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Atlas Copco QAS366 Gd USA User manual

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The policy of Atlas Copco is to provide the users of their equipment with safe,
reliable and efficient products. Factors taken into account are among others:
- the intended and predictable future use of the products, and the
environments in which they are expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper service and
maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the relevant instruction manual.
Besides giving detailed operating instructions, it also gives specific
information about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy accessible to the operating
personnel.
See also the safety precautions of the engine and possible other equipment,
which are separately sent along or are mentioned on the equipment or parts of
the unit.
These safety precautions are general and some statements will therefore not
always apply to a particular unit.
Only people that have the right skills should be allowed to operate, adjust,
perform maintenance or repair on Atlas Copco equipment. It is the
responsibility of management to appoint operators with the appropriate
training and skill for each category of job.
6NLOOOHYHO 2SHUDWRU
An operator is trained in all aspects of operating the unit with the push-buttons,
and is trained to know the safety aspects.
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A mechanical technician is trained to operate the unit the same as the operator.
In addition, the mechanical technician is also trained to perform maintenance
and repair, as described in the instruction manual, and is allowed to change
settings of the control and safety system. A mechanical technician does not
work on live electrical components.
6NLOOOHYHO (OHFWULFDOWHFKQLFLDQ
An electrical technician is trained and has the same qualifications as both the
operator and the mechanical technician. In addition, the electrical technician
may carry out electrical repairs within the various enclosures of the unit. This
includes work on live electrical components.
6NLOOOHYHO 6SHFLDOLVWIURPWKHPDQXIDFWXUHU
This is a skilled specialist sent by the manufacturer or its agent to perform
complex repairs or modifications to the equipment.
In general it is recommended that not more than two people operate the unit,
more operators could lead to unsafe operating conditions. Take necessary steps
to keep unauthorized persons away from the unit and eliminate all possible
sources of danger at the unit.
When handling, operating, overhauling and/or performing maintenance or
repair on Atlas Copco equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local safety requirements and
ordinances. The following list is a reminder of special safety directives and
precautions mainly applicable to Atlas Copco equipment.
Neglecting the safety precautions may endanger people as well as environment
and machinery:
- endanger people due to electrical, mechanical or chemical influences,
- endanger the environment due to leakage of oil, solvents or other
substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting from neglecting these
precautions or by non-observance of ordinary caution and due care required in
handling, operating, maintenance or repair, also if not expressly mentioned in
this instruction manual, is disclaimed by Atlas Copco.
The manufacturer does not accept any liability for any damage arising from the
use of non-original parts and for modifications, additions or conversions made
without the manufacturer’s approval in writing.
If any statement in this manual does not comply with local legislation, the
stricter of the two shall be applied.
Statements in these safety precautions should not be interpreted as suggestions,
recommendations or inducements that it should be used in violation of any
applicable laws or regulations.
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1 The owner is responsible for maintaining the unit in a safe operating
condition. Unit parts and accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at all times make sure that
all instructions regarding machinery and equipment operation and
maintenance are strictly followed and that the machines with all
accessories and safety devices, as well as the consuming devices, are in
good repair, free of abnormal wear or abuse, and are not tampered with.
3 Whenever there is an indication or any suspicion that an internal part of a
machine is overheated, the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling time has elapsed; this to
avoid the risk of spontaneous ignition of oil vapor when air is admitted.
4 Normal ratings (pressures, temperatures, speeds, etc.) shall be durably
marked.
5 Operate the unit only for the intended purpose and within its rated limits
(pressure, temperature, speeds, etc.).
6 The machinery and equipment shall be kept clean, i.e. as free as possible
from oil, dust or other deposits.
7 To prevent an increase in working temperature, inspect and clean heat
transfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.
See the maintenance schedule.
8 All regulating and safety devices shall be maintained with due care to
ensure that they function properly. They may not be put out of action.
