Table of Contents
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OPERATION, MAINTENANCE
G10WMI-2D-T2 (B63)
G25WMI-2A-T2 (B54)
G40WMI-2A-T2 (B50)
G60WJD-2A-T2 (B55)
G70WJD-2A-T3 (D63)
G80
G90WJD-2A-T3 (C24)
G125
G145WJD-2A-T3 (C27)
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 22637300 (8-2-2010) Rev H
MANUAL
GENERATOR MODELS
G185WJD-2A-T3 (C28)
G240WJD-2B-T3 (C31)
G240WCU-2C-T3 (D97)
G290WCU-3B-T3 (C38)
G290WCU-3C-T3 (D77)
G450WCU-2B-T2 (C34)
G450WCU-2C-T2 (D96)
G570WCU-2B-T2 (C37)
G570WCU-2C-T2 (D78)
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Table of Contents
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Summary of Contents for Doosan G10WMI-2D-T2
- Page 1 GENERATOR MODELS This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this machine. Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com Book: 22637300 (8-2-2010) Rev H...
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Page 3: Table Of Contents
TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE DRAWBAR NOTICE........... . . 5 SAFETY SYMBOLS . - Page 4 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE MAINTENANCE ............65 General .
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Page 5: Drawbar Notice
Drawbar Notice 22637300... - Page 6 Operation & Maintenance Manual Drawbar Notice Drawbar Notice This machine may have been shipped from the factory with the drawbar positioned upright. To convert from shipping position to towing position, the following tools are required: Tool Required: Ratchet, 24mm socket and an 18mm socket to fit ratchet Torque wrench set to 166 ft-lbs (226 Nm) and 67 ft-lbs.
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Page 7: Safety Symbols
Safety Symbols 22637300... - Page 8 Operation & Maintenance Manual Safety Symbols Symbols below point out potential safety hazards and provide important information about this machine. Read and understand. Heed warnings and follow instructions. If you do not understand, inform your supervisor. Prohibition/ Mandatory Information/Instructions WARNING WARNING - Read the WARNING - Do not open WARNING - Read the...
- Page 9 Safety Symbols Operation & Maintenance Manual WARNING - Diesel fuel is WARNING - Battery WARNING - Do not flammable. No open contains acid. Gases are perform maintenance until flames or sparks. flammable. No open all electrical power has flames or sparks. been disconnected.
- Page 10 Operation & Maintenance Manual Safety Symbols Safety Symbols Look for these signs on machines manufactured in North America, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor.
- Page 11 Safety Symbols Operation & Maintenance Manual 22637300...
- Page 12 Always use genuine replacement parts! 22637300...
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Page 13: Safety
Safety 22637300... - Page 14 Operation & Maintenance Manual Safety Safety DANGER This machine is not designed for operating life-sustaining equipment. It is equipped with a safety shutdown system that will cause the machine to stop operating whenever a shutdown condition is present. DANGER Never operate the engine of this machine inside a building without adequate ventilation.
- Page 15 Safety Operation & Maintenance Manual CAUTION Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the bosster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present).
- Page 16 Operation & Maintenance Manual Safety WARNING Flammable Fuels - Do not fill tank when engine is running. Do not smoke or use an open flame in the vicinity of the generator set or fuel tank. Do not permit smoking, open flame, or sparks to occur near the battery, fuel, cleaning solvents or other flammable substances and explosive gases.
- Page 17 Safety Operation & Maintenance Manual WARNING The Generator Set can produce high voltages, which can cause severe injury or death to personnel and damage to equipment. The Generator Set should have proper internal and external ground when required by the National Electric Code.
- Page 18 Operation & Maintenance Manual Safety WARNING TOWING - Do not tow this unit in excess of 65 mph (104 km/hr). Do not tow this unit with a vehicle whose towing capacity is less than the gross vehicle weight. Steps for determining correct load limit - 1.
- Page 19 Safety Operation & Maintenance Manual WARNING If the drawbar is removed from this machine, use new OEM fasteners, thread locking compound and torque per the tables included in this manual, when re-installing the drawbar. WARNING Voltage Selection - Do not turn Voltage Selector Switch while engine is running.
