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G60, G80, G100, G150, G200-SIIIA
OPERATION & MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46606373_en_B_06/15
G60-SIIIA
SERIAL No : G06030001 ->
G80-SIIIA
SERIAL No : G08030001 ->
G100-SIIIA
SERIAL No : G10030001 ->
G150-SIIIA
SERIAL No : G15030001 ->
SERIAL No : G20030001 ->
G200-SIIIA
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Summary of Contents for Doosan G60-SIIIA
- Page 1 G60, G80, G100, G150, G200-SIIIA OPERATION & MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to G60-SIIIA SERIAL No : G06030001 -> personnel who operate and G80-SIIIA SERIAL No : G08030001 -> maintain this machine.
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Page 3: Table Of Contents
Write the correct information for YOUR DIPP generator in the spaces below. Always use these numbers when referring to your DIPP generator. Generator Serial Number Engine Serial Number NOTES: YOUR DIPP DEALER: ADDRESS: PHONE: Doosan Benelux SA Drève Richelle 167 B-1410 Waterloo BELGIUM G60, G80, G100, G150, G200-SIIIA OM Manual... - Page 4 G60, G80, G100, G150, G200-SIIIA OM Manual...
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Page 5: Foreword
FOREWORD CONTENTS FOREWORD ............................6 DECLARATION OF CONFORMITY ......................7 G60, G80, G100, G150, G200-SIIIA OM Manual... - Page 6 English or work situation that may arise. version. IF IN DOUBT CONSULT SUPERVISION. © COPYRIGHT 2015 DOOSAN COMPANY This machine has been designed and supplied for use only following specified conditions applications: •...
- Page 7 Machine description: Portable Generator Machine description: Portable Generator Machine Model: G10, G20, G30, G40, G40-SIIIA, G60-SIIIA, G80-SIIIA, G100-SIIIA, G150-SIIIA, G200-SIIIA, G250, Machine Model: G10, G20, G30, G40, G60, G80-SIIIA, G100-SIIIA, G150-SIIIA, G200-SIIIA, G250, G400, G500 G400, G500 Commercial name: G10, G20, G30, G40, G60, G80-SIIIA, G100-SIIIA, G150-SIIIA, G200-SIIIA, G250, G400, G500...
- Page 8 G60, G80, G100, G150, G200-SIIIA OM Manual...
- Page 9 G60, G80, G100, G150, G200-SIIIA OM Manual...
- Page 10 G60, G80, G100, G150, G200-SIIIA OM Manual...
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Page 11: General Data
GENERAL DATA CONTENTS GENERAL DATA............................ 12 GENERAL INFO ............................ 12 ELECTRICAL DATA ..........................13 G60, G80, G100, G150, G200-SIIIA OM Manual... - Page 12 GENERAL DATA UNIT MODEL G100 G150 G200 Engine Speed - RPM 1500 / 1800 1500 / 1800 1500 / 1800 1500 / 1800 1500 / 1800 Engine Fuel Diesel Diesel Diesel Diesel Diesel Manufacturer John Deere John Deere John Deere John Deere John Deere Model...
- Page 13 ELECTRICAL DATA UNIT MODEL G100 G150 G200 Nominal Apparent Power (kVA Prime) Nominal Active Power (kW Prime) Nominal Voltage Nominal Current (PF=1) Nominal Current (PF=0,8) G60, G80, G100, G150, G200-SIIIA OM Manual...
- Page 14 G60, G80, G100, G150, G200-SIIIA OM Manual...
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Page 15: Safety
SAFETY CONTENTS SAFETY DECALS ..........................16 GRAPHIC FORM AND MEANING OF ISO SYMBOLS ..............16 SAFETY INSTRUCTIONS ........................19 EARTHING ............................20 IF USED AS ALTERNATE POWER SUPPLY .................. 20 HAZARDOUS SUBSTANCE PRECAUTION ................... 21 GENERAL INFORMATION ......................21 Electricity Materials Battery Radiator... -
Page 16: Safety Decals
SAFETY DECALS GRAPHIC FORM AND MEANING OF ISO SYMBOLS PROHIBITION / MANDATORY INFORMATION / INSTRUCTIONS WARNING WARNING: Electrical shock risk WARNING - Pressurised component WARNING - Hot surface. or system. WARNING - Pressure control. WARNING - Corrosion risk. WARNING - Air/gas flow or Air discharge. - Page 17 WARNING - Maintain correct tyre WARNING - Before connecting the tow WARNING - For operating temperature pressure. bar or commencing to tow consult the below 0° C (32° F), consult the Operation & Maintenance manual. Operation & Maintenance manual. WARNING - Do not undertake any WARNING - Consult the Operation &...