9 Pressure and temperature gauges shall be checked regularly with regard to
their accuracy. They shall be replaced whenever outside acceptable
tolerances.
10 Safety devices shall be tested as described in the maintenance schedule of
the instruction manual to determine that they are in good operating
condition.
11 Mind the markings and information labels on the unit.
12 In the event the safety labels are damaged or destroyed, they must be
replaced to ensure operator safety.
13 Keep the work area neat. Lack of order will increase the risk of accidents.
14 When working on the unit, wear safety clothing. Depending on the kind of
activities these are: safety glasses, ear protection, safety helmet (including
visor), safety gloves, protective clothing, safety shoes. Do not wear the
hair long and loose (protect long hair with a hairnet), or wear loose
clothing or jewelry.
15 Take precautions against fire. Handle fuel, oil and anti-freeze with care
because they are inflammable substances. Do not smoke or approach with
naked flame when handling such substances. Keep a fire-extinguisher in
the vicinity.
16a
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Earth the generator as well as the load properly.
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This generator is built to supply a sheer alternating current IT
network.
Earth the load properly.
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To lift a unit, all loose or pivoting parts, e.g. doors and towbar, shall first be
securely fastened.
Do not attach cables, chains or ropes directly to the lifting eye; apply a crane
hook or lifting shackle meeting local safety regulations. Never allow sharp
bends in lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone under a lifted load.
Never lift the unit over people or residential areas. Lifting acceleration and
retardation shall be kept within safe limits.
1 Before towing the unit:
- check the towbar, the brake system and the towing eye. Also check the
coupling of the towing vehicle,
- check the towing and brake capability of the towing vehicle,
- check that the towbar, jockey wheel or stand leg is safely locked in the
raised position,
- ascertain that the towing eye can swivel freely on the hook,
- check that the wheels are secure and that the tires are in good condition
and inflated correctly,
- connect the signalisation cable, check all lights and connect the
pneumatic brake couplers,
- attach the safety break-away cable or safety chain to the towing vehicle,
- remove wheel chocks, if applied, and disengage the parking brake.
2 To tow a unit use a towing vehicle of ample capacity. Refer to the
documentation of the towing vehicle.
3 If the unit is to be backed up by the towing vehicle, disengage the overrun
brake mechanism (if it is not an automatic mechanism).
4 Never exceed the maximum towing speed of the unit (mind the local
regulations).
5 Place the unit on level ground and apply the parking brake before
disconnecting the unit from the towing vehicle. Unclip the safety break-
away cable or safety chain. If the unit has no parking brake or jockey
wheel, immobilize the unit by placing chocks in front of and/or behind the
wheels. When the towbar can be positioned vertically, the locking device
must be applied and kept in good order.
6 To lift heavy parts, a hoist of ample capacity, tested and approved
according to local safety regulations, shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only have
stress in line with their design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an angle to its load axis.
8 For maximum safety and efficiency of the lifting apparatus all lifting
members shall be applied as near to perpendicular as possible. If required,
a lifting beam shall be applied between hoist and load.
9 Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the object will be lifted
perpendicular. If that is not possible, the necessary precautions must be
taken to prevent load-swinging, e.g. by using two hoists, each at
approximately the same angle not exceeding 30°from the vertical.
11 Locate the unit away from walls. Take all precautions to ensure that hot air
exhausted from the engine and driven machine cooling systems cannot be
recirculated. If such hot air is taken in by the engine or driven machine
cooling fan, this may cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
12 Generators shall be stalled on an even, solid floor, in a clean location with
sufficient ventilation. If the floor is not level or can vary in inclination,
consult Atlas Copco.
13 The electrical connections shall correspond to local codes. The machines
shall be earthed and protected against short circuits by fuses or circuit
breakers.
14 Never connect the generator outlets to an installation which is also
connected to a public mains.
15 Before connecting a load, switch off the corresponding circuit breaker, and
check whether frequency, voltage, current and power factor comply with
the ratings of the generator.