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Page 20: Hazardous Substance Precaution
Operation & Maintenance Manual Safety CAUTION Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping). HAZARDOUS SUBSTANCE PRECAUTION Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly. -
Page 21: General Data
General Data 22637300... -
Page 22: Unit Model
Operation & Maintenance Manual General Data General Data Unit Model: UNIT MODEL G10A G25B, G25C G40B, G40C Engine Speed - RPM 1800 1800 1800 1800 ENGINE Diesel Diesel Diesel Diesel Manufacturer Model 3IRL2N 4IRQ2N 4IRS2N 5030TF270 FLUID CAPACITIES Engine Crankcase Lubricant 1.7 gal 2.64 gal 2.96 gal... -
Page 23: Unit Model
General Data Operation & Maintenance Manual Unit Model: UNIT MODEL G70A G80A G90A G125 G145B G185 Engine Speed - RPM 1800 1800 1800 1800 1800 1800 ENGINE Diesel Diesel Diesel Diesel Diesel Diesel Manufacturer Model 4045 4045 4045 6068 4045 6068 TF285E TF275... -
Page 24: Unit Model
Operation & Maintenance Manual General Data Unit Model: UNIT MODEL G240 G290 G450 G570 Engine Speed - RPM 1800 1800 1800 1800 ENGINE Diesel Diesel Manufacturer Cummins Cummins Cummins Model 6068HF485 QSL9G3 QSX15 QSX15 FLUID CAPACITIES Engine Crankcase Lubricant 8.59 gal 7 gal (gal) Fuel Tank (gal) -
Page 25: Consumables Service Parts
General Data Operation & Maintenance Manual Consumables Service Parts: For Models: G10A G25B G40B G70A G80A G125 Air Cleaner Element 36890135 35393685 35393685 54471834 54471834 54471834 54717145 (Engine) primary Air Cleaner Element 54471842 54717152 (Engine) secondary - optional Engine Oil Filter 85426849 85426856 22712467... -
Page 26: Consumable Service Parts
Operation & Maintenance Manual General Data Consumable Service Parts: For Models: G450 G570 Air Cleaner Element 36864361 36864361 (Engine) primary Air Cleaner Element 36864379 36864379 (Engine) secondary - optional Engine Oil Filter 54662028 54662028 Element Fuel Water Separator 22201396 22201396 Element Engine Fuel Element 54662036... -
Page 27: Expendable Service Parts
General Data Operation & Maintenance Manual Expendable Service Parts: For Models: G90A G145B G185 G240 G290 Air Cleaner Element 54471834 54717145 54717145 22119168 89288971 (Engine) primary Air Cleaner Element 54717152 54717152 22119176 89288989 (Engine) secondary - optional Engine Oil Filter 22206148 22206148 22206148... - Page 28 22637300...
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Page 29: Operating Instructions
Operating Instructions 22637300... -
Page 30: Before Towing
Operation & Maintenance Manual Operating Instructions Operating Instructions Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine. BEFORE TOWING WARNING Failure to follow these instructions can cause severe injury or death. CAUTION - Position the tow vehicle to align its hitch with the pintle eye or coupler. -
Page 31: Towing
Operating Instructions Operation & Maintenance Manual TOWING WARNING Failure to follow these instructions can cause severe injury or death. — Ensure that tires, wheels and running gear are in good condition and secure. — Ensure that tires are inflated to 50 psi. —... -
Page 32: Before Starting
Operation & Maintenance Manual Operating Instructions BEFORE STARTING 1. Ensure load wiring connections are tight. 2. Check for fluid leaks. 3. Check for fluid level in container base. 4. Check engine oil and coolant level. 5. Check proper grounding circuit. Refer to Safety-Grounding. 6. -
Page 33: Starting (Autostart Models)
Operating Instructions Operation & Maintenance Manual STARTING (AUTOSTART MODELS) CAUTION Use the EMERGENCY STOP button ONLY in the event of an emergency. NEVER use it for normal shut-down. Verify the following: 1. All external electrical power loads are turned “OFF”. 2. -
Page 34: Stopping (Autostart Models)
Operation & Maintenance Manual Operating Instructions 8. Allow the engine to warm-up for 3 to 5 minutes. If the engine stops unexpectedly, refer to Trouble Shooting Section. 9. Check the CONTROL Panel for proper voltages. No RED diagnostic lamps should be glowing. Otherwise, shut down the unit and refer to Trouble Shooting. -
Page 35: Diagnostics/Auto Shutdown (Autostart Models)
Operating Instructions Operation & Maintenance Manual DIAGNOSTICS/AUTO SHUTDOWN (AUTOSTART MODELS) The operating controls and instruments are arranged on the control panel as shown. A description of each panel device is as follows: 1. High Engine Temperature - Indicates engine shutdown due to high coolant temperature or low coolant level. - Page 36 Operation & Maintenance Manual Operating Instructions (19) (20) (21) (22) (18) 22637300...