- Page 18 Lifting point. On (power). Off (power). Read the Operation & Maintenance When parking use prop stand, Compressor oil filling manual before operation or handbrake and wheel chocks. maintenance of this machine is undertaken. Diesel fuel Parking brake. Rough Service Designation. No open flame.
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Page 19: Safety Instructions
SAFETY INSTRUCTIONS DANGER CAUTION This machine is not designed for operating life- Exercise extreme caution when using booster sustaining equipment. It is equipped with a safety battery. To jump battery, connect ends of one booster shutdown system that will cause the machine to stop cable to the positive (+) terminal of each battery. -
Page 20: Earthing
WARNING WARNING Failure to properly earth the Generator Set can result Electrical Shock - in severe injury or death. Do not operate electrical equipment while standing in IF USED AS ALTERNATE POWER SUPPLY water, on wet earth or with wet hands or shoes. Connect only after the main service entrance switch Use extreme caution when working on electrical has been DISCONNECTED and LOCKED OPEN. -
Page 21: Hazardous Substance Precaution
HAZARDOUS SUBSTANCE PRECAUTION Make sure that all protective covers are in place and that the canopy / doors are closed during operation. The specification of this machine is such that the CAUTION machine is not suitable for use in flammable gas risk areas. -
Page 22: Battery
The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: • anti-freeze • engine lubricant • preservative grease • rust preventative • diesel fuel • battery electrolyte AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES. -
Page 23: Operating Instructions
OPERATING INSTRUCTIONS CONTENTS OPERATING INSTRUCTIONS ....................24 COMMISSIONING ........................... CONNECTING THE LOAD ......................PRIOR TO STARTING ........................STARTING ............................STOPPING ............................REMOTE STARTING AND STOPPING (ANALOG CONTROLLER) ..........DIAGNOSTICS / AUTO SHUTDOWN (ANALOG CONTROLLER) ..........GENERATOR CONTROL PANEL (ANALOG CONTROLLER) ............Meters Monitor Switches Protection / Regulation... -
Page 24: Operating Instructions
OPERATING INSTRUCTIONS PRIOR TO STARTING Never operate unit without first observing all safety warnings and carefully reading the operation & Before starting the engine, carry out the following checks: maintenance manual shipped from the factory with this machine. 1. Engine oil level: Add as required. COMMISSIONING Upon receipt of the unit, and prior to putting it into CAUTION... -
Page 25: Starting
STARTING STOPPING 1. Turn off all external electrical power loads. CAUTION 2. Turn Main Breaker “OFF”. 3. Allow 5 minute cool down. Use the EMERGENCY STOP button ONLY in the event of an emergency. 4. Push controller “STOP” Button. NEVER use it for normal shut-down. 5. -
Page 26: Diagnostics / Auto Shutdown (Analog Controller)
DIAGNOSTICS / AUTO SHUTDOWN (ANALOG CONTROLLER) Figure 2 The operating controls and instruments are arranged on 10. Engine Communication - Indicates the controller the control panel as shown. A description of each panel has communication with the engine ECU. device is as follows: 11. -
Page 27: Generator Control Panel (Analog Controller)
GENERATOR CONTROL PANEL (ANALOG CONTROLLER) Figure 3 Meters Protection / Regulation 1. AC VOLTS - Indicates the generator output voltage. 10. 3 Phase Direct Hookup Connections - L1, L2, L3, N (neutral), PE (Protective Earth). (Not shown.) 2. AC AMPERES - Indicates the generator load in amperes corresponding to AMPERAGE OUTPUT 11. -
Page 28: Options
BASIC DIGITAL CONTROLS OPERATION Overview Doosan'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. Multiple real-time parameters can also be viewed. -
Page 29: Display Buttons
OPTIONS [CONT’D] Display Buttons Figure 5 OFF AUT MAN Use this button to scroll the display between measurement screen, adjustment screen and the default Ready screen. Use it also to back out of the screens. 1800 Timer Use this button to select an adjustment parameter confirm proper... - Page 30 OPTIONS [CONT’D] Figure 8 This screen is ONLY shown on Engines utilising J1939 engine communications. Indication of faults / shutdowns I000000 from the engine control unit is shown here. The ECU Yellow Lamp indicates an engine warning and the ECU Red Lamp indicates an engine shutdown.