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1 When the unit has to operate in a fire-hazardous environment, each engine
exhaust has to be provided with a spark arrestor to trap incendiary sparks.
2 The exhaust contains carbon monoxide which is a lethal gas. When the
unit is used in a confined space, conduct the engine exhaust to the outside
atmosphere by a pipe of sufficient diameter; do this in such a way that no
extra back pressure is created for the engine. If necessary, install an
extractor. Observe any existing local regulations. Make sure that the unit
has sufficient air intake for operation. If necessary, install extra air intake
ducts.
3 When operating in a dust-laden atmosphere, place the unit so that dust is
not carried towards it by the wind. Operation in clean surroundings
considerably extends the intervals for cleaning the air intake filters and the
cores of the coolers.
4 Never remove a filler cap of the cooling water system of a hot engine. Wait
until the engine has sufficiently cooled down.
5 Never refill fuel while the unit is running, unless otherwise stated in the
Atlas Copco Instruction Book (AIB). Keep fuel away from hot parts such
as air outlet pipes or the engine exhaust. Do not smoke when fuelling.
When fuelling from an automatic pump, an earthing cable should be
connected to the unit to discharge static electricity. Never spill nor leave
oil, fuel, coolant or cleansing agent in or around the unit.
6 All doors shall be shut during operation so as not to disturb the cooling air
flow inside the bodywork and/or render the silencing less effective. A door
should be kept open for a short period only e.g. for inspection or
adjustment.
7 Periodically carry out maintenance works according to the maintenance
schedule.
8 Stationary housing guards are provided on all rotating or reciprocating
parts not otherwise protected and which may be hazardous to personnel.
Machinery shall never be put into operation, when such guards have been
removed, before the guards are securely reinstalled.
9 Noise, even at reasonable levels, can cause irritation and disturbance
which, over a long period of time, may cause severe injuries to the nervous
system of human beings.
When the sound pressure level, at any point where personnel normally has
to attend, is:
below 70 dB(A): no action needs to be taken,
above 70 dB(A): noise-protective devices should be provided for people
continuously being present in the room,
below 85 dB(A): no action needs to be taken for occasional visitors
staying a limited time only,
above 85 dB(A): room to be classified as a noise-hazardous area and an
obvious warning shall be placed permanently at each
entrance to alert people entering the room, for even
relatively short times, about the need to wear ear
protectors,
above 95 dB(A): the warning(s) at the entrance(s) shall be completed
with the recommendation that also occasional visitors
shall wear ear protectors,
above 105 dB(A): special ear protectors that are adequate for this noise
level and the spectral composition of the noise shall be
provided and a special warning to that effect shall be
placed at each entrance.
10 Insulation or safety guards of parts the temperature of which can be in
excess of 80 °C (175 °F) and which may be accidentally touched by
personnel shall not be removed before the parts have cooled to room
temperature.
11 Never operate the unit in surroundings where there is a possibility of
taking in flammable or toxic fumes.
12 If the working process produces fumes, dust or vibration hazards, etc., take
the necessary steps to eliminate the risk of personnel injury.
13 When using compressed air or inert gas to clean down equipment, do so
with caution and use the appropriate protection, at least safety glasses, for
the operator as well as for any bystander. Do not apply compressed air or
inert gas to your skin or direct an air or gas stream at people. Never use it
to clean dirt from your clothes.
14 When washing parts in or with a cleaning solvent, provide the required
ventilation and use appropriate protection such as a breathing filter, safety
glasses, rubber apron and gloves, etc.
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15 Safety shoes should be compulsory in any workshop and if there is a risk,
however small, of falling objects, wearing of a safety helmet should be
included.
16 If there is a risk of inhaling hazardous gases, fumes or dust, the respiratory
organs must be protected and depending on the nature of the hazard, so
must the eyes and skin.
17 Remember that where there is visible dust, the finer, invisible particles will
almost certainly be present too; but the fact that no dust can be seen is not
a reliable indication that dangerous, invisible dust is not present in the air.
