Doosan G10WMI-2D-T2 Page 98 Installation, Operation & Maintenance Manual Download

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Operation & Maintenance Manual

Alternator Installation and Maintenance

22637300

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. Ratchet s extension

2. Torque wrench

3. 7 mm flat spanner

4. 8 mm flat spanner

5. 10 mm flat spanner

6. 12 mm flat spanner

7. 8 mm socket

8. 10 mm socket

9. 13 mm socket

10. 15 mm Allen key (eg. Facom: ET5)

11. 16 mm Allen key (ego Facom: ET6)

12. TORX T20 bit

13. TORX T30 bit

14. Puller (eg. Facom: U35)

15. Puller (eg. Facom: U32/350)

Summary of Contents for G10WMI-2D-T2

Page 1: ...anual must be available to the personnel who operate and maintain this machine OPERATION MAINTENANCE GENERATOR MODELS MANUAL 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 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 G5...

Page 2: ...2 ...

Page 3: ...HUTDOWN AUTOSTART MODELS 35 ENGINE CONTROLS and INSTRUMENTS AUTOSTART MODELS 35 CUSTOMER DIAGNOSTIC GAUGE OPERATION 37 STARTING KEY START MODELS 38 STOPPING KEYSTART MODELS 40 DIAGNOSTICS and AUTO SHUTDOWN KEYSTART MODELS 40 ENGINE CONTROLS and INSTRUMENTS Keystart Models 41 GENERATOR SYSTEM 42 MONITOR SWITCHES 42 CIRCUIT BREAKERS Flip to Reset if equipped 43 RECEPTACLES if equipped 43 PROTECTION ...

Page 4: ...RES 71 ACCESSING COMPARTMENT 71 VOLTAGE REGULATOR ADJUSTMENT 71 OVERCURRENT RELAY ADJUSTMENT Set Dial on the OCR Relay 72 POWER BYPASS SWITCH FOR ENGINE ECU SERVICE 73 PACKAGE PREVENTIVE MAINTENANCE SCHEDULE 74 ALTERNATOR INSTALLATION AND MAINTENANCE 75 SAFETY MEASURES 76 INSTALLATION COMMISSIONING 83 SERVICING MAINTENANCE 88 TECHNICAL CHARACTERISTICS 94 ...

Page 5: ...22637300 5 Drawbar Notice ...

Page 6: ...unit so that the end of the drawbar is approximately 1 inch above the ground 4 While holding the drawbar carefully remove the temporary retaining bolt that holds the drawbar to the top of the enclosure See Fig 1 5 Carefully lower drawbar to the Level Position 6 Install the bolt that was removed in Step 4 with the washers and nut from the included hardware to secure the end of the drawbar underneat...

Page 7: ...22637300 7 Safety Symbols ...

Page 8: ...Read and understand Heed warnings and follow instructions If you do not understand inform your supervisor Prohibition Mandatory Information Instructions WARNING WARNING Read the operator s manual before operating this machine WARNING Do not open radiator until radiator is cool and pressure is relieved WARNING Read the operator s manual before towing machine ...

Page 9: ...ING Diesel fuel is flammable No open flames or sparks WARNING Battery contains acid Gases are flammable No open flames or sparks WARNING Do not perform maintenance until all electrical power has been disconnected WARNING Rotating fan 65 MPH maximum towing speed ...

Page 10: ...and thoroughly Heed warnings and follow instructions If you do not understand inform your supervisor Safety Decals area available free of charge Safety decals are identified by the decal heading DANGER WARNING or CAUTION Decal part numbers are on the bottom of each decal and are listed in the parts manual Help promote product safety Assure that decals are present on the machines Replace decals tha...

Page 11: ...Safety Symbols Operation Maintenance Manual 22637300 11 ...

Page 12: ...12 22637300 Always use genuine replacement parts ...

Page 13: ...22637300 13 Safety ...

Page 14: ...aust fumes when working on on near the machine WARNING A battery contains sulfuric acid and can give off gases which are corrosive and potentially explosive Avoid contact with skin eyes and clothing In case of contact flush area immediately with water WARNING Improper operation of this equipment can cause severe injury or death Read Operator s Manual supplied with this machine before operation or ...

