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Maintenance Instructions

Seite/Page 146 - Kaptitel/Chapter 7: Maintenance Instructions 16.1.15

7.22

Table of Contents

Manual Vehicle Generator1
Current Revision Status2
- Table of Contents3
1 General Instructions and Regulations12
- Safety First12
- Tools16
- Manufacturer Declaration in Accordance with the Machinery Directive 2006/42/EC18
- Customer Registration and Guarantee18
  - Technical Support18
  - Caution, Important Information for Start-Up18
- Safety Instructions - Safety First19
- Warning and Instruction Signs22
2 In Case of Emergency First Aid / IM Notfall - Erste Hilfe27
- When an Adult Stops Breathing28
3 Basics29
- Intended Use of the Machine29
- Purpose of the Manual and Description of the Definitions of the Trained Persons/Operators/Users29
- Components of the I System30
- Range of Operation31
- Panda Transport Box31
  - Bolted Fischer Panda Transport Box31
  - Fischer Panda Transport Box with Metal Tab Closure31
- Opening the MPL Sound Insulation Capsule32
  - Opening the GFK Sound Insulation Capsule33
- Transport and Loading/Unloading34
  - Transporting the Generator34
  - Loading/Unloading of the Generator34
- Special Service Instructions and Measures for Extended Machine Downtimes and Decommissioning34
4 The Panda Generator39
- Type Plate at the Generator39
- Details of Function Units45
- The Panda Icontrol2 Panel45
5 Installation Instructions53
- Personal Requirements53
- Environmental Protection55
- Placement56
  - General Instructions56
  - Preparing the Base - Placement56
  - Advice for Optimal Sound Insulation56
- Connections58
- Fuel System Installation59
  - Fischer Panda Installation Kit - Fuel System59
    - The Following Items Need to be Installed61
  - Connection of the Fuel Lines at the Tank64
  - Position of the Pre-Filter with Water Separator65
- Generator DC System Installation65
  - Connection of the Starter Battery Block65
  - How to Connect Two 12 V Batteries to a 24 V Battery Bank69
  - Connection of the Remote Control Panel - See Separate Control Panel Manual71
- Connection of Electrical Components71
  - Connection of the External Radiator72
  - Installation Pmgi Inverter - See Separate Pmgi 8000 Inverter Manual73
- Installation of the Cooling System73
  - The Cooling System / General Instructions73
  - Optionally Available Components for the Installation of the Cooling System73
- Radiator Baseplate75
  - Determining the Size of the Radiator75
  - Radiator Design76
  - Radiator Types76
  - Coolant Hoses83
  - Connection of the External Radiator84
  - Coolant Expansion Tank84
  - Installation of a Coolant Temperature Indicator84
  - Permissible Coolant Temperatures84
  - Coolant Pump84
  - Radiator Fan85
  - Anti-Freeze and Corrosion Protection85
  - Logging the Temperature Values During Initial Start-Up85
- Custom Installations86
  - External Heat Exchangers86
  - External Engine Pre-Heater86
  - Keel Cooling86
- Installation Schematics87
  - Installation for Vertical Radiator Installation87
  - Installation for Mounting the Radiator under the Vehicle88
  - Installation Schematic for Roof Mounted Radiator with Expansion Tank89
- Radiator Fan Control / Electronic Fan Control90
- Standard Fan Control for 1-Phase and 3-Phase Generators90
- Electronic Fan Control for DC Fans RE 020192
- Brief Description92
  - Function92
  - Master - Slave - Operation93
  - Function of the Clamps for the Master-Slave-Operation94
  - Remote Controlled Switching on and off of the Fan Controller94
  - 24V - Operation94
- Technical Data95
- Electronic Fan Control for Single Phase Fans PKE-2.5V_Ziehl Abegg97
  - Preset for the Use with Fischer Panda Generators97
  - Connection of the Sensor (Ziehl Abegg KTY)98
- Electronic Fan Control for Single Phase Fans Pxet6Q_Ziehl Abegg99
  - Preset for the Use with Fischer Panda Generators99
  - Connection of the Sensor (Ziehl Abegg KTY)100
- Electronic Fan Control for 3 Phase Fans PKD T5 Ziehl Abegg101
  - Configuration of the Electronic Fan Control PKD T5 for Fischer Panda Generators102