18 Never operate the generator in excess of its limits as indicated in the
technical specifications and avoid long no-load sequences.
19 Never operate the generator in a humid atmosphere. Excessive moisture
causes worsening of the generator insulation.
20 Do not open electrical cabinets, cubicles or other equipment while voltage
is supplied. If such cannot be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a qualified electrician only,
with appropriate tools, and ascertain that the required bodily protection
against electrical hazards is applied.
21 Never touch the power terminals during operation of the machine.
22 Whenever an abnormal condition arises, e.g. excessive vibration, noise,
odor, etc., switch the circuit breakers to OFF and stop the engine. Correct
the faulty condition before restarting.
23 Check the electric cables regularly. Damaged cables and insufficient
tightening of connections may cause electric shocks. Whenever damaged
wires or dangerous conditions are observed, switch the circuit breakers to
OFF and stop the engine. Replace the damaged wires or correct the
dangerous condition before restarting. Make sure that all electric
connections are securely tightened.
24 Avoid overloading the generator. The generator is provided with circuit
breakers for overload protection. When a breaker has tripped, reduce the
concerned load before restarting.
25 If the generator is used as stand-by for the mains supply, it must not be
operated without control system which automatically disconnects the
generator from the mains when the mains supply is restored.
26 Never remove the cover of the output terminals during operation. Before
connecting or disconnecting wires, switch off the load and the circuit
breakers, stop the machine and make sure that the machine cannot be
started inadvertently or there is any residual voltage on the power circuit.
27 Running the generator at low load for long periods will reduce the lifetime
of the engine.
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Maintenance, overhaul and repair work shall only be carried out by adequately
trained personnel; if required, under supervision of someone qualified for the
job.
1 Use only the correct tools for maintenance and repair work, and only tools
which are in good condition.
2 Parts shall only be replaced by genuine Atlas Copco replacement parts.
3 All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped. Steps shall be taken to prevent
inadvertent starting. In addition, a warning sign bearing a legend such as
”work in progress; do not start”shall be attached to the starting equipment.
On engine-driven units the battery shall be disconnected and removed or
the terminals covered by insulating caps.
On electrically driven units the main switch shall be locked in open
position and the fuses shall be taken out. A warning sign bearing a legend
such as ”work in progress; do not supply voltage”shall be attached to the
fuse box or main switch.
4 Prior to stripping an engine or other machine or undertaking major
overhaul on it, prevent all movable parts from rolling over or moving.
5 Make sure that no tools, loose parts or rags are left in or on the machine.
Never leave rags or loose clothing near the engine air intake.
6 Never use flammable solvents for cleaning (fire-risk).
7 Take safety precautions against toxic vapors of cleaning liquids.
8 Never use machine parts as a climbing aid.
9 Observe scrupulous cleanliness during maintenance and repair. Keep away
dirt, cover the parts and exposed openings with a clean cloth, paper or
tape.
10 Never weld on or perform any operation involving heat near the fuel or oil
systems. Fuel and oil tanks must be completely purged, e.g. by steam-
cleaning, before carrying out such operations. Never weld on, or in any
way modify, pressure vessels. Disconnect the alternator cables during arc
welding on the unit.
11 Support the towbar and the axle(s) securely if working underneath the unit
or when removing a wheel. Do not rely on jacks.
12 Do not remove any of, or tamper with, the sound-damping material. Keep
the material free of dirt and liquids such as fuel, oil and cleansing agents.
If any sound-damping material is damaged, replace it to prevent the sound
pressure level from increasing.
13 Use only lubricating oils and greases recommended or approved by Atlas
Copco or the machine manufacturer. Ascertain that the selected lubricants
comply with all applicable safety regulations, especially with regard to
explosion or fire-risk and the possibility of decomposition or generation of
hazardous gases. Never mix synthetic with mineral oil.
