTOR TURNS OVER BUT DOES NOT START

Cause Solution

Stop solenoid valve not opening. Check wire connections and circuitry to solenoid valve.ref. DC wiring diagram: Relay K2, Fuse)

Fuel pump does not operate. Check fuel-filter and pump: clean if necessary.

Lack of fuel. Check fuel supply.

Glow-plugs not working correctly. Check glow plugs and heating time.

Too much air in fuel lines. Test fuel system for leakage. Bleed air from fuelsystem (refer to section "Air-bleeding of the FuelSystem").

Fuel filter blocked. Replace fuel filter.

Low compression pressure. See Kubota motor-manual.

MOTOR DOES NOT TURN OVER AT THE NORMAL SPEED DURING THE STARTING PROCESS

Cause Solution

Starter battery voltage insufficient. Check battery.

Damaged bearing(s) piston (seized). Repairs need to be carried out by Kubota-Service.(refer to Kubota motor-manual)

Cooling water in combustion chamber. 1. Turn generator "OFF" at control panel.

2. Remove the glow plug (see Kubota-manual).

3. Rotate the motor by hand carefully.

4. Check if there is water in the oil and change both oil and filter if necessary.

5. Determine cause for excess water in the combus tion chamber. The excess water can be caused by a defective air vent in the cooling water system, which should be checked and cleaned, or replaced if faulty.

MOTOR RUNS IRREGULARLY

Cause Solution

Faulty centrifugal injector governor. Have the centrifugal governor inspected by a Kubota-Service technician.

Too much air in fuel lines. Bleed air from fuel system.

Appendix

Page VI Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix 29.12.04

DROP IN THE SPEED OF THE MOTOR

Cause Solution

Too much oil. Drain oil.

Too much oil. Check fuel supply system:

• fuel filter, renew if necessary

• check fuel pump

• check fuel lines (bleed if necessary)

Lack of intake air. Check air intake paths.

Check and clean air filter (and intake muffler if instal-led).

Generator overloaded by too many load. Reduce the electrical load (switch off load).

Generator overloaded by over-energizing. Check that the proper capacitor type is installed andthat they are connected correctly.

Defective generator (windings, bearings, or other). Generator must be sent to manufacturer for repair ofdamaged bearings or winding.

Damaged engine. Repair of bearing damage, etc., by Kubota-Service.

MOTOR SWITCHES ITSELF OFF

Cause Solution

Fuel solenoid valve or throttle shut solenoid is not swit-ching off.

Check wire connections to solenoid. Check valvefunctions as in the "Inlet Fuel Solenoid Valve" or in thetrottle shut off solenoid sections. Replace if necessary.

MOTOR STOPS BY ITSELF

Cause Solution

Lack of fuel. Check fuel supply system.

Excess heat in cooling system (thermo switch tripped)-lack of cooling water. Is indicated on the remote controlpanel.

Check cooling water system flow: water pump, inletwater filter, extra heat exchanger coolant flow.

Lack of oil (oil pressure sensor tripped). Check oil-level and if necessary top up.

Check motor's oil-pressure and have repaired byKubota-Service if necessary.

Appendix

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix Page VII

SOOTY, BLACK EXHAUST

Cause Solution

Generator is overloaded. Check electrical load and switch off unnecessary load

Insufficient intake air. Check intake air filter; clean if necessary.

Fuel injector nozzles faulty. Replace injector nozzles.

Valve clearance incorrect. Readjust valve clearance to correct value (refer toKubota-manual).

Poor fuel quality. Use better quality diesel (recommended: 2-D Diesel).

Poor combustion. Incorrect AFR (air/fuel ratio) due to motor timing adjust-ment. Have motor serviced by Kubota.

Low compression pressure. See Kubota motor manual.

GENERATOR MUST BE SHUT OFF IMMEDIATELY IF:

Cause Solution

• motor rpm suddenly rises or drops

• unusual noise comes from genset

• exhaust colour suddenly becomes dark

• motor overheats

• oil pressure drops, oil light suddenly flashes

Refer to respective section of manual and if necessary,have repaired by Kubota-Service, or Panda represen-tative.

TROUBLESHOOTING VCS SYSTEM

Cause Solution

Actuator does not move. Check voltage supply and wire connections to actuator.

Motor connected?

Check connection to VCS.

Actuator sets throttle too high or too low. Check that the wires to the actuator are connected pro-perly (±).