Page 15: ...ttery to avoid a spark occurring near any explosive gases that may be present After starting unit always disconnect cables in reverse order WARNING Never inspect or service unit without first disconnecting battery cable s to prevent accidental starting Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eyes WARNING HOT PRESSURIZED FLUID Remove cap slowly to...

Page 16: ...e standing in water on wet ground or with wet hands or shoes Use extreme caution when working on electrical components Battery voltage 12V 24V DC is present unless the battery cables have been disconnected Higher voltage potentially 480V is possibly present at all times WARNING Always treat electrical circuits as if they were energized Disable Start Control before attempting any repair service dis...

Page 17: ...en grounding is required A qualified licensed electrical contractor knowledgeable in local codes should be consulted The Generator Set has two main applications 1 If the Generator Set is supplying electrical power to portable equipment the vehicle frame shall NOT be grounded to earth per National Electrical Code Article 250 34 b All other provisions of the Article shall be complied with 2 If the G...

Page 18: ...oad capacity 3 Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage load capacity Always make sure the wheels tires and towbar connectors are in safe operating condition and tow bar is properly connected before towing Chock the wheels of the unit when it is not connected to the tow vehicle Do not store or t...

Page 19: ...l be performed only by qualified personnel CAUTION Welding Prior to any welding disconnect alternator relays diagnostic circuit board voltage regulator circuit board meters circuit breakers and battery cables Open all circuit breakers and remove any external connections except grounding rod Connect the welding ground as close as possible to the area being welded WARNING Electrical Loading Never ma...

Page 20: ...machine and may be hazardous to health if used incorrectly Avoid ingestion skin contact and breathing fumes for the following substances Antifreeze Engine Lubricating Oil Preservative Grease Rust Preventative Diesel Fuel and Battery Electrolyte The following substances may be produced during the operation of this machine and may be hazardous to health Avoid build up of engine exhaust fumes in conf...

Page 21: ...22637300 21 General Data ...

Page 22: ...l 103 gal Radiator Engine Coolant 2 0 4 gal 5 gal 6 gal Electrical System 12VDC 12VDC 12VDC 12VDC RUNNING GEAR Tire Size ST175 80D13 ST205 75D15 ST205 75D15 ST205 75D15 Inflation Pressure Cold 50 psi 50 psi 50 psi 50 psi Towing Speed Maximum 65 mph 65 mph 65 mph 65 mph UNIT MEASUREMENTS WEIGHTS w running gear Overall length inches 121 131 143 156 Overall width inches 56 60 66 69 Overall height inc...

Page 23: ...lant Only 6 gal 6 gal 3 1 gal 5 3 gal 3 1 gal 3 1 gal Electrical System 12VDC 12VDC 12VDC 12VDC 12VDC 12VDC RUNNING GEAR Tire Size ST205 75D15 ST205 75D15 ST205 75D15 ST205 75D15 ST205 75D15 9 50 16 5 LT E Inflation Pressure Cold 50 PSI 50 PSI 50 PSI 50 psi 50 psi 50 psi Towing Speed Maximum 65 mph 65 mph 65 mph 65 mph 65 mph 65 mph UNIT MEASUREMENTS WEIGHTS w running gear Overall length inches 15...

Page 24: ... Only gal 3 1 gal 2 91 gal 15 15 Electrical System VDC 12VDC 24VDC 24VDC 24VDC RUNNING GEAR Tire Size 9 50 16 5 LT E 9 50 16 5 LT E 9 50 16 5 LT E 9 50 16 5 LT E Inflation Pressure Cold psi 50 PSI 50 PSI 75 75 Towing Speed Maximum 65 mph 65 mph 65 mph 65 mph UNIT MEASUREMENTS WEIGHTS Overall length in mm 204 221 261 6626 261 6626 Overall width in mm 76 78 86 2181 86 2181 Overall height in mm 95 11...