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Page 31: Checking Software Version / Lamp Test
OPTIONS [CONT’D] This screen displays the load parameters of the Figure 15 generator set in terms of active power, power factor, reactive power, and apparent power. These values are Alarm List indicated in total and per phase. Not in Auto Figure 13 Wrn Coolant Level Run Hours... -
Page 32: Setpoints Descriptions
OPTIONS [CONT’D] Press “ENTER” to select the desired parameter menu. Mode [OFF, MAN, AUT] This is the equivalent of controller "Mode" buttons. Use the “INCREASE” and / or “DECREASE” buttons to scroll to the parameter to be adjusted. Fault Reset Go to Manual Press “ENTER”... - Page 33 OPTIONS [CONT’D] PreHeat Time Cooling Time Runtime of the unloaded generator set to cool the engine The time delay for preheating after the unit gets the start before stop. command. The unit begins to start after preheating. Select No Preheat with a setting = O. Factory default setting = 10 After Cool Time seconds.
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Page 34: Engine Protection
OPTIONS [CONT’D] ENGINE PROTECTION Batt Undervolt Warning threshold for low battery voltage. Eng prot del [s] Battvolt del During the start of the generator set, some engine protections have to be blocked (e.g. Oil Pressure). The Delay for low battery voltage alarm. protections are unblocked after the protection del time. -
Page 35: Date / Time
OPTIONS [CONT’D] Volt unbal del Delay for generator voltage unbalance alarm. Gen >f SD Shutdown level for generator over frequency. Gen>f Wrn Warning level for generator over frequency. Gen <f Wrn Warning level for generator under frequency. Gen <f SD Shutdown level for generator under frequency. -
Page 36: Electronic Regulation - G60 Siiia Only
OPTIONS [CONT’D] ELECTRONIC REGULATION - G60 SIIIA ONLY Controller The ELECTRONIC REGULATION option provides for a Figure 20 precise, isochronous, speed regulation, keeping the frequency stable within +/- 0.25%. This option is factory set and should not be custom set in any way. - Page 37 OPTIONS [CONT’D] ELECTRONIC REGULATION - DUAL FREQUENCY Controller 50 / 60 HZ - G60 SIIIA ONLY Figure 23 The ELECTRONIC REGULATION option provides for a precise, isochronous, speed regulation, keeping the frequency stable within +/- 0.25%. This option is factory set and should not be custom set in any way.
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Page 38: 3-Way Fuel Valve
OPTIONS [CONT’D] 3-WAY FUEL VALVE Figure 26: Valve lever position This machine may be equipped with a 3-way fuel valve. Description The 3-way fuel valve combined with an external fuel connection module will provide maximum autonomy. Installation and usage Connecting directly to 3-way fuel valve block. Stop the engine. -
Page 39: Oil Sump Pump
OPTIONS [CONT’D] Figure 28: Oil pan drain Figure 30: Hand pump Hand pump Oil pan drain valve Recycle or dispose of used oil in an environmentally safe manner. OIL SUMP PUMP Close the engine oil pan drain valve. This machine may be equipped with an oil sump pump Description WARNING The oil sump pump allows for easier removing of engine... -
Page 40: Decommissioning
DECOMMISSIONING LONG TERM STORAGE RECOMMENDATIONS (6 MONTHS OR MORE) When the machine is to be permanently decommissioned • Engine cooling system - Treat with rust inhibitor and or dismantled, it is important to ensure that all hazard drain. Check with engine dealer further... -
Page 41: Maintenance
MAINTENANCE CONTENTS MAINTENANCE INFORMATION ......................GENERAL ............................SCHEDULED MAINTENANCE ....................... Wiring Routing Clamps Electrical Terminals Earthing Circuit Hoses Wiring Insulation Fuel / Water Separator Air Vents Air Cleaner MAINTENANCE..........................MAINTENANCE INTERVAL CHART ....................MAINTENANCE / DAILY OR EVERY 10 HOURS ................. CHECK ENGINE OIL LEVEL ...................... - Page 42 REPLACE FAN / ALTERNATOR POLY V-BELT................BLEED THE FUEL SYSTEM ......................4045 Engines with Mechanical Fuel System Engines with HPCR Fuel System ENGINE TROUBLESHOOTING ......................SPECIFICATIONS ..........................G60, G80, G100, G150, G200-SIIIA OM Manual...