- Exhaust Installation103
- Isolation Test103
- Set into Operation104
6 Generator Operation Instruction105
- Personal Requirements105
- Hazard Notes for the Operation105
- General Operating Instruction105
- Instructions for Capacitors - Not Present at All Models107
- Checks before Start - See Remote Control Panel Data Sheet107
- Starting the Generator - See Remote Control Panel Data Sheet108
- Stopping the Generator - See Remote Control Panel Data Sheet108
7 Maintenance Instructions109
- Personal Requirements109
- Hazard Notes for the Maintenance109
- Environmental Protection111
- Maintenance Requirements111
- Maintenance Interval111
- Checking Oil-Level111
  - Refilling Oil113
  - After the Oil Level Check and Refilling the Oil113
- Replacement of Engine Oil and Engine Oil Filter113
  - After the Oil Change116
- Verifying the Starter Battery and (if Necessary) the Battery Bank116
  - Battery116
- Ventilating the Fuel System118
  - Replacement of the Fuel Filter119
    - Optional Fuel Filter with Sight Glass119
- Rreplacing the Air Filter120
  - Ventilation of the Coolant Circuit / Freshwater121
- V-Belt Replacement for the Internal Cooling Water Pump124
- Replacing the Electric Starter126
- Replacing the Injection Nozzles129
- Replacing the Glow Plugs131
- Replacing the Oil Pressure Switch134
  - Replacing the Oil Pressure Sensor (Optional Component)135
- Replacing the Stop Solenoid (Energize to Stop)136
- Replacing the Valve Cover Gasket at Kubota 02 Series140
- Replacing the Water Pump at Kubota 02 Series141
- Adjusting the Valve Clearance at Kubota 02 Series142
- Replacing the Operating Current Relays144
- Replacing the Fuses145
8 Generator Failure147
- Personal Requirements147
- Hazard Notes for the Maintenance147
- Environmental Protection149
- Tools and Measuring Instruments149
- Overloading the Generator149
- Starting Problems150
- Troubleshooting Table152
9 Tables157
- Technical Data157
- Diameter of Conduits Vehicle Generators162
- Cable Cross Section for Vehicle Generator164
- Coolant Specifications164
  - Coolant Mixture Ratio165
- Engine Oil165
  - Engine Oil Classification165
    - Operating Range165
    - Quality of Oil165
- Fuel166
Panda Icontrol2167
Current Revision Status168
Hardware168
10 Safety Instructions for the Panda Icontrol2169
- Personnel169
- Safety Instructions169
11 General Operation171
- The Panda Icontrol2 Panel171
- Starting Preparation / Checks (Daily)172
  - Marine Version172
  - Vehicle Version172
- Operation173
- Other Operating Functions181
12 Installation187
- Personnel187
  - Hazard Warnings for Installation187
- Disposal of the Components188
  - Panda Icontrol2 Panel with Installation Housing189
  - Terminal Assignments on the Panda Icontrol2 Panel189
- Dimensions190
- Wiring of the Panda Icontrol2 Controller191
  - Terminal Assignments on the Panda Icontrol2 Controller192
- Start-Up193
13 Maintenance195
- Maintenance of the Icontrol2 Controller195
  - Cleaning the Icontrol2 Controller195
- Maintenance of the Icontrol2 Remote Control Panel195
14 Warnings and Error Messages197
- Warnings197
  - Examples of Warnings on the Display197
  - Warning Messages198
- Faults198
15 Annex201
- Technical Data201
  - Technical Data for Icontrol2 Control Unit201
  - Technical Data for Icontrol2 Remote Control Panel201
16 Inverter Panda Pmgi 8000 / Pmgi 10000203
- Safety Instruction204
- Type Plate204
- Front Side/Connection Side205
  - Socket Pins of the Pmgi 8000206
- Back Side207
- Settings for the Use of Igenerators with Power Inverter208
  - Settings in the Victron VE Configure II Software - General208
    - Uninterrupted AC Power (UPS Function)208
    - Dynamic Current Limiter208
  - Settings in the Victron VE Configure II Software - Inverter209
    - Assist Current Boost Factor209
- Operation Manual210
- Status Led´s210
- Cooling of the Pmgi210
- Installation of the Pmgi211
  - Electrical Connection211
    - Connection to a System with RCD211
    - Connection to a System with Isolation Control211
- Technical Data212

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