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Page 37: Customer - Diagnostic Gauge Operation
Operating Instructions Operation & Maintenance Manual CUSTOMER - DIAGNOSTIC GAUGE OPERATION AUTO Mode Any active engine SPN codes are automatically deployed for 3 seconds each. Auto mode is default on power up. Press “SPN” for 3 seconds to return to AUTO mode from MANUAL mode. -
Page 38: Starting (Key Start Models)
Operation & Maintenance Manual Operating Instructions STARTING (KEY START MODELS) CAUTION Use the EMERGENCY STOP button ONLY in the event of an emergency. NEVER use it for normal shut-down. Verify the following: 1. All external electrical power requirements are turned “OFF”. 2. - Page 39 Operating Instructions Operation & Maintenance Manual CAUTION Allow starter to cool for one minute between start attempts. If engine does not start after a few attempts, refer to Trouble Shooting Section. If engine shuts down when ENGINE START switch in in the “ON” position, diagnostic lamps will indicate the problem.
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Page 40: Stopping (Keystart Models)
Operation & Maintenance Manual Operating Instructions 1. Allow the engine to warm-up for 3 to 5 minutes. If the engine stops unexpectedly, refer to Trouble Shooting Section. 2. Check the CONTROL Panel for proper voltages. No RED diagnostic lamps should be glowing. Otherwise, shut down the unit and refer to Trouble Shooting Section. -
Page 41: Engine Controls And Instruments (Keystart Models)
Operating Instructions Operation & Maintenance Manual ENGINE CONTROLS and INSTRUMENTS (Keystart Models) 5. Engine Start Switch Positions - PREHEAT, OFF, RUN, START. 6. Emergency Stop- Disables running, cranking, and trips main breaker. 7. Hourmeter - Records operating time. 8. Fuel Level - Indicates fuel level in fuel tank. 9. -
Page 42: Generator System
Operation & Maintenance Manual Operating Instructions GENERATOR SYSTEM METERS 1. AC Volts - Indicates the generator output voltage corresponding to VOLTAGE OUTPUT MONITOR switch position. 2. AC Amperes - Indicates the generator load in amperes corresponding to AMPERAGE OUTPUT MONITOR switch position. 3. -
Page 43: Circuit Breakers - Flip To Reset (If Equipped)
Operating Instructions Operation & Maintenance Manual CIRCUIT BREAKERS - Flip to Reset (if equipped) 9. 20 AMP/120 Volt - (two) 10. 50 AMP/120V/240 Volt (one, two or three) RECEPTACLES (if equipped) 11. 125 Volt 1 Phase - GFI, straight blade, duplex. 12. -
Page 44: Voltage Selection/Adjustments G25 Thru G185
VOLTAGE SELECTION/ADJUSTMENTS G25 thru G185 DANGER This set up procedure shall be performed only by knowledgeable qualifed persons. Ensure all external electrical connections are disconnected. Use extreme CAUTION when working on electrical components. Battery voltage (12V or 24V) is present unless the battery cables are disconnected. -
Page 45: Switch Position - 120/208V 3 Phase
Operating Instructions Operation & Maintenance Manual SWITCH POSITION - 120/208V 3 Phase 1. Turn Voltage Output Monitor to L position. 2. Turn Voltage Adjust Rheostat (VAR) Shaft to read 208V on AC Voltmeter. 3. Turn Voltage Output Monitor to L position and verify 208V ±... -
Page 46: Switch Position - 120/240 1Phase
Operation & Maintenance Manual Operating Instructions SWITCH POSITION - 120/240 1Phase 1. Turn Voltage Output Monitor to L position. 2. Turn Voltage Adjust Shaft to read 240V on AC Voltmeter. CAUTION Do not use L due to the likelihood of equipment damage. 3. -
Page 47: Voltage Selection/Adjustments G240 Thru G570
Operating Instructions Operation & Maintenance Manual VOLTAGE SELECTION/ADJUSTMENTS G240 thru G570 DANGER This set up procedure shall be performed only by knowledgeable qualifed persons. Ensure all external electrical connections are disconnected. Use extreme CAUTION when working on electrical components. Battery voltage (12V or 24V) is present unless the battery cables are disconnected. - Page 48 Operation & Maintenance Manual Operating Instructions Figure A: Connection Chart Desired Output Voltage 208/240 Output Busbar Links T1-T7, T2-T8, T3-T9, T4 to T10, T5 to T11, T6 to T12 T10 to T11 to T12 Figure B: DANGER Electric power is present at all times when the Generator Set Engine is running.