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Page 43: Maintenance Information
MAINTENANCE INFORMATION Hoses Each month it is recommended that the intake hoses from the air cleaner and all flexible hoses used for water WARNING and fuel be inspected for the following: 1. All rubber hose joints and the screw type hose clamps Any unauthorised modification or failure to maintain must be tight and the hoses showing no signs of wear, this equipment may make it unsafe and out of factory... -
Page 44: Maintenance
MAINTENANCE Observe service intervals Use correct fuels, lubricants and coolant Using hour meter as a guide, perform all services at the hourly intervals indicated on following pages. At each CAUTION scheduled maintenance interval, perform all previous maintenance operations in addition to the ones specified. Keep a record of hourly intervals and services performed Use only fuels, lubricants, and coolants meeting using charts provided in Maintenance Records Section. -
Page 45: Maintenance Interval Chart
MAINTENANCE INTERVAL CHART Item 10 H / Every 2 500 H 1000 H / 2000H / 3000 H / 4500 H Daily Weeks 1 Year 2 Years 3 Years Required • Check engine oil and coolant level Check air filter restriction indicator •... -
Page 46: Maintenance / Daily Or Every 10 Hours
MAINTENANCE / DAILY OR EVERY 10 HOURS CHECK ENGINE OIL LEVEL CHECK COOLANT LEVEL Figure 32: Oil Dipstick and Oil Filler Neck Figure 33: Crosshatch Area on Oil Dipstick WARNING Explosive release of fluid from pressurized cooling system can cause serious burns. Only remove filler cap when engine is cold or when cool enough to touch with bare hands. -
Page 47: Check Air Filter
MAINTENANCE / DAILY OR EVERY 10 HOURS (CONT’D) CHECK AIR FILTER CHECK FUEL FILTER NOTE: Engines have two fuel filters (primary and Figure 35: Check Dust Unloader Valve final) equipped with a water-in-fuel sensor. Depending on application, an indicator light on the instrument panel will signal the operator that water should be drained from filter bowls. - Page 48 MAINTENANCE / DAILY OR EVERY 10 HOURS (CONT’D) Figure 38: Oil Pan Drain Valve CAUTION Filtration of oils is critical to proper lubrication. Always change filter regularly. Use filter meeting John Deere performance specifications NOTE: Change engine oil and filter for the first time after 100 hours maximum of operation, then every 500 hours thereafter.
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Page 49: Maintenance / 500 Hours
MAINTENANCE / 500 HOURS CHANGE ENGINE OIL AND FILTER NOTE: Crankcase oil capacity may vary slightly. ALWAYS fill crankcase to full mark or within Figure 42: Oil Filler Cap and Dipstick crosshatch area on dipstick (A), whichever is present. DO NOT overfill. Figure 44: Crosshatch Area on Oil Dipstick Figure 43: Oil Filler Cap on Rocker Arm Cover 7. -
Page 50: Change Fuel Filter Elements
MAINTENANCE / 500 HOURS (CONT’D) CHANGE FUEL FILTER ELEMENTS 1. Thoroughly clean fuel filter assembly and surrounding area. 2. Disconnect water-in-fuel sensor wiring. 3. Loosen drain plug (C) and drain fuel into a suitable container. NOTE: Lifting up on retaining ring as it is rotated helps to get it past raised locators. -
Page 51: Check Engine Mounts
MAINTENANCE / 500 HOURS (CONT’D) CHECK ENGINE MOUNTS CHECK BELT (Engines with Manual Tensioner) Engine mounting is the responsibility of the vehicle or Figure 47: Manual Belt Tensioner generator manufacturer. Follow manufacturer's guidelines for mounting specifications CAUTION Use only Grade SAE 8 or higher grade of hardware for engine mounting. -
Page 52: Check Belt (Engines With Automatic Tensioner)
MAINTENANCE / 500 HOURS (CONT’D) Check tensioner spring tension 3. Using the gauge (A) on the alternator bracket, stretch Figure 50: Marks on Tensioner belt by prying outward on alternator front frame. Stretch the belt 1 gauge unit for a used belt and 1.5 gauge units for a new belt. -
Page 53: Check Cooling System