Page 25: ...426815 85426823 22712475 22556138 22969257 22206197 22206197 Inline Fuel Filter NA NA NA NA NA NA NA MAINTENANCE KITS 250 hour Maintenance Kit without fluids 44003929 44003945 44000404 44003960 44029098 44003986 44003986 250 hour Maintenance Kit engine fluids 44003648 44003663 44000388 44003705 44029072 44003721 44003747 500 hour Maintenance Kit without fluids 44003937 44003952 44000412 44003978 4...

Page 26: ...nt 54662028 54662028 Fuel Water Separator Element 22201396 22201396 Engine Fuel Element 54662036 54662036 MAINTENANCE KITS 250 hour Maintenance Kit without fluids 44020279 44020295 250 hour Maintenance Kit engine fluids 44020212 44020238 500 hour Maintenance Kit without fluids 44020287 44020303 500 hour Maintenance Kit Engine fluids fluids 44020220 44020246 Protec Eng Fluid 5 gal 54480918 54480918...

Page 27: ...nt 54525530 22969265 22969265 22969265 22637904 Engine Fuel Element 22206197 22969257 22969257 22969257 22765325 MAINTENANCE KITS 250 hour Maintenance Kit without fluids TBD 44016038 44016038 44016038 44020253 250 hour Maintenance Kit engine fluids TBD 44016004 44016004 44016004 44020196 500 hour Maintenance Kit without fluids TBD 44016046 44016046 44016020 44020261 500 hour Maintenance Kit Engine...

Page 28: ...28 22637300 ...

Page 29: ...22637300 29 Operating Instructions ...

Page 30: ...ensure pin is FULLY inserted secure in tube of jack Crank jack to lower pintle eye coupler onto the hitch and to raise foot off the ground Pull pin from tube of jack Fold jack handle down and forward Swing up jack tube and FULLY insert pin in tube Connect machine towing lights to tow vehicle Remove chocks from tow vehicle wheels Steps for determining correct load limit 1 Locate the statement The w...

Page 31: ...evel for towing SETTING UP Place the unit in an open well ventilated area Position as level as possible The design of these units permits a 15 degree limit on out of level operation When the unit is to be operated out of level it is important to keep the engine crankcase oil level near the high level mark with the unit level DISCONNECT Set the vehicle parking brake Chock wheels of unit Disconnect ...

Page 32: ...heck engine oil and coolant level 5 Check proper grounding circuit Refer to Safety Grounding 6 Check for frayed or loose fan belts hoses or wiring insulation 7 Check for leaves paper debris in air vents 8 Check Fuel Level Add CLEAN diesel fuel WARNING Do not remove the cap from a HOT engine radiator The sudden release of pressure from a heated cooling system can cause severe injury or death ...

Page 33: ...ure that both the VOLTAGE SELECTOR if equipped and DIRECT HOOK UP Doors are closed 5 Reset pull to unlatch Emergency Stop Button 6 Push the Engine START Button 7 Wait for preheating if enabled CAUTION Do NOT use engine starting fluids DANGER POWER is present upon cranking the engine CAUTION Allow starter to cool for one minute between start attempts If engine does not start after a few attempts re...

Page 34: ... Turn Main Breaker OFF 3 Allow 5 minute cool down 4 Push Engine STOP Button 5 Wait at least 15 seconds before restarting 6 Fill fuel tank at end of working day to prevent condensate REMOTE STARTING AND STOPPING 1 Connect the remote start contacts located in the Generator System direct hookup compartment to a customer supplied contact that closes to initiate a genset start 2 Push the Autostart Mode...

Page 35: ...ndicates preheating is on 10 Engine Communication Indicates the controller has communication with the engine ECU N A for G20 G40 11 Engine Fault Indicates that engine service is required N A for G25 G40 ENGINE CONTROLS and INSTRUMENTS AUTOSTART MODELS 12 Engine Start Switch 13 Engine Stop Reset Switch Stops engine and resets diagnostics Also awakens controller from sleep mode Wait 15 seconds for r...

Page 36: ...Operation Maintenance Manual Operating Instructions 36 22637300 20 18 19 21 22 ...

Page 37: ...e from MANUAL mode MEM indicator is on if engine ECU contains stored codes Go to MAN mode to see codes MANUAL Mode Used to see both active and stored engine codes and to see additional SPN data FMI OC SRC Press i or SPN for MANUAL mode if in AUTO Press SPN to advance to the next SPN code Press i to get additional data on any displayed SPN If the MEM indicator is lit then the displayed SPN is a sto...