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Page 49: 120/208V 3 Phase
Operating Instructions Operation & Maintenance Manual 120/208V 3 Phase 1. Turn Voltage Output Monitor to L position. 2. Turn Voltage Adjust Rheostat (VAR) Shaft to read 208V on AC Voltmeter. 3. Turn Voltage Output Monitor to L position and verify 208V ± 5%. 4. -
Page 50: Basic Digital Controls Operation
Operation & Maintenance Manual Operating Instructions BASIC DIGITAL CONTROLS OPERATION Overview Ingersoll Rand's Digital Controller is a comprehensive generator set controller that is used as the primary interface between the operator and the generator set. It provides a high degree of engine and generator protection. - Page 51 Operating Instructions Operation & Maintenance Manual IDENTIFYING KEYPAD BUTTONS AND INDICATORS OPERATION BUTTONS 22637300...
- Page 52 Operation & Maintenance Manual Operating Instructions Status LED’s Shutdown - Indicates the generator set has shutdown due to a fault. Not in Auto - Indicates that the generator set operation mode is not in the automatic position. Running - Indicates that the generator set is running. Warning - Indicates that the generator set is operating in a condition outside its normal operational parameters.
- Page 53 Operating Instructions Operation & Maintenance Manual VIEWING REAL-TIME DATA - ACCESSING THE SCREENS 22637300...
- Page 54 Operation & Maintenance Manual Operating Instructions 22637300...
- Page 55 Operating Instructions Operation & Maintenance Manual 22637300...
- Page 56 Operation & Maintenance Manual Operating Instructions CHECKING SOFTWARE VERSION/LAMP TEST To check the software version and to test the operation of the LED's on the control panel, simultaneously press ADJUSTING THE CONTRAST ON THE LCD To adjust the contrast on the LCD display, simultaneously press 22637300...
- Page 57 Operating Instructions Operation & Maintenance Manual PARAMETER ADJUSTMENTS VIA KEYPAD 22637300...
- Page 58 Operation & Maintenance Manual Operating Instructions SETPOINTS DESCRIPTIONS BASIC SETTINGS Gen-Set Name User defined name, used for the CONTROLLER identification at remote phone or mobile connection. The Gen-set name is max 14 characters long and has to be entered using Lite Edit software.
- Page 59 Operating Instructions Operation & Maintenance Manual IL Power OFF The time limit in minutes for the controller to go to Sleep Mode. The control power is restored by pushing the Control Power Button for 5 seconds. Controller ADDR The setting of the controller address. RS232 Mode The communication protocol selection.
- Page 60 Operation & Maintenance Manual Operating Instructions Min Stability Time Generator nominal voltage starts being detected after starter is switched off, idle time elapses, and this time has elapsed. Max Stability Time If generator nominal voltage is not stable within the time after starter is OFF and idle time elapes, then the genset will shutdown.
- Page 61 Operating Instructions Operation & Maintenance Manual D+ Function ENABLED: The D+ terminal is used for both functions - "running engine" detection and charge fail detection. CHRGFAIL: The D+ terminal is used for charge fail detection only. DISABLED: The D+ terminal is not used, but still provides flash voltage to battery alternator. ECU Freq Select This function is not used.
- Page 62 Operation & Maintenance Manual Operating Instructions Engine Temp Del Delay for high/low engine coolant temperatures. Wrn Fuel Level Warning threshold level for low fuel level. Sd Fuel Level Shutdown threshold level for low fuel level. Fuel Level Del Delay for low fuel level. Batt Overvolt Warning threshold for high battery voltage.
- Page 63 Operating Instructions Operation & Maintenance Manual Gen >V Sd Shutdown level for generator over voltage. All three phases are checked. Maximum out of three is used. Gen >V Wrn Warning level for generator over voltage. All three phases are checked. Maximum out of three is used.