MAINTENANCE / 500 HOURS (CONT’D) CHECK COOLING SYSTEM Test Cooling System NOTE: Engine should be warmed up to test overall cooling system. WARNING Figure 53: Test Radiator Cap Explosive release of fluid from pressurized cooling system can cause serious burns. Shut off engines. -
Page 54: Check Air Intake System
MAINTENANCE / 500 HOURS (CONT’D) CHECK AIR INTAKE SYSTEM CAUTION Figure 54 The air intake system must not leak. Any leak, no matter how small, may result in engine failure due to abrasive dirt and dust entering the intake system. 1. -
Page 55: Maintenance / 2000 Hours / 2 Years
MAINTENANCE / 2000 HOURS / 2 YEARS CHECK AND ADJUST ENGINE VALVE CLEARANCE 4. If valves need adjusting, loosen the locknut on rocker arm adjusting screw. Turn adjusting screw until feeler Adjust engine valve clearance as follows or have your gauge slips with a slight drag. - Page 56 MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) 6068 Engine: NOTE: Firing order is 1-5-3-6-2-4. Figure 58: Valve Clearance Adjustment on 6068 Engines Front of Engine No. 1 Piston at TDC Compression Stroke No. 6 Piston at TDC Compression Stroke Exhaust Valve Intake Valve Compression Stroke 1.
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Page 57: Drain And Flush Cooling System
MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) DRAIN AND FLUSH COOLING SYSTEM 6. Stop engine and immediately drain the water from system before rust and sediment settle. NOTE: Drain and flush cooling system every 3000 hours/3 years when John Deere COOL-GARD 7. -
Page 58: Welding Near Electronic Control Units
MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) WELDING NEAR ELECTRONIC CONTROL UNITS CLEAN OR REPLACE AIR FILTER (ONE-PIECE) Figure 62 CAUTION jump-start engines with welding equipment. Currents and voltages are too high and may cause permanent damage. 1. Disconnect the negative (-) battery cable(s). 2. -
Page 59: Clean Or Replace Air Filter Element
MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) CLEAN OR REPLACE AIR FILTER ELEMENT Figure 63: Replace Air Filter Element (6090 Engine Shown) Air Filter Cover Air Filter Element NOTE: The procedure for replacing air filter element can vary depending on air filter configuration. Clean air filter element when restriction indicator is red. -
Page 60: Replace Fan/Alternator Poly-V Belt
MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) REPLACE FAN/ALTERNATOR POLY-V BELT 2. On engines with automatic belt tensioner, release tension on belt using a breaker bar and socket on Figure 64: Fan/Alternator Belt Installation on 4045 tension arm. Engine On engines with manual tensioner, loosen cap screws holding the alternator. -
Page 61: Bleed The Fuel System
MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) BLEED THE FUEL SYSTEM Fuel Pump Primer Lever WARNING 1. Loosen the air bleed screw (A) two full turns. 2. Operate fuel pump primer lever (B) until fuel flow is free from air bubbles. Escaping fluid under pressure can penetrate the skin causing serious injury. -
Page 62: Engines With Hpcr Fuel System
MAINTENANCE / 2000 HOURS / 2 YEARS (CONT’D) Figure 69: Bleed Fuel System at Fuel Injection Figure 70: Final Fuel Filter Bleed Screw Nozzles Air Bleed Screw 6. At Fuel Injection Nozzles: Figure 71: Fuel Pump Primer Lever a. Using two open-end wrenches, loosen fuel line connection at injection nozzle. -
Page 63: Engine Troubleshooting
ENGINE TROUBLESHOOTING NOTE: Before troubleshooting the engine, first retrieve any diagnostic trouble codes on the diagnostic gauge display and perform the corrective actions. If any problems remain, use the following charts to solve engine problems. SYMPTOM PROBLEM SOLUTION Engine cranks but will not Incorrect starting procedure. - Page 64 Lack of power Engine overloaded. Reduce load. Intake air restriction. Service air cleaner. Clogged fuel filter. Replace filter elements. Improper type of fuel. Use proper fuel. Overheated engine. See ”Engine Overheats”. Below normal engine Remove and check thermostat. temperature. Improper valve clearance. See your authorized servicing dealer or engine distributor.
