G10, G20, G30, G40, G60, G80,

EN
G100, G160, G200, G250, G400, G500
OPERATION & MAINTENANCE MANUAL

23033996-EN (11-12) Rev. F Printed in Belgium © Doosan Company 2012

Original Instructions
 TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOTE STARTING AND STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSTICS/AUTO SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE CONTROLS and INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
GENERATOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MONITOR SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PROTECTION/REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
STARTING (KEY START MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STOPPING (KEYSTART MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSTICS/AUTO SHUTDOWN (KEYSTART MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
GENERATOR SYSTEM (KEYSTART MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MONITOR SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CIRCUIT BREAKERS - Flip to Reset (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SOCKETS (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PROTECTION/REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
BASIC DIGITAL CONTROLS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ADJUSTMENT INSTRUCTIONS and TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 56
VOLTAGE REGULATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
POWER BYPASS SWITCH FOR ENGINE ECU SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

ALTERNATOR INSTALLATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 59

SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION - COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SERVICING-MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
TECHNICAL CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3
 **Always use Doosan Replacement parts!**

4
 Foreword

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 Operation & Maintenance Manual Foreword

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 Safety Symbols

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 Operation & Maintenance Manual Safety Symbols

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Safety Symbols Operation & Maintenance Manual

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 Operation & Maintenance Manual Safety Symbols

Crush Warning

No Water Coolant Fill

No Flame

Fill with fuel before start-up

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 Safety

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 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. Avoid breathing exhaust 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
service.

Modification or alteration of this machine CAN result in severe injury or

death. Do not alter or modify this machine without the express written
consent of the manufacturer.

! WARNING
This machine is equipped with an Auto Start System, which can cause the
machine to start at any time. Follow all safety recommendations outlined
in this manual to avoid injury to personnel. DISCONNECT BATTERY
BEFORE SERVICING.

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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
booster 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). 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 relieve PRESSURE
from HOT radiator. Protect skin and eyes. HOT water or steam and
chemical additives can cause serious personal injury.

! 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.

Do not operate Genset if fuel has been spilled inside or near the unit.

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 Operation & Maintenance Manual Safety

! WARNING
Electrical Shock -

Do not operate electrical equipment while 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, disconnect all
leads to electrical power requirements and disconnect battery to prevent
start up.

GROUNDING
Comply with applicable electrical codes.

! 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 IEC
364-4-41.

The Generator Set is internally grounded neutral to the frame of the

Generator Set. This internal ground connection is essential for proper
Generator Set performance and personal protection.

External grounding consists of connecting the generator neutral to a

solid earth ground, and is the responsibility of the operator, when
grounding is required by IEC 364-4-41 Protection Against Electric Shock,
and other local codes as applicable.

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Safety Operation & Maintenance Manual

Several methods are employed to externally ground portable generator

sets, depending on the intended use and code requirements. In all cases,
a continuous length of splice-free copper cable, no smaller than 10 mm2,
shall be used for the external ground conductor, when grounding is
required.

A qualified, licensed electrical contractor, knowledgeable in local codes,

should be consulted.

! WARNING
Failure to properly ground the Generator Set can result in severe injury
or death.

IF USED AS ALTERNATE POWER SUPPLY

Connect only after the main service entrance switch has been DISCONNECTED and
LOCKED OPEN. In addition, circuit overload protection must be provided in accordance with
National Electrical Codes and local regulations.

! 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 make electrical connections with the unit running.

Before placing the unit in operation, verify the electrical rating of the
Generator Set and do not exceed generator set ratings.

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 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.
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 confined spaces.

• Avoid breathing exhaust fumes.

• Avoid breathing brake lining dust during maintenance.

• Always operate in a well ventilated area.