- Page 64 Operation & Maintenance Manual Operating Instructions DATE/TIME Time Stamp Per Fixed time interval when history of all parameters is recorded. Factory Default Setting = 0. Summer Time Mod Automatic time adjustment for daylight savings time. Time Time of day setting. Date Date setting Timer 1 Repeat...
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Page 65: Maintenance
Maintenance 22637300... -
Page 66: General
Operation & Maintenance Manual Maintenance Maintenance CAUTION Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty. WARNING Before attempting any repair service, disconnect engine battery cables and all leads to electrical power requirements. Failure to do so can result in severe personal injury, death or damage to the equipment. - Page 67 Maintenance Operation & Maintenance Manual Hoses Each month it is recommended that the intake hoses from the air cleaner and all flexible hoses used for water and fuel be inspected for the following: 1. All rubber hose joints and the screw type hose clamps must be tight and the hoses showing no signs of wear, abrasion or deterioration.
- Page 68 Operation & Maintenance Manual Maintenance Fasteners (See following inch torque chart, metric torque chart and wheel torque chart). All fasteners should be torqued in accordance to size and grade. Torque Chart 22637300...
- Page 69 Maintenance Operation & Maintenance Manual Wheel Torque Chart M12 Bolts Torque (Ft-Lbs) 13” wheel 60-70 1/2" lug nuts 13” wheel 80-90 15” wheel 105-115 16” wheel 105-115 16.5 wheel 105-115 5/8" lug nuts 16” wheel 190-210 17.5 wheel 190-210 Tires Weekly check the condition of the tires, and gauge the air pressure.
- Page 70 Operation & Maintenance Manual Maintenance Diagnostic Lamps On Keystart models, each month the diagnostic lamps should be tested. With unit shutdown and emergency stop pushed, turn the Engine Start Switch to “START”, or pull the ESTOP to apply power to the controller. All diagnostic lamps should glow; If not, refer to troubleshooting. Diagnostic Trouble Code (DTC) Display On models with Electronic (ECU) engines, each month, the DTC display should be tested.
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Page 71: Adjustment Instructions And Testing Procedures
Maintenance Operation & Maintenance Manual ADJUSTMENT INSTRUCTIONS and TESTING PROCEDURES ACCESSING COMPARTMENT 1. Disconnect all electrical loads to the unit. DANGER High Voltage is present in alternator and control compartments when engine is running. Battery voltage is present whenever battery is connected. -
Page 72: Overcurrent Relay Adjustment (Set Dial On The Ocr Relay)
Operation & Maintenance Manual Maintenance OVERCURRENT RELAY ADJUSTMENT (Set Dial on the OCR Relay) Overcurrent Relay Adjustment Setting ± AMPS 22637300... -
Page 73: Power Bypass Switch For Engine Ecu Service
Maintenance Operation & Maintenance Manual POWER BYPASS SWITCH FOR ENGINE ECU SERVICE Push the Power Bypass Switch to temporarily apply power to the engine ECU during engine computer diagnostics on a stopped engine. The switch is located on the side of the engine next to the Can Bus diagnostic connector. -
Page 74: Package Preventive Maintenance Schedule
PACKAGE PREVENTIVE MAINTENANCE SCHEDULE 3 Mon. 6 Mon. 12 Mon. Daily Weekly Mon. 250 hrs 500 hrs 1000 hrs Evidence of Arcing around electrical terminals Loose Wire Routing Clamps Engine Oil and Coolant Level Proper Grounding Circuit Instruments Frayed/Loose Fan belts, hoses, wiring insulation Fuel/Water Separator drain Precleaner Dumps... -
Page 75: Alternator Installation And Maintenance
Alternator Installation and Maintenance 22637300... -
Page 76: Safety Measures
Operation & Maintenance Manual Alternator Installation and Maintenance Leroy Somer Alternator LSA 42.2/43.2/44.2/46.2/47.2 - 4 POLE This section concerns the alternator used in the generator set, which you have just purchased. We wish to draw your attention to the contents of this maintenance section. By following certain important points during installation, use and servicing of your alternator, you can look forward to many years of trouble-free operation. - Page 77 Alternator Installation and Maintenance Operation & Maintenance Manual WARNING Safety symbol for an operation capable of damaging or destroying the machine or surrounding equipment or danger to personnel. Safety symbol for electrical danger to personnel. Identification The alternator is identified by means of a nameplate glued to the frame. Make sure that the nameplate on the machine conforms to your order.