Check connection to VCS.

If the VCS electronics are faulty, the generator can still run by over-riding the system.

Appendix

Page VIII Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix 29.12.04

Technical data engine

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix Page IX

F.4 Technical data engine

Generator Panda AGT 4000 PVMV-N

Type Kubota EA 300

Governor mechanical + VCS

Automatic Startbooster no

No. cylinders 1

Bore 75 mm

Stroke 70 mm

Stroke volume 309 ccm

max. power (DIN 6270-NA) at 3000rpm 4,5 kW

Rated speed 50Hz 3000 rpm

Idle running speed 2800 rpma

a. progressive govenor by VCS

Valve clearance (engine cold) 0,16 - 0,20 mm

Cylinder head nut torque 58,8 - 63,7 Nm

Lubrication oil capacity 1,3 l

Fuel consumption b

b. 0,35l/kW electrical power, the randomized values between 30% and 80% of the power rating.

0,42 - 1,12 l

Oil consumption max. 1% of fuel consumption

Permissible max. permanent tilt of engine a) 25° across the longitudinal axis

b) 20° in the longitudinal direction

F.5 Technical data generator

Generator Panda AGT 4000 PVMV-N

Power 4 kW , 3000mtr alt., 50°C

Voltage 28V

Current 140A

Frequency 2200-3000 UpM

Stator Da 240 mm

Stator Di 170 mm

Rotor Lfe 20 mm

Technical data generator

Page X Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix 29.12.04

Tabelle 1: Technical Data

TypeNominal power

[kW]Continuous power [kW]

Nominal voltage[VDC]

Continuous charging

current [A]

Nominal charging

current [A]

AGT-DC 4000-24V 4 3,2 24 110 140

Tabelle 2: Cable cross-section

Wiring for vehicle.

single phase, not tin-plated, PVC-isolated.

nominal wire cross-section[mm²]

allowed conrinuous current (reference point) a

a. DIN VDE 0298, part 4.

at +30°C [A] at +50°C [A]

1 19 13,5

1,5 24 17,0

2,5 32 22,7

4 42 29,8

6 54 38,3

10 73 51,8

16 98 69,6

25 129 91,6

35 158 112

50 198 140

70 245 174

95 292 207

120 344 244

Measurements

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix Page XI

F.6 Measurements

Measurements

Page XII Panda AGT-DC 4000 PVMV-N s00670 - Chapter F: Appendix 29.12.04

XIII

5 Safety steps to follow if someone is the victim of electrical shock

Do not try to pull or grab the individual.

Send for help as soon as possible.

If possible, turn off the electrical power.

If you cannot turn off the electrical power, pull, push, or lift the person to safety using awooden pole, rope, or some nonconductive material.

After the injured person is free of contact with the source of electrical shock, move them ashort distance away and immediately start necessary first aid procedures.

1

1

1

2

1

3

1

4

1

5

XIV

WHEN AN ADULT STOPS BREATHING

WARNING

DO NOT attempt to perform the rescue breathing techniques provided on this page, unless certified. Perfor-mance of these techniques by uncertified personnel could result in further injury or death to the victim.

1 Does the Person Respond? 2 Shout, "Help!"

• Tap or gently shake victim.

• Shout, "Are you OK?"

• Call people who can phone for help.

3 Roll Person onto Back.

• Roll victim toward you by pulling slowly.

4 Open Airway. 5 Check for Breathing.

• Tilt head back, and lift chin.

• Shout, "Are you OK?"

• Look, listen, and feel for brea-thing for 3 to 5 seconds.

6 Give 2 Full Breaths.

• Keep head tilted back. • Pinch nose shut.

• Seal your lips tight around victim's mouth.

• Give 2 full breaths for 1 to 1½ secon-ds each.

7 Check for Pulse at side of Neck. 8 Phone EMS for Help.

• Feel for pulse for 5 to 10 seconds. • Send someone to call an ambu-lance.

9 Begin Rescue Breathing. 10 Recheck Pulse Every Minute.

• Keep head tilted back.

• Lift chin.• Pinch nose shut.

• Give 1 full breath every 5 seconds.• Look, listen, and feel for breathing

between breaths.

• Keep head tilted back.

• Feel for pulse for 5 to 10 seconds.• If victim has pulse, not breathing,

continue rescue breathing. If no pulse, begin CPR.

Date post:	11-Aug-2019
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