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 General Data

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 Operation & Maintenance Manual General Data

General Data

UNIT MODEL G10 (1PH) G10 (3PH) G20 G30 G40 G60 G80

Engine Speed - RPM 1500 1500 1500 1500 1500 1500 1500

Engine Fuel Diesel Diesel Diesel Diesel Diesel Diesel Diesel

Manufacturer Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi John John Deere

Deere

Model S3L2-61IR S3L2-61IR S4Q2- S4S- S4S- 4045TF270 4045HF275

Z361SD Z361SD Z3DT61SD

FLUID CAPACITIES

Engine Crankcase Lubricant (Liters) 4.2 4.2 6.5 10 10 14.8 14.8

Fuel Tank (Liters) 101 101 150 199 413 413 716

Radiator & Engine Coolant (Liters) 4.2 4.2 9.1 11.4 11.4 22.7 26.5

Electrical System 12VDC 12VDC 12VDC 12VDC 12VDC 12VDC 12VDC

UNIT MEASUREMENTS/ WEIGHTS

Overall length (mm) 1567 1567 1862 2165 2471 2471 2720

Overall width (mm) 851 851 889 1003 1003 1003 1214

Overall height (mm) 1118 1118 1382 1448 1750 1750 1763

Weight (with fuel) (kg) 694 694 999 1329 1649 1949 2377

Weight (less fuel) (kg) 608 608 846 1134 1260 1560 1714

UNIT MODEL G100 G160 G200 G250 G400 G500

Engine Speed - RPM 1500 1500 1500 1500 1500 1500

Engine Fuel Diesel Diesel Diesel Diesel Diesel Diesel

Manufacturer John Deere John Deere John Deere Cummins Cummins Cummins

Model 4045HF279 6068HF279 6068HF475 QSL9-G3 QSX15-G6 QSX15-G8

FLUID CAPACITIES

Engine Crankcase Lubricant (Liters) 14.8 32.5 32.5 26.5 91 91

Fuel Tank (Liters) 716 961 961 1461 2173 2173

Radiator & Engine Coolant (Liters) 26.5 31.2 31.2 32 57 57

Electrical System 12VDC 12VDC 12VDC 24VDC 24VDC 24VDC

UNIT MEASUREMENTS/ WEIGHTS

Overall length (mm) 2720 3566 3566 4049 5037 5037

Overall width (mm) 1214 1265 1265 1425 1623 1623

Overall height (mm) 1763 2017 2017 2385 2385 2548

Weight (with fuel) (kg) 2614 3567 3674 4783 7619 7746

Weight (less fuel) (kg) 1951 2678 2785 3441 5622 5749

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General Data Operation & Maintenance Manual

General Info
G10 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
77 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
92 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G20 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
80 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
94 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G30 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
80 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
94 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G40 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
81 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
96 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G60 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
78 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
92 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G80 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
81 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
94 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO 8528-
10:1998

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 Operation & Maintenance Manual General Data

G100 INFORMATION ON AIRBORNE NOISE

- The A-weighted emission sound pressure level
82 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
96 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO 8528-
10:1998
G160 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
80 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
95 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G200 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
80 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
97 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G250 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
84 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
97 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO
8528-10:1998
G400 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
84 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
98 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO 8528-
10:1998
G500 INFORMATION ON AIRBORNE NOISE
- The A-weighted emission sound pressure level
85 dB(A), uncertainty 1 dB(A)
- The A-weighted emission sound power level
99 dB(A), uncertainty 1 dB(A)
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO 8528-
10:1998.

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 Operating Instructions

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 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 STARTING
1. Fill with CLEAN diesel fuel. Units are shipped without fuel.
2. Ensure load wiring connections are tight.
3. Check for fluid leaks.
4. Check for fluid level in container base.
5. Check engine oil and coolant level.
6. Check proper grounding circuit. Refer to Safety-Grounding.
7. Check for frayed or loose fan belts, hoses or wiring insulation.
8. Check for leaves, paper, debris in air vents.

! 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.

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Operating Instructions Operation & Maintenance Manual

STARTING

! 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. Main Breaker is “OFF”.
3. Battery Disconnected Switch is “ON”.
4. Reset (pull to unlatch) Emergency Stop Button.
5. Push the Engine “START” Button.
6. 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, refer to Engine O&M Book.

If engine shuts down, diagnostic lamps will indicate the problem. Correct
the problem before continuing.

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 Operation & Maintenance Manual Operating Instructions

7. Allow the engine to warm-up for 3 to 5 minutes. If the engine stops

unexpectedly, refer to Trouble Shooting Section.
8. Check the CONTROL Panel for proper voltages. No RED diagnostic lamps
should be glowing. Otherwise, shut down the unit and refer to Trouble
Shooting.
9. With main breaker “ON” power is present and available for use.
10. Close side doors for optimum cooling of the unit while running.