- Page 65 Engine overheats Engine overloaded. Reduce load. Low coolant level. Fill radiator to proper level, check radiator and hoses for loose connections or leaks. Faulty radiator cap. Have serviceman check. Stretched poly V-belt or Check automatic belt tensioner and check belts for defective belt tensioner.
- Page 66 Starter cranks slowly Low battery output. See your authorized servicing dealer or engine distributor. Crankcase oil too heavy. Use proper viscosity oil. Loose or corroded Clean and tighten connections. connections. Entire electrical system Faulty battery connection. Clean and tighten connections. Sulfated or worn-out See your authorized servicing dealer or engine distributor.
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Page 67: Specifications
SPECIFICATIONS Unifie Inch Bolt and Screw Torque Values Bolt or SAE Grade 1 SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2 SAE Grade 2 Screw Size Lubricated Lubricated Lubricated Lubricated N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. 13.5 N·m lb.-ft. - Page 68 SPECIFICATIONS (CONT’D) Metric Bolt and Screw Torque Values Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Screw Size Lubricated Lubricated Lubricated Lubricated N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. 11.3 16.5 15.5...
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Page 69: Alternator Installation & Maintenance
ALTERNATOR INSTALLATION AND MAINTENANCE CONTENTS FOREWORD ............................SAFETY MEASURES ........................WARNING SYMBOLS ........................RECEIPT .............................. STANDARDS AND SAFETY MEASURES ..................INSPECTION ........................... IDENTIFICATION ..........................Nameplate STORAGE ............................APPLICATION ..........................CONTRAINDICATIONS TO USE ....................TECHNICAL CHARACTERISTICS ....................... ELECTRICAL CHARACTERISTICS ....................MECHANICAL OPTIONS ........................ INSTALLATION ............................ - Page 70 ELECTRICAL FAULTS ........................Checking the winding Checking the diode bridge Checking the windings and rotating diodes using separate excitation DISMANTLING, REASSEMBLY ..................... Tools required Screw tightening torque Access to diodes Access to connections and the regulation system Replacing the NDE bearing Dismantling the rotor assembly Reassembling the machine Dismantling and reassembly of the filters...
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Page 71: Foreword
FOREWORD A set of self-adhesive decals depicting the various warning symbols is included with this maintenance manual. They should be positioned as shown in the This section concerns the alternator which you have just drawing below once the machine has been fully installed. purchased. -
Page 72: Receipt
RECEIPT APPLICATION These alternators are mainly designed to produce STANDARDS AND SAFETY MEASURES electricity in the context of applications involving the use of generators. Our alternators comply with most international standards. See the EC Declaration of Incorporation on the last page. CONTRAINDICATIONS TO USE INSPECTION Use of the machine is restricted to operating conditions... -
Page 73: Installation
INSTALLATION CAUTION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards. When coupling the alternator to the prime mover, do not use the fan to turn the alternator or rotor. The ASSEMBLY holes of the coupling discs should be aligned with the flywheel holes by cranking the engine. -
Page 74: Mechanical Checks
• the winding connection corresponds to the site operating voltage (See “TERMINAL CONNECTION WARNING DIAGRAMS” on page 74). TERMINAL CONNECTION DIAGRAMS Ensure that the alternator has the degree of protection matching the defined environmental To modify the connection, change the position of the conditions. - Page 75 Connection codes Voltage L.L Factory connection 50 Hz 60 Hz Winding 220 - 240 220 - 240 1 phase 240 - 254 220 - 240 R 250 voltage detection : L1(U) 0 => (T4) / 110 V => (T1) R 450 voltage detection : L2(V) 0 =>...