Page 38: ...ments are turned OFF 2 Main Breaker is OFF 3 Battery Disconnect Switch ON 4 Ensure both the VOLTAGE SELECTOR if equipped and DIRECT HOOK UP terminal doors are closed 5 Reset pull to unlatch Emergency Stop Button 6 Turn the ENGINE START SWITCH to PREHEAT for maximum of 10 seconds for cold weather starts 7 Turn ENGINE START switch to START Release after engine starts CAUTION Do NOT use engine starti...

Page 39: ...tarter 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 Correct the problem before continuing ...

Page 40: ...f all external electrical power loads 2 Turn Main Breaker OFF 3 Allow 5 minute cool down 4 Turn the Engine Start Switch to OFF 5 Fill fuel tank at end of working day to prevent condensate DIAGNOSTICS and AUTO SHUTDOWN KEYSTART MODELS On some 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 Temper...

Page 41: ...nd 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 Voltmeter Indicates battery charging voltage 8 7 ...

Page 42: ... switch position 3 Hertz Indicates frequency of generator output 4 Panel Lamp Illumination Only MONITOR SWITCHES 5 Voltage Output Selects the line to line phase or line to neutral phase to neutral generator voltage to be displayed on the AC Voltmeter 6 Amperage Output Selects the line phase amperage to be displayed on the AC Ammeter 7 Voltage Adjust Rheostat VAR Turn to adjust generator output vol...

Page 43: ... 1 Phase GFI straight blade duplex 12 125 250 VOLT 1 Phase Special Tempower Twist Lock CS 6369 PROTECTION REGULATION 13 3 Phase Direct Hookup Connections LO L1 L2 L3 14 Fuse Holders Fuses for voltage output selector switch and meter not shown 15 Overcurrent Protection Relay not shown but is located behind reset button 8 16 Main Circuit Breaker 17 Alarm Horn not shown but is located on back of cont...

Page 44: ...120 and 240 volts 1 phase and direct wiring hook ups Any of the voltages listed below are obtainable by connection to the direct hook up terminal block NOTICE Do not hook up electrical loads until following adjustments have been completed otherwise damage to the equipment may result SET UP PROCEDURE Before starting and making electrical connections 1 Open the VOLTAGE SELECTOR switch door 2 Positio...

Page 45: ...0V 3 Phase 1 Turn Voltage Output Monitor to L1 L0 position 2 Turn Voltage Adjust Rheostat VAR Shaft to read 277V on AC Voltmeter 3 Turn Voltage Output Monitor to L2 L0 position and verify 277V 5 4 Turn Voltage Output Monitor to L3 L0 position and verify 277V 5 5 One of the 120V 15A or 20A panel receptacles now has power The right duplex receptacle is not active in 480V mode 6 Turn Voltage Output M...

Page 46: ...6 Shut down unit 7 Make 120 240V connections at either the panel receptacles or the direct hook up terminal blocks 8 At start up 120 240V will be present It may be necessary to check the voltage at the end of long drop cord and increase the voltage to compensate for losses Voltages required other than those specified above may be adjustable within the following ranges Follow the National Electrica...

Page 47: ...hook up terminal block NOTICE Do not hook up electrical loads until following adjustments have been completed otherwise damage to the equipment may result SET UP PROCEDURE Before starting and making electrical connections 1 Remove the top cover on junction box located on the AC Alternator 2 Remove all nuts and washers from all the studs in the junction box and position the copper bars on the studs...

Page 48: ...ction Chart DANGER Electric power is present at all times when the Generator Set Engine is running 5 Fine tuning of the VOLTAGE ADJUSTMENTS are as follows 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 ...

Page 49: ...wn unit 7 Make 120 208V connections at the direct hook up terminal blocks 8 At start up 120 208V will be present 277 480V 3 Phase 1 Turn Voltage Output Monitor to L1 L0 position 2 Turn Voltage Adjust Rheostat VAR Shaft to read 277V on AC Voltmeter 3 Turn Voltage Output Monitor to L2 L0 position and verify 277V 5 4 Turn Voltage Output Monitor to L3 L0 position and verify 277V 5 5 Turn Voltage Outpu...