STOPPING
1. Turn off all external electrical power loads.
2. 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
hook-up compartment) to a customer-supplied contact that closes to initiate a
genset start.
2. Push the Autostart Mode Switch to illuminate the Autostart Mode LED on
control panel.
3. When the customer contact closes, a 10-second alarm will sound prior to each
crank cycle until the engine starts. Preheating will also occur if enabled.
4. The engine will stop when the customer-supplied contact opens, and the
controller will return to Auto Start Mode.

DIAGNOSTICS/AUTO SHUTDOWN
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.
2. Low Engine Oil Pressure - Indicates engine shutdown due to low engine oil
pressure.
3. Low Fuel Level - Indicates engine shutdown due to low fuel level.

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Operating Instructions Operation & Maintenance Manual

4. High Containment Level - Indicates high level of fluids in the containment

base.
5. Over Crank - Indicates engine did not start after 3 cranks.
6. Battery Not Charging - Indicates battery voltage is low or not being charged.
7. Engine Speed - Indicates engine overspeed.
8. Engine Operating - Indicates engine is cranking or operating.
9. Preheat - Indicates preheating is on.
10. Engine Communication - Indicates the controller has communication with the
engine ECU.
11. Engine Fault - Indicates that engine service may be required.

ENGINE CONTROLS and INSTRUMENTS

12. Engine Start Switch
13. Engine Stop/Reset Switch - Stops engine and resets diagnostics. Also,
awakens controller from sleep mode. Wait 15 seconds for reset to complete
before attempting start.
14. Autostart Mode Switch - Puts engine in Autostart Mode.
15. Autostart Mode - Indicates genset is in Autostart Mode. Note: the controller
will enter low power sleep mode after a short time and all other LED’s will go off.
16. Emergency Stop Switch - Disables running, cranking, and trips main breaker.

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 Operation & Maintenance Manual Operating Instructions

17. Alarm Horn - Sounds prior to a start when in Auto Start Mode.

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Operating Instructions Operation & Maintenance Manual

GENERATOR SYSTEM
METERS

1. AC VOLTS - Indicates the generator output voltage.

2. AC AMPERES - Indicates the generator load in amperes corresponding to
AMPERAGE OUTPUT MONITOR switch position.
3. Hertz - Indicates frequency of generator output.
4. Panel Lamp - Illumination Only.
5. Battery Voltage - Indicates battery charging voltage.
6. Fuel - Indicates fuel level in tank.

MONITOR SWITCHES

7. Amperage Output - Selects the line (phase) amperage to be displayed on the

AC Ammeter.
8. Voltage Adjust Rheostat (VAR) - Turn to adjust generator output voltage.
9. Hourmeter- Records running time for maintenance.

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 PROTECTION/REGULATION

10. 3 Phase Direct Hookup Connections - L1, L2, L3, N (neut), PE (Protective
Earth Ground). (not shown).
11. Fuse Holders- Fuses for voltage output meter. (not shown)
12. Residual Current Release Device (RCD)- Provides earth leakage protection.
(not shown).
13. Main Circuit Breaker - (not shown)
14. Alarm Horn - (not shown) but is located on back of control box.

Voltage Adjustment Range

Line - Neutral Line - Line
L1-N, L2-N, L3-N L1-L2, L1- L3, L2 - L3

207V - 253V 360V - 440V

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Operating Instructions Operation & Maintenance Manual

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 loads are turned “OFF”.

2. Main Breaker is “OFF”.
3. Battery Disconnected Switch is “ON”.
4. Reset (pull to unlatch) Emergency Stop Button.
5. Turn the ENGINE START SWITCH to “PREHEAT” for maximum of 10 seconds
for cold weather starts.
6. Turn ENGINE START switch to “START”. Release after engine starts.

! 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, refer to Trouble Shooting.

If engine shuts down when ENGINE START switch is in the “ON” position,
diagnostic lamps will indicate the problem. Correct the problem before
continuing.

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 Operation & Maintenance Manual Operating Instructions

7. Allow the engine to warm-up for 3 to 5 minutes. If the engine stops

unexpectedly, refer to Trouble Shooting Section.
8. Check the CONTROL Panel for proper voltages. No RED diagnostic lamps
should be glowing. Otherwise, shut down the unit and refer to Trouble
Shooting.
9. With main breaker “ON” power is present and available for use.
10. Close side doors for optimum cooling of the unit while running.