- Page 78 Operation & Maintenance Manual Alternator Installation and Maintenance Nameplate So that you can identify your machine quickly and accurately, we suggest you fill in its specifications on the nameplate below. Voltage Regulation - AREP System with R438 AVR (42.2, 43.2, 44.2), R448 (46.2, 47.2) AREP Excitation System With AREP excitation, the R438 electronic AVR is powered by two auxiliary windings which are...
- Page 79 Alternator Installation and Maintenance Operation & Maintenance Manual R 438 or R448 Regulator • Short-circuit current = 3 x IN for 10 seconds • Standard power supply; 2 auxiliary windings • Shunt power supply; max 150V -50/60 Hz • Rated overload current: 8A-10S (R448: 10A-10S) •...
- Page 80 Operation & Maintenance Manual Alternator Installation and Maintenance R438 and R448 LAM Characteristics The LAM system is integrated as standard in the R438 and R448 LS regulators. Role of the "LAM" (Load Adjustment Module): • On load impact, the rotation speed of the generator set decreases. When it passes below the preset frequency threshold, the "LAM"...
- Page 81 Alternator Installation and Maintenance Operation & Maintenance Manual Older Model AVR Older Model AVR 22637300...
- Page 82 Operation & Maintenance Manual Alternator Installation and Maintenance Typical effects of the “LAM” with a diesel engine (Figure 12). 22637300...
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Page 83: Installation - Commissioning
Alternator Installation and Maintenance Operation & Maintenance Manual INSTALLATION - COMMISSIONING Assembly All mechanical handing operations must be undertaken using approved equipment. While being handled, the machine should remain horizontal (when travelling bar removed). Handling The generously sized lifting rings are for handling the alternator alone. They must not be used to lift the alternator alone. - Page 84 Operation & Maintenance Manual Alternator Installation and Maintenance Tighten the coupling discs screws to the recommended torque and check that there is lateral ply on the crankshaft. Inspection Prior to First Use Electrical checks Under no circumstances should an alternator, new or otherwise, be operated if the isolation is less than 1 megohm for the stator and 100,000 ohms for the other windings.
- Page 85 Alternator Installation and Maintenance Operation & Maintenance Manual R438 Adjustments (AREP System) a) Initial potentiometer settings (see table on following page). -remote voltage adjustment potentiometer: centre (ST4 strap removed) b) Install a D.C. analogue voltmeter (needle dial) cal. 50V on terminals E+, E- and an A.C. voltmeter cal.
- Page 86 Operation & Maintenance Manual Alternator Installation and Maintenance I) Readjust the speed of the unit to its rated no-load value. ADJUSTMENT SETTING G25, G40, G60, G70, G80, G90, G125, G145, G185-R438 AREP ST 1 (Sensing jumper - single phase) Not cut ST2 (response Time jumper - normal) Not cut ST3 (Frequency - 60 Hz)
- Page 87 Alternator Installation and Maintenance Operation & Maintenance Manual ST5 (LAM jumper - with LAM) Installed ST6 (Alternator jumper - LSA 46.2.47.2) Not cut ST9 (AREP) Not cut ST10 (Voltage drop amplitude jumper) 13% position (lower) ST11 (Underfrequency knee point jumper - 58 Hz) Not cut P1 (Droop - 0%) Fully counter-clockwise...
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Page 88: Servicing-Maintenance
Operation & Maintenance Manual Alternator Installation and Maintenance SERVICING-MAINTENANCE Safety Measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state. All such operations performed on the alternator should be undertaken by personnel with training of electrical and mechanical components. - Page 89 Alternator Installation and Maintenance Operation & Maintenance Manual Cleaning the stator, rotor, exciter and diode bridge The isolating components and the impregnation system are not at risk of damage from solvents (see the list of authorized products above). Avoid letting the cleaning product run into the slots. Apply the product with a brush, sponging frequently to avoid accumulation in the housing.
- Page 90 Operation & Maintenance Manual Alternator Installation and Maintenance Mechanical Defects Mechanical defects Bearing Defect Action Excessive overheating of one or both If the bearing has turned blue or if the grease has bearings (temp of bearings over 80°C) turned black, change the bearing. (With or without abnormal bearing noise) Bearing race badly locked (moving in its housing) Overheating...
- Page 91 Alternator Installation and Maintenance Operation & Maintenance Manual Electrical Faults Fault Action Symptoms Cause No voltage at no load or Connect a battery of 4 to - The alternator builds up - Lack of residual magnetism startup 12 volts to terminals E+ or and voltage is correct E- respecting the polarity when the battery is...