Page 50: ...ive 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 The parameters include but are not limited to kW KVA kVAr power factor oil pressure coolant temperature engine speed and diagnostic history ...

Page 51: ...Operating Instructions Operation Maintenance Manual 22637300 51 IDENTIFYING KEYPAD BUTTONS AND INDICATORS OPERATION BUTTONS ...

Page 52: ...hat 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 Ready Auto Indicates the generator set is ready and is in automatic mode Supplying Load Indicates that the generator set is under load ...

Page 53: ...Operating Instructions Operation Maintenance Manual 22637300 53 VIEWING REAL TIME DATA ACCESSING THE SCREENS ...

Page 54: ...Operation Maintenance Manual Operating Instructions 54 22637300 ...

Page 55: ...Operating Instructions Operation Maintenance Manual 22637300 55 ...

Page 56: ...6 22637300 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 ...

Page 57: ...Operating Instructions Operation Maintenance Manual 22637300 57 PARAMETER ADJUSTMENTS VIA KEYPAD ...

Page 58: ... s are not needed on 480 Volt systems and below Nominal Voltage 1 Line to neutral voltage in LOW WYE Parallel connection Nominal Voltage 2 Line to neutral voltage in HI WYE series connection Gear Teeth Number of teeth on the engine gear for the pick up Set to zero if no pick up is used Engine speed is counted from the generator frequency Electronic engines get the speed signal from the engine cont...

Page 59: ...OFF Starting POil When reached controller stops cranking starter goes OFF There are three conditions for stop cranking Starting RPM Starting POil and D when enabled The starter goes off when any of these conditions are valid PreHeat Time The time delay for preheating after the unit gets the start command The unit begins to start after preheating Select No Preheat with a setting O Factory default s...

Page 60: ...he unloaded generator set to cool the engine before stop After Cool Time This function is not used Factory default setting 0 Stop Time When genset stop sequence is initiated fuel solenoid output cannot activate during this time Fuel Solenoid Determines behavior of the Binary output FUEL SOLENOID DIESEL Output closes together with Binary output STARTER The output opens if Emergency stop comes or Co...

Page 61: ... Pressure The protections are unblocked after the protection del time The time starts after reaching START RPM Alarm Horn Three selections possible NONE Horn only sounds for 10 seconds prior to a start in Auto Mode SHUTDOWN Horn sounds for any shutdown and also for an Autostart SD WARNING Horn sounds for any alarm or shutdown and also for an Autostart Overspeed Threshold for overspeed protection W...

Page 62: ... for low battery voltage alarm NextServTime h Counts down when engine running If reaches zero an alarm appears ALTERNATOR PROTECTION Overload Threshold for generator overload in of nominal power Overload Wrn Threshold for generator overload warning in of nominal power Overload del Delay for generator overload alarm Ishort Shutdown occurs when lshort circuit limit is reached Ishort del Delay for ls...

Page 63: ...s used Gen V Wrn Warning level for generator under voltage All three phases are checked Minimum out of three is used Gen V del Delay for generator under voltage and over voltage alarm Volt unbal Threshold for generator voltage unbalance alarm 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 fr...

Page 64: ...ings time Time Time of day setting Date Date setting Timer 1 Repeat Selection of day days when exercise Timer 1 will run Timer 1 on Time Selection of time of day when Timer 1 will start the genset Timer 1 Duration Selection of length of run time Timer 2 Repeat Selection of day days when exercise Timer 2 will run Timer 2 on Time Selection of time of day when Timer 2 will start the genset Timer 2 Du...

Page 65: ...22637300 65 Maintenance ...

Page 66: ...lure and consequently the need for repair Preventive maintenance is the easiest and the least expensive type of maintenance Maintaining your unit and keeping it clean at all times will facilitate servicing Scheduled Maintenance The maintenance schedule is based on normal operation of the unit In the event unusual environmental operating conditions exist the schedule should be adjusted accordingly ...