STOPPING (KEYSTART MODELS)

1. Turn off all external electrical power loads.
2. 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.

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Operating Instructions Operation & Maintenance Manual

DIAGNOSTICS/AUTO SHUTDOWN (KEYSTART 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.
2. Low Engine Oil Pressure - Indicates engine shutdown due to low engine oil
pressure.
3. Engine Start Switch Positions - OFF, RUN, PREHEAT, START.
4. Emergency Stop - Disables running, cranking, and trips main breaker.
5. Hourmeter - Records operating time.
6. Controller - (Not shown)

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GENERATOR SYSTEM (KEYSTART MODELS)

METERS

1. AC VOLTS - Indicates the generator output voltage.

2. AC AMPERES - Indicates the generator load in amperes corresponding to
AMPERAGE OUTPUT MONITOR switch position.

MONITOR SWITCHES

3. Amperage Output - Selects the line (phase) amperage to be displayed on the

AC Ammeter.

CIRCUIT BREAKERS - Flip to Reset (if equipped)

4. 16 Amp/400V Socket

5. 16 Amp/230V Socket

SOCKETS (if equipped)

6. 400V - 3 Phase

7. 230V - 1 Phase

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PROTECTION/REGULATION

8. Fuse Holders - Fuses for voltage output selector switch and meter. (not
shown).

9. Main Circuit Breaker -

10. RCD Breaker - (Earth Leakage)

Voltage Adjustment Range

Line - Neutral Line - Line
L1-N, L2-N, L3-N L1-L2, L1- L3, L2 - L3

207V - 253V 360V - 440V

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 Operation & Maintenance Manual Operating Instructions

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

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IDENTIFYING KEYPAD BUTTONS AND INDICATORS

OPERATION BUTTONS

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 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.
Ready/Auto - Indicates the generator set is ready and is in automatic mode.
Supplying Load - Indicates that the generator set is under load.

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VIEWING REAL-TIME DATA - ACCESSING THE SCREENS

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 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

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PARAMETER ADJUSTMENTS VIA KEYPAD

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 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.
Nomin Power (3ph)
Nominal power of the generator in three phase HI-WYE series connection.
Nomin Current
Nominal current of the generator in three phase LOW-WYE parallel connection.
CT Ratio
The generator set current transformer ratio.
PT Ratio
The generator set potential transformers ratio. PT'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 controller.
Alternator Frequency
Frequency of the battery alternator when the controller stops cranking.
Nominal RPM
The nominal engine speed of the generator set.
Mode [OFF, MAN, AUT]
This is the equivalent of controller "Mode" buttons.
Fault Reset Go to Manual
Enables or Disables return to MAN mode when reset is pushed.
Display Backlight Timeout
The time limit in minutes for the backlight to go off.

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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.
Standard = Lite Edit
Modbus = Modbus Protocol
Cummins MB = Cummins Modbus Protocol

ENGINE PARAMETERS
Start RPM
"Firing" speed when controller stops cranking (starter goes 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 setting = 10 seconds.
MaxCrank time
Maximum time limit of cranking.
Crank Fail Pause
Pause time between crank attempts.
Crank Attempts
Maximum number of crank attempts.
Idle Time
Idle time delay starts when RPM exceeds Start RPM. Start fail is detected when during idle
state RPM decrease below 2.

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 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. Stability means that voltage and frequency are within
warning setting limits.

Cooling Speed
This function is not used. Reserved for future applications. Factory default setting = NOMINAL.
Cooling Time
Runtime of the 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 Cooled generator set is stopped or in pause
between repeated starts.
GAS: Output closes together with Binary output IGNITION if RPM is over the 30 RPM (Fix
value). Output opens after stop command or in pause between repeated start.
Fuel Pull Coil
Time duration that output Fuel Pull Coil is active. This output is used for momentary activation
of a fuel solenoid pull coil.

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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. Factory Setting = DEFAULT.
ECU Speed Adjust
This function is not used. Factory Default Setting = O

ENGINE PROTECTION
Eng prot del [s]
During the start of the generator set, some engine protections have to be blocked (e.g. Oil
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.
Wrn Oil Press
Warning threshold for low oil pressure.
Sd Oil Press
Shutdown threshold level low oil pressure.
Oil Press Del
Delay for oil pressure warning/shutdown.
Sd Engine Temp
Shutdown threshold level for high engine coolant temperature.
Wrn Engine Temp
Warning threshold level for high engine coolant temperature.
Wrn Eng Temp Low
Warning threshold level for low engine coolant temperature.