14 Protect the engine, alternator, air intake filter, electrical and regulating
components, etc., to prevent moisture ingress, e.g. when steam-cleaning.
15 When performing any operation involving heat, flames or sparks on a
machine, the surrounding components shall first be screened with non-
flammable material.
16 Never use a light source with open flame for inspecting the interior of a
machine.
17 When repair has been completed, the machine shall be barred over at least
one revolution for reciprocating machines, several revolutions for rotary
ones to ensure that there is no mechanical interference within the machine
or driver. Check the direction of rotation of electric motors when starting
up the machine initially and after any alteration to the electrical
connection(s) or switch gear, to check that the oil pump and the fan
function properly.
18 Maintenance and repair work should be recorded in an operator’s logbook
for all machinery. Frequency and nature of repairs can reveal unsafe
conditions.
19 When hot parts have to be handled, e.g. shrink fitting, special heat-
resistant gloves shall be used and, if required, other body protection shall
be applied.
20 When using cartridge type breathing filter equipment, ascertain that the
correct type of cartridge is used and that its useful service life is not
surpassed.
21 Make sure that oil, solvents and other substances likely to pollute the
environment are properly disposed of.
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22 Before clearing the generator for use after maintenance or overhaul,
submit it to a testrun, check that the AC power performance is correct and
that the control and shut down devices function correctly.
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Apply the proper tool for each job. With the knowledge of correct tool use and
knowing the limitations of tools, along with some common sense, many
accidents can be prevented.
Special service tools are available for specific jobs and should be used when
recommended. The use of these tools will save time and prevent damage to
parts.
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When servicing batteries, always wear protecting clothing and glasses.
1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it
hits your eyes, and which can cause burns if it contacts your skin.
Therefore, be careful when handling batteries, e.g. when checking the
charge condition.
2 Install a sign prohibiting fire, open flame and smoking at the post where
batteries are being charged.
3 When batteries are being charged, an explosive gas mixture forms in the
cells and might escape through the vent holes in the plugs.
Thus an explosive atmosphere may form around the battery if ventilation
is poor, and can remain in and around the battery for several hours after it
has been charged. Therefore:
- never smoke near batteries being, or having recently been, charged,
- never break live circuits at battery terminals, because a spark usually
occurs.
4 When connecting an auxiliary battery (AB) in parallel to the unit battery
(CB) with booster cables: connect the + pole of AB to the + pole of CB,
then connect the - pole of CB to the mass of the unit. Disconnect in the
reverse order.
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The QAS366 is an AC generator, built for continuous running at sites
where no electricity is available or as stand-by in cases of interruption
of the mains.
The QAS366 generator is driven by a water-cooled diesel engine, man-
ufactured by DETROIT DIESEL.
The generator can run in 2 different modes:
An overview of the main parts is given in the diagram below.
3 phase - lower voltage 60 Hz 208 V 386.2 hp / 288 kW
3 phase - higher voltage 60 Hz 480 V 386.2 hp / 288 kW
1 Lifting eye A Alternator FCF Filler cap fuel
2 Guiding rod AF Air filter FCO Filler cap engine oil
3 Side doors, access to engine and alternator C Coupling FCW Filter cap cooling water
4 Engine exhaust DFO Drain flexible engine oil FF Fuel filter
5 Data Plate DFW Drain flexible cooling water FPF Fuel pre-filter
6 Grounding rod DH Drain and access hole (in the frame) G1 Battery
7 Side door, access to control and indicator panel DPF Drain plug fuel OF Oil filter
8 Output terminal board DPO Drain pump engine oil OLD Engine oil level dipstick
9 Hole for forklift E Engine S1 Battery switch
F Fan 3WV 3-way valve for external fueltank connection
diesel
ATLASCOPCOAIRPOWER n.v.
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The alternator, the engine, the cooling system, etc. are enclosed in a
sound-insulated bodywork that can be opened by means of side doors
(and service plates).
The generator’s lifting eye is located in the middle of the roof. The re-
cesses in the roof have guiding rods at both sides.