Page 67: ... of poor quality or contaminated replace the bowl elements s Air Vents Daily clean the air vents of any obstruction or debris Air Cleaner Proper maintenance of the air cleaner provides maximum protection against airborne dust Squeeze the rubber valve precleaner dirt dump periodically to ensure that it is not clogged To service the air cleaners proceed as follows 1 Remove filter element 2 Inspect a...

Page 68: ...ion Maintenance Manual Maintenance 68 22637300 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 ...

Page 69: ...ction to 35 F 37 C The use of such a mixture is recommended for both summer and winter operation When using water alone be sure to add a reputable brand of rust inhibitor to prevent internal corrosion It is recommended to test the freezing protection of the coolant every six months or prior to freezing temperatures Replenish with a fresh mixture every twelve months Each month inspect the radiator ...

Page 70: ...CTOR door This will shutdown the engine and trip the main breaker To reset close the door Engine Protection Shutdown System The operation of the engine protection shutdown system should be checked whenever it appears not to be operating properly The three devices involved in this protective shutdown system are the engine coolant high temperature switch sensor the engine oil pressure switch sensor ...

Page 71: ...n turn VOLTAGE SELECTOR Switch to 277 480V position and close and latch the VSS door 2 Adjust Voltage POT P2 on regulator to full counterclockwise position 3 Adjust Voltage POT on control panel to full clockwise position 4 Start unit 5 Verify generator frequency to 62 63 Hz at no load on G10 G40 60 60 5 Hz on G60 G570 6 Set the VOLTAGE OUTPUT MONITOR switch on the control panel to L1 L2 position 7...

Page 72: ...CURRENT RELAY ADJUSTMENT Set Dial on the OCR Relay Overcurrent Relay Adjustment KVa Setting 0 1 AMPS 25 2 1 34 40 2 3 47 60 1 9 77 70 1 9 96 80 2 2 109 90 2 4 124 125 2 1 165 145 2 4 190 185 2 0 242 240 2 0 314 290 1 9 384 315 2 1 415 450 2 0 603 570 2 4 754 ...

Page 73: ...ER 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: ...es and Flexible Hoses C Fasteners tighten C Emergency Stop Switch Operation C Engine Protection Shutdown System C Diagnostic Lamps C Voltage Selector Interlock Switches C High Containment Fluid Alarm System C Air Cleaner Housing C Control Compartment Interior C Fuel Tank fill at end of each day drain Fuel Water Separator Element R Wheel Bearings Grease Seals repack Engine Shutdown System Switches ...

Page 75: ...22637300 75 Alternator Installation and Maintenance ...

Page 76: ...etic Compatibility EMC 89 336 EEC The European Community directives 73 23 EEC and 93 68 EEC Low Voltage Directive The are CE marked with regard to the LVD Low Voltage Directive in their role as a machine component A declaration of incorporation can be supplied on request SAFETY MEASURES Before using your machine for the first time it is important to read the whole of this installation and maintena...

Page 77: ...el 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 The machine name is defined according to various criteria see below Example of description LSA 43 2 M45 J6 4 LSA Name used in the PARTNER range M Marine C Cogeneration T Telecommunications 43 2 Machine Type M45 Model J Excitation System C AREP...

Page 78: ...th AREP excitation the R438 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 The power supply voltage is rectified and filtered before being used by th...

Page 79: ... 520V Voltage regulation 1 R448 0 5 Rapid or normal response time via strap ST2 Voltage adjustment via potentiometer P2 Other voltages via step down transformer Current detection parallel operation C T 2 5VA cl1 secondary 1A Option Quadrature droop adjustment via potentiometer P1 Underspeed protection U f and LAM Frequency threshold adjustable via potentiometer P4 on older models Strap ST5 is conn...

Page 80: ... voltage to drop by approximately 13 or 25 and consequently the amount of active load applied is reduced by approximately 25 to 50 until the speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engine To avoid voltage oscil...

Page 81: ...Alternator Installation and Maintenance Operation Maintenance Manual 22637300 81 Older Model AVR Older Model AVR ...