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 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.
Batt Undervolt
Warning threshold for low battery voltage.
Battvolt del
Delay 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 lshort Alarm.
2Inom del
IDMT is "very inverse" generator over current protection. 2Inom del is Reaction time of IDMT
protection for 200% overcurrent Igen = 2* Nominal current.
Curr unbal del
Delay for generator current asymmetry.

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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.
Gen <V Sd
Shutdown level for generator under voltage. All three phases are checked. Minimum out of
three is 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 frequency.
Gen <f Wrn
Warning level for generator under frequency.
Gen <f SD
Shutdown level for generator under frequency.
Gen f del
Delay for generator under frequency and over frequency alarm.

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 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
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 Duration
Selection of length of run time.

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 Maintenance

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 Operation & Maintenance Manual Maintenance

Maintenance Information

! 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.

General
In addition to periodic inspections, many of the components in this unit requires periodic
servicing to provide maximum output and performance. Servicing may consist of pre-operation
and post-operation procedures to be performed by the operating or maintenance personnel.
The primary function of preventive maintenance is to prevent failure 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.

Wiring Routing Clamps

Daily check for loose wire routing clamps. Clamps must be secure and properly mounted. Also
check wiring for wear, deterioration and vibration abrasion.

Electrical Terminals
Check daily for evidence of arcing around electrical terminals.

Grounding Circuit
Daily check that the grounding circuit is in accordance with the Safety CE Directives, IEC 364-
4-41 and the local code requirements. As a minimum, the copper wire size should be 10mm2
from the grounding terminal, frame, generator and engine block.
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:

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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.
2. All flexible hoses must be free of wear, deterioration and vibration abrasion.
Routing clamps must be secure and properly mounted.

Wiring Insulation
Daily check for loose, or frayed wiring insulation or sleeving.

Fuel/Water Separator
Daily check for water in the fuel filter/water separator unit. Some engines have a translucent
bowl for visual indication, and others have a drain valve below the primary element.
Every six months or 500 hours, or less if fuel is 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 air cleaner housing for any condition that might cause a leak and
correct as necessary.
3. Wipe inside of air cleaner housing with a clean, damp cloth to remove any dirt
accumulation. This will permit better seal for gasket on filter element.
4. Install element.

The air cleaner assembly (housing) should be inspected every 3 months or 500 hours for any
leakage paths.

Note: Make sure the inlet is free from obstruction.

Make sure the air cleaner mounting bolts and clamps are tight and the air cleaner is mounted
securely. Check the air cleaner housing for dents or damage to the cleaner, which could lead
to a leak.

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 Operation & Maintenance Manual Maintenance

Fasteners Torque Chart

All fasteners should be torqued in accordance to size and grade. See following inch torque
chart, metric torque chart and wheel torque chart.

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 Operation & Maintenance Manual Maintenance

Engine Radiator
Check the coolant level in the radiator. The coolant must cover the tubes in the top tank
(approximately 1 inch high on a clean measuring rod, stuck down filler neck).

! WARNING
Remove cap slowly to relieve pressure from HOT radiator. Protect skin
and eyes. Hot water or steam and chemical additives can cause serious
personal injury.

The engine coolant system is normally filled with a 50/50 mixture of water and ethylene glycol.
This permanent type anti-freeze contains rust inhibitors and provides protection 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 exterior for obstructions, dirt and debris. If present, blow
water or compressed air containing a non-flammable solvent between the fins in a direction
opposite the normal air flow. Should the radiator be clogged internally, reverse flushing, using
a commercial product and the supplier’s recommended procedure, may correct the problem.

Emergency Stop Switch

Each month, check the operation of the emergency stop switch. Running with no electrical
loads and the main breaker “ON”, press the EMERGENCY STOP SWITCH. The unit should
shutdown immediately and the main breaker should trip with cranking disabled. Emergency
Stop Switch must be reset (pull to unlatch) for operation.

Engine Protection Shutdown System

The operation of the engine protection shutdown system should be checked every month or,
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 and the low fuel switch.
The engine oil pressure switch/sensor prevents the engine from operating with low oil
pressure. Once a month, remove a wire from the engine oil pressure switch/sensor to check
the shutdown system for proper operation. Do the same for the wire on the engine temperature
switch/sensor.