- Page 92 Operation & Maintenance Manual Alternator Installation and Maintenance WARNING *During single-phase operation, check that the sensing wires from the AVR are connected to the correct output terminals. WARNING ** The AVR internal protection may cut in (overload lost connection, short circuit).
- Page 93 Alternator Installation and Maintenance Operation & Maintenance Manual Checking the diode bridge CAUTION Damage caused to the AVR in such conditions is not covered by our warranty. A diode in good working condition allows the current to flow in only one direction, from anode to cathode.
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Page 94: Technical Characteristics
Operation & Maintenance Manual Alternator Installation and Maintenance TECHNICAL CHARACTERISTICS Electrical Characteristics The PARTNER alternator is a machine without slip rings and revolving field brushes, wound as "2/3 pitch"; 12-wire, with class H insulation and a field excitation system available in either "SHUNT"... - Page 95 Alternator Installation and Maintenance Operation & Maintenance Manual AREP Field Excitation System With AREP excitation, the R438/448 electronic AVR is powered by two auxiliary windings which are independent of the voltage sensing circuit. The first winding has a voltage in proportion to that of the alternator (shunt characteristic), the second has a voltage in proportion to the stator current (compound characteristic: booster effect).
- Page 96 Operation & Maintenance Manual Alternator Installation and Maintenance R438 A.V.R Options • Current transformer for parallel operation. • Remote voltage adjustment potentiometer: 470 Q, 0.5 W min: adjustment range :t 5% (range limited via internal voltage potentiometer P2). Remove ST4 to connect the potentiometer.
- Page 97 Alternator Installation and Maintenance Operation & Maintenance Manual LAM Characteristics The LAM system is integrated as standard in the R438/448 LS regulator. Role of the "LAM" (Load Adjustment Module): • On load impact, the rotation speed of the generator set decreases. When it passes below the preset frequency threshold, the "LAM"...
- Page 98 Operation & Maintenance Manual Alternator Installation and Maintenance Dismantling reassembly During the warranty period, this operation should only be carried out in a LEROY SOMER approved workshop or in our factory, otherwise the warranty may be invalidated. The machine must be horizontal when handled (when travelling bar removed). See fig 23. Tools Required To fully dismantle the machine, we recommend you have the tools listed below: 1.
- Page 99 Alternator Installation and Maintenance Operation & Maintenance Manual Screw tightening torque Identification Screw Ø Torque N•m Field term. block screw Field screw Diode bridge screw Diode nut Assembly rod Earthing screw Balancing bolt Disc/shaft screw Lifting screw Louvre screw Cover screw Accessing connections and the regulation system The terminals are accessed by removing the terminal box lid.
- Page 100 Operation & Maintenance Manual Alternator Installation and Maintenance Reassembly -Replace the diodes, respecting the polarity. -Replace the surge suppressor. -Insert a new O ring in the bearing housing. -Refit the NDE bracket (see fig 24) and pass the bundle of wires between the top bars of the flange.
- Page 101 Alternator Installation and Maintenance Operation & Maintenance Manual -After extraction, be careful with the fan. It is necessary to replace the fan in case of disassembling. NOTE: If intervention is required on the main field (rewinding, replacement of components), the rotor assembly must be rebalanced. Reassembly -Follow the dismantling procedure in reverse order.
- Page 102 Operation & Maintenance Manual Alternator Installation and Maintenance Electrical characteristics table Alternator - 2/4 - pole - 50/60 Hz - No. 6 standard winding. (400V for the excitation values). The voltage and current values are given for no-load operation and operation at rated load with separate field excitation.
- Page 103 Alternator Installation and Maintenance Operation & Maintenance Manual 22637300...
- Page 104 Operation & Maintenance Manual Alternator Installation and Maintenance EXPLODED VIEWS Desc Desc Stator assy Inspection door Rotor assy Terminal block suprt Terminal block Fixing screws Voltage regulator Earth terminal AVR damper seal DE shield Terminal block Air outlet grille PMG hsg Sheild on exciter end Adaption shaft Tie rod...
- Page 105 Revision History Rev Level EC Number Comments Original Release Revisions Revisions Revisions Revisions Revisions 12-09 Revisions SVC31253 8-2-2010 Revisions...
- Page 106 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2009 Doosan Infracore International, Inc. Printed in the USA...
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