Page 82: ...Operation Maintenance Manual Alternator Installation and Maintenance 82 22637300 Typical effects of the LAM with a diesel engine Figure 12 ...

Page 83: ... the alternator alone They must not be used to lift the genset Choose a lifting system which respects the positioning of the rings See Fig 13 Coupling Single Bearing Alternator Before coupling to the prime mover check that both are compatible by Undertaking a torsional analysis of the transmission Checking the dimensions of the flywheel and its housing the flange coupling discs and offset WARNING ...

Page 84: ...R Short circuit the output phases using connections capable of supporting the rated current try not to exceed 6 A mm2 Insert a clamp ammeter to monitor the current passing through the short circuit connections Connect a 48 Volt battery in series with a rheostat of approximately 10 ohms 50 Watts to the exciter field terminals respecting the polarity Connect a 48 Volt battery in series with a rheost...

Page 85: ...travel anti clockwise CCW g Start the engine and set its speed to a frequency of 48 Hz for 50 Hz or 58 for 60 Hz h Adjust the output voltage to the desired value using P2 rated voltage UN for solo operation eg 400 V or UN 2 to 4 for parallel operation with C T eg 410V If the voltage oscillates use P3 to make adjustments try both directions observing the voltage between E and E approx 10V D C The b...

Page 86: ...per wiring diagram 5 ST5 LAM jumper with LAM Installed 7 ST9 AREP Not cut 8 ST10 Voltage drop amplitude jumper 13 position lower 9 ST11 Underfrequency knee point jumper 58 Hz Not cut 10 P1 Droop 0 Fully counter clockwise 11 P2 Voltage Set to limit remote pot to 504V max output 12 P3 Stability Center position 13 P5 Excitation current 10A maximum Fully clockwise G240 G290 G450 G570 R448 AREP 1 ST 1 ...

Page 87: ...p amplitude jumper 13 position lower 9 ST11 Underfrequency knee point jumper 58 Hz Not cut 10 P1 Droop 0 Fully counter clockwise 11 P2 Voltage Set to limit remote pot to 504V max output for 600V units set to 610V max output 12 P3 Stability Center position 13 P5 Excitation current 10A maximum Fully clockwise G10 R438 AREP G10 is same as G25 G185 except ST4 is with jumper has no external potentiomet...

Page 88: ... tight plus the general state of the machine and the various electrical connections in the installation Cooling circuit It is advisable to check that circulation of air is not reduced by partial blocking of the suction and discharge louvres mud fibre grease etc Bearings The bearings are greased for life approximate life of the grease depending on use 20 000 hours or 3 years Monitor the temperature...

Page 89: ...ctions comply with the diagrams in the manuals supplied with the machine the speed of the unit is correct Repeat the operations instructions Mechanical Servicing CAUTION Cleaning the machine using a water spray or a high pressure washer is strictly prohibited Any problems arising from such treatment are not covered by our warranty The machine should be cleaned with a degreasing agent applied using...

Page 90: ...is functioning at too high a voltage over 105 of rated voltage on load Alternator overloaded Vibration Problem Action Too much vibration Misalignment coupling Defective mounting or play in coupling Incorrect balancing of shaft Engine Alternator Excessive vibration and humming noise coming from the alternator Three phase alternator is single phase loaded in excess of acceptable level Short circuit ...

Page 91: ...circuited Check the resistance Speed too low Increase the speed of primer mover Do not touch the AVR voltage pot P2 before running at the correct speed Voltage too high Adjust potentiometer voltage No adjustment of voltage measure voltage E E on AVR Voltage between E and E 12V or AVR faulty Voltage oscillations Adjust the stability potentiometer on A V R If no effect change recovery mode normal ra...

Page 92: ...isconnect the leads E 5 and E 6 from the terminals located on the side of the voltage regulator AVR Using jumper wires and a momentary normally open switch connect the E 5 lead to one side of the switch and connect the other side of the switch to the positive terminal of a 6 VDC dry cell battery Then take the E 6 lead and ground it to the frame of the unit and ground the negative terminal of the b...

Page 93: ...ion Maintenance Manual 22637300 93 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 ...