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High Containment Fluid Alarm System

The operation of the high containment fluid alarm system should be checked every 3 months
or, whenever it appears not to be operating properly.
The level switch is located at the lower end of a pipe at the bottom of the containment tank.
Test the switch by unfastening the u-bolts holding the pipe, and then inverting the pipe to allow
the switch float to fall.
The “High Containment Level” LED should illuminate. Replace any defective switch.
Drain the containment area as required, by lowering a suction hose into the containment basin
at the rear of the unit, (just behind the instrument panel).

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 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. **Always use Doosan Replacement parts!**

2. With engine stopped, remove the plate on the left side or front of the alternator
junction box.
3. Locate voltage regulator.

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VOLTAGE REGULATOR ADJUSTMENT

Refer to ACCESSING COMPARTMENT Section and Figure 8-1 for locations.

1. Disconnect all electric loads. Stop Engine. Turn main breaker OFF.

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 52-53 Hz at no load. If adjustment is required, see

procedures (50-50.5 Hz if electronic speed control).

6. Adjust “VOLTAGE” POT(P2) on the regulator to read 440V on AC voltmeter.

7. Adjust “Stability” POT(P3) counter clockwise until the AC volts within ± 1 volt.
Then turn the adjusting “Stability” POT (P3) some 5-10 degrees clockwise.

8. Adjust “Voltage” POT on control panel to read 400V on AC voltmeter.

9. Stop Generator Set.

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 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.

**Always use Doosan Replacement parts!**

Can Bus Diagnostic Connector

Power Bypass Switch

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 Alternator Installation and
Maintenance

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 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.
Our alternators comply with most international standards and are compatible with:

• The recommendations of the International Electrotechnical Commission IEC 34-1,

(EN60034).
• The recommendation of the International Standards Organization ISO 8528.
• The European Community directive on Electromagnetic 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 maintenance manual.
All necessary operations and interventions on this machine must be performed by a qualified
technician.
Our technical support service will be pleased to provide any additional infomation you may
require.
The various operations described in this manual are accompanied by recommendations or
symbols to alert the user to potential risk of accident. It is vital that you understand and take
notice of the different warning symbols used.

! CAUTION
Warning symbol for an operation capable of damaging or destroying the
machine or surrounding equipment.

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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. 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/J: SHUNT or PMG/E: COMPOUND)
• 6/4: Winding number/number of poles

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 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)

AREP Excitation System

With 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 the AVR monitoring
transistor. This principle ensures that regulation is
not affected by distortions generated by the load.

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R 438 LS Regulator

• Short-circuit current = 3 x IN for 10 seconds

• Short-circuit current = 3 x IN for 10 seconds
• Standard power supply; 2 auxiliary windings
• Shunt power supply; max 4SV -50/60 Hz
• Rated overload current: 8A-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)

• Fuse F2 on output side (E+, E-)
• Voltage detection: 5 VA isolated via transformer. 0-110V terminals = 95 to 140V, 0-
220V terminals = 170 to 260V, 0-380V terminals = 340 to 520V
• Voltage regulation ±%
• 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)
• Guadrature droop adjustment via potentiometer P1
• Underspeed protection (U/f) and LAM: frequency threshold adjustable via
potentiometer P4.
• Potentiometer P5, Max. excitation current adjustment via P5: 4.5 to 10A
• 50/60 Hz selection via strap ST3.

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. (A 1 k potentiometer can also be used to

extend the adjustment range).

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 Operation & Maintenance Manual Alternator Installation and Maintenance

LAM Characteristics
The LAM system is integrated as standard in the R438 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" causes the voltage to drop by
approximately 15% and consequently the amount of active load applied is reduced
by approximately 25%, 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" function should be set approximately 2 Hz below the lowest frequency in
steady state.
• LAM: action eliminated by cutting strap ST5.

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Typical effects of the “LAM” with a diesel engine (Figure 12).

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 Operation & Maintenance Manual Alternator Installation and Maintenance

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. 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
When coupling the alternator to the prime mover, the holes of the
coupling discs should be aligned with the flywheel holes by cranking the
engine.

Do not use the alternator fan to turn the rotor.