To be able to lift the QAS366 by means of a forklift, rectangular holes
are provided in the frame.
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A brief description of all markings provided on the QAS366 is given
hereafter.
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The control and indicator panel is located behinda door in the side pan-
el. The hinged door is partly transparent and allows easy access to the
parts mounted behind it. Panel light H1 lights up as soon as the starter
switch is turned into position or the remote start/stop switch is put
in position start, indicating that the fuel solenoid is energized.
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Indicates the outgoing current in the first line (L1).
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Indicates the outgoing current in the second line (L2).
3 $PPHWHUOLQH/
Indicates the outgoing current in the third line (L3).
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Indicates the voltage selected by means of voltage selector
switch S4.
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Indicates the frequency of the supply voltage and the speed of
the engine.
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Allows to measure the voltage between each of the phases and
between each phase and the neutral. It also allows to switch off
the voltmeter.
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Allows to connect the diagnostic data reader. Refer to chapter
“Checks and trouble shooting - Engine trouble shooting”.
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Indicates that an electric voltage, dangerous to life,
is present. Never touch the electric terminals during
operation.
Indicates that the engine exhaust is a hot and harm-
ful gas, which is toxic in case of inhalation. Always
make sure that the unit is operated outside or in a
well-ventilated room.
Indicates that these parts can become very hot dur-
ing operation (e.g. engine, cooler, etc.). Always
make sure that these parts are cooled down before
touching them.
Indicates that the generator may be refuelled with
diesel fuel only.
Indicates the drain for the engine oil.
Indicates the drain for the coolant.
Indicates the drain plug for the engine fuel.
Indicates that the guiding rods may not be used to
lift the generator. Always use the lifting eye in the
roof of the generator to lift it.
Indicates the lifting eye of the generator.
Indicates that the unit may start automati-
cally and that the instruction book has to be
consulted prior to use.
Indicates the 3-way valve.
Indicates the battery switch.
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Enables the generator (combined with the SAPE unit) to oper-
ate in parallel mode. For details refer to the SAPE unit instruc-
tion manual.
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Lights up when the electrical system of the engine is energized.
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Goes out after starting, indicating that the alternator is charg-
ing. A failing alternator however will not shut theengine down.
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Lights up when no AC input (< 75 V) is present.
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Lights up when the engine’s speed has exceeded 115 % of the
nominal speed.
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Can be used to wire an extra shut down.
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Lights up when a major fault occurred which shuts down the
engine.
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Can be used to wire an extra shut down.
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With the starter switch into the P1/P5 position and the engine
running, push and hold the diagnostic request switch to have
the inactive codes flashing on the check engine light.
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With the starter switch into the P1/P5 position and the engine
running, push and hold the diagnostic request switch to have
the active codes flashing on the stop engine light.
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Lights up when the fuel level is below 20 % of the maximum
fuel tank capacity.
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Used to select normal start and to disable remote start. If the
unit fails to start the first time, two more starting attempts will
take place with 12 seconds waiting time in between.
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Used to switch off the power supply from the battery or to reset
after a shutdown due to a failure. The unit will not be able to
start up.
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Used to select remote start.
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The generator will not start. When the starter switch is in this
position, the engine faults can be read out by the diagnostic re-
quest button (DB).
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With the ignition switch on and the engine at idle or not run-
ning, push and hold the switch to have the active codes flashing
on the stop engine light (L6), followed by the inactive codes
flashing on the check engine light (L7). For detailed informa-
tion concerning the engine diagnostic codes, see chapter “En-
gine trouble shooting”- “Engine diagnostic codes”on page 19.
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The fuse activates when the current from the battery to the en-
gine control circuit exceeds its setting. The fuse can be
switched on and off by pushing the button.
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Allows to adjust the frequency of the output voltage. This ad-
justment has no influence on the output voltage.
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Allows to adjust the output voltage. R11 is located on the con-
trol and indicator panel.
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