Page 94: ...REP version Interference suppression conforms with standard EN 55011 group 1 Class B Options Stator temperature detection probes space heaters Mechanical Characteristics Steel Frame End shields in cast iron or aluminium Ball bearings greased for life Mounting arrangement MD 35 STANDARD single bearing with standard feet and SAE coupling discs B 34 STANDARD two bearing feet mounteed with standard ba...

Page 95: ...0 Hz Rated overload current 8A 10S R448 10A 10S Electronic protection overload short circuit opening on voltage detection excitation ceiling current for 10 seconds then return to approx 1A The alternator must be stopped or the power switched off in order to reset the protection Fuse F1 on input side X1 X2 Voltage detection 5 VA isolated via transformer 0 110V terminals 95 to 140V 0 220V terminals ...

Page 96: ... 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 A 1 k potentiometer can also be used to extend the adjustment range ...

Page 97: ... 25 and consequently the amount of active load applied is reduced by approximately 25 to 50 until the speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engine To avoid voltage oscillations the trip threshold for the LAM ...

Page 98: ...e 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 Ratchet spanner extension 2 Torque wrench 3 7 mm flat spanner 4 8 mm flat spanner 5 10 mm flat spanner 6 12 mm flat spanner 7 8 mm socket 8 10 mm socket 9 13 mm socket 10 15 mm Allen key eg Facom ET5 11 16 mm Allen key ego Facom ET6 1...

Page 99: ...e fixing clamps on the power output cables disconnect E E on the exciter and R 791 module Remove the 4 nuts on the tie rods Remove the NDE bracket using an extractor eg U 32 350 FACOM Remove the surge suppressor Remove the 4 fixing screws from the diode bridges on the armature Disconnect the diodes Check the 6 diodes using either an ohmmeter or a battery lamp Identification Screw Ø Torque N m Fiel...

Page 100: ...e R791 module Refit the air intake louvre Replace the terminal box lid Replacing the NDE bearing on a single bearing machine Dismantling Dismantle the NDE bracket and remove the bearing using a puller See Fig 25 Reassembly Heat the inner slipring of a new bearing by induction or in a drying oven at 80 C do not use an oil bath and fit it to the machine Place the preloading wavy washer in the flange...

Page 101: ...e main field rewinding replacement of components the rotor assembly must be rebalanced Reassembly Follow the dismantling procedure in reverse order Take care not to knock the windings when refitting the rotor in the stator If you replace the fan respect the assembly guide fig 27 Use a tube and a screw Follow the procedure for reassembling the bearings After final adjustments the access panels or c...

Page 102: ...ing Alternator 4 pole with AREP excitation Resistances at 20 C 50 60 Hz Alternator 4 pole with AREP excitation Field excitation current i exc A 400V 50Hz Symbols i exc excitation current of the exciter field Lister type machine For 60Hz machines the i exc values are approximately 5 to 10 less Type 42 2 VS2 S4 S5 M6 M7 L9 L N stator 0 76 0 34 0 34 0 22 0 22 0 2 Rotor 2 1 2 7 2 7 3 3 3 3 3 7 Auxil w...

Page 103: ...Alternator Installation and Maintenance Operation Maintenance Manual 22637300 103 ...

Page 104: ... Earth terminal 207 1 AVR damper seal 30 1 DE shield 217 1 Terminal block 33 1 Air outlet grille 290 1 PMG hsg 36 1 Sheild on exciter end 291 1 Adaption shaft 37 4 Tie rod 292 1 Magnetic rotor 41 1 Cover front panel 293 1 Stator 47 1 Cover rear panel 294 1 Fixing screws 48 1 Cover top panel 295 1 Tie rod 49 34 Fixing screws 296 1 Cable gland washer nut 297 1 End Plate 320 1 Hub 322 1 Coupling disc...

Page 105: ...Revision History Rev Level EC Number Comments A B C D E F G H SVC31253 Original Release Revisions Revisions Revisions Revisions Revisions 12 09 Revisions 8 2 2010 Revisions ...

Page 106: ... 2009 Doosan Infracore International Inc Printed in the USA Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com ...

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Doosan G10WMI-2D-T2, Installation, Operation & Maintenance Manual

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