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Page 76: Terminal Connection: 6 Wire (Not Possible With The R 250)
Terminal connection: 6 wire (not possible with the R 250) Connection codes Voltage L.L Factory connection 50 Hz 60 Hz L1(U) Winding L3(W) 380 - 480 380 - 415 3-phase L2(V) 380 - 416 L1(U) R 450 voltage detection : 0 =>... -
Page 77: Setting Up
The machine is tested and set up at the factory. When Bearings first used with no load, make sure that the drive speed is correct and stable (see the nameplate). With the As standard, the alternator is fitted with permanently regreasable bearing option, we recommend greasing the greased bearings. -
Page 78: Mechanical Servicing
Mechanical servicing CAUTION Cleaning the machine using water or a high pressure washer is strictly prohibited. Any problems arising from such treatment are not covered by our warranty. Degreasing: Use a brush and detergent (suitable for paint work). Dusting: Use an air gun. If the machine is fitted with air inlet and outlet filters, the maintenance personnel should clean them routinely at regular intervals. -
Page 79: Mechanical Defects
MECHANICAL DEFECTS FAULT ACTION Bearing Excessive temperature rise - If the bearing has turned blue or if the grease has turned black, change in one or both bearings the bearing (bearing temperature more - Bearing not fully locked (abnormal play in the bearing cage) than 80 °... -
Page 80: Electrical Faults
ELECTRICAL FAULTS FAULT ACTION EFFECT CHECK / CAUSE No voltage at Connect a new battery of 4 The alternator builds up and its - Lack of residual magnetism no load on to 12 volts to terminals E- voltage is still correct when the start-up and E+, respecting the battery is removed... -
Page 81: Checking The Diode Bridge
Checking the diode bridge 3. Run the unit at its rated speed. A diode in good working order should allow the current to 4. Gradually increase the exciter field current by flow only in the anode-to cathode direction. adjusting the rheostat or the variac and measure the output voltages on L1 - L2 - L3, checking the excitation voltage and current at no load (see the C a t h o d e... -
Page 82: Screw Tightening Torque
• 1 set of flat spanners: 8 mm, 10 mm, 18 mm -1 socket • Mount the new pre loading (wavy) washer (79) + the set: 8, 10, 13, 16, 18, 21, 24, 30 mm new “O” ring seal (349) in the shield (36) and coat the bearing seat with adhesive paste (see After Sales •... -
Page 83: Dismantling The Rotor Assembly
Dismantling the rotor assembly • Reconnect exciter wires E+, E-. • Remove the non-drive end shield (36) (See • Finish reassembling the cover. “Replacing the non-drive end bearing” on page 82). • Refit the flange (30) on the stator (1). •... -
Page 84: Table Of Characteristics
TABLE OF CHARACTERISTICS G60-SIIIA G100-SIIIA Three-phase: 4-pole, AREP excitation Three-phase: 4-pole, AREP excitation Resistances at 20 ° C ( ) Resistances at 20 ° C ( ) 42.3 Stator L/N Rotor Field coil Armature 44.2 Stator L/N Rotor Field coil Armature 0.095... - Page 85 G200-SIIIA Three-phase: 4-pole, AREP excitation Resistances at 20 °C ( ) 44.2 Stator L/N Rotor Field coil Armature 0.0182 0.24 0.035 Resistance of auxiliary windings at 20 ° C ( ) Type X1, X2 auxil. wdgs Z1, Z2 auxil. wdgs 0.216 0.363 Field excitation current i exc (A) - 400V - 50 Hz...
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Page 86: Exploded View, Parts List And Tightening Torque
EXPLODED VIEW, PARTS LIST AND TIGHTENING TORQUE LSA 42.3 single-bearing - G60SIIIA SCREW TORQUE REF. DESCRIPTION Ø Plastic cover Terminal box lid Terminal box screw 3.6 ±0.4 Plug Access flap 3.6 ±0.4 NDE bearing Preloading wavy washer Wound exciter field Field fixing screw Exciter armature Terminal plate support... - Page 87 LSA 43.2 - G80SIIIA, LSA 44.2 - G100SIIIA and G150-SIIIA SCREW TORQUE REF. DESCRIPTION Ø Cover front panel Cover rear panel Cover top panel Fixing screws Inspection door NDE bearing Preloading wavy washer Wound exciter field Field fixing screw Exciter armature Terminal block support Terminal block Voltage regulator (AVR)
- Page 88 LSA 46.2 single-bearing - G200-SIIIA SCREW TORQUE REF. DESCRIPTION Ø Non drive end bearing Preloading (wavy) washer Exciter field Exciter armature Terminal plate Voltage regulator (AVR) Diode bridge assembly Protection varistor (+ PCB) G60, G80, G100, G150, G200-SIIIA OM Manual...
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