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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.
There are three possible methods for restoring the above minimum values.
a) Dry out the machine for 24 hours in a drying oven at a temperature of approximately 110°C.
b) Blow hot air into the air input, having made sure that the machine is rotating with the exciter
field disconnected.
c) Run in short-circuit mode (disconnect the AVR).

• 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 rheostat of approximately 10 ohms (50
Watts), to the exciter field terminals, respecting the polarity.
• Open fully all the alternator orifices.
• Run the alternator at rated speed. Adjust the exciter field current using the rheostat
to obtain the rated output current in the short-circuit connections.
Note: Prolonged standstill: In order to avoid these problems, we recommend the use of space
heaters, as well as turning over the machine from time to time.
Space heaters are only really effective if they are working continuously while the machine is
stopped.

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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. 300 - 500 or 1000V on the alternator output terminals.
c) Make sure that the ST3 strap is positioned on the desired frequency (50 or 60 Hz).
d) Voltage potentiometer P2 at minimum, fully to anti-clockwise.
e) Turn the V/Hz potentiometer P4, fully to clockwise.
f) Stability potentiometer P3 approximately 1/3 of travel anti-clockwise.
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 best response times are obtained at the limit of
the instability. If no stable position can be obtained, try cutting or replacing the ST2 strap
(normal/rapid).
i) Check LAM operation: STS closed
j)Turn potentiometer P4 slowly anti-clockwise until there is a significant voltage drop (approx.
15 %).
k) Vary the frequency (speed) of both parts between 48 or 58 Hz according to the operating
frequency, and check the change in voltage previously observed ( -15%).

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I) Readjust the speed of the unit to its rated no-load value.

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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.
Before any intervention on the machine, ensure that it cannot be started by a manual or
automatic system and that you have understood the operating principles of the system.

Checks after startup

After approximately 20 hours of operation, check that all fixing screws on the machine are still
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 rise in the bearings, which should not exceed 60°C
above the ambient temperature. Should this value be exceeded, the machine must be stopped
and checks carried out.

Electrical servicing
Cleaning product for the windings

! WARNING
Do not use: Trichlorethylene, perchlorethylene, trichloroethane and any
alkaline products.

Certain strictly defined pure volatile degreasing products can be used, such as:
-Normal petrol (without additives)
-Toluene (slightly toxic); flammable
-Benzene (or benzine, toxic); flammable
-Ciclohexare (non toxic); flammable

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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. Dry
the winding with a dry cloth. Let any traces evaporate before reassembling the machine.
After cleaning the alternator it is essential to check the isolation of the windings.

Fault detection
If, when first commissioned. the alternator does not work normally, the source of the
malfunction must be identified.
To do this, check that:
-the protective devices are fitted correctly
-all connections 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 a brush. Check that
the degreasing agent will not affect the paint. Compressed air should be used to remove any
dust. If filters have been added to the machine after manufacturer and do not have thermal
protection, the service personnel should clean the air filters periodically and systematically, as
often as necessary (everyday in very dusty atmospheres). Cleaning can be performed using
water for dry dust or in a bath containing soap or detergent in the case of greasy dust. Petrol
or chloroethylene can also be used. After cleaning the alternator, it is essential to check the
winding insulation.

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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 Action
Excessive overheating of alternator frame Air flow (inlet-outlet) partially clogged or hot air is
(temperature rise of more than 40°C being recycled either from alternator or prime
above ambient) mover.
Alternator 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 Three phase alternator is single phase loaded in
coming from the alternator excess of acceptable level.
Short circuit in the alternator stator
Abnormal Noises Action
Alternator damaged by a significant System short circuit
impact which is followed by humming and
vibration MIS paralleling
Possible consequences (according to the
seriousness of the above faults):
Broken or damaged coupling
Broken or bent shaft end
Shifting and short circuit of main field rotor
Fractured fan or coming loose on shaft
Blown rotating diodes, or and A.V.R

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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
on the A.V.R. for 2 to 3 removed.
seconds
The alternator builds up - Check the connections of the
but voltage does not sending leads to the A.V.R.
reach nominal value when - Faulty rotating diode
the battery is removed. - Short-circuit on rotor windings
The alternator builds up - Faulty A.V.R.
but voltage collapses - Exciter field short-circuited or
when the battery is open circuit (check windings)
removed. - Main field winding open circuit
(check resistance).
Voltage too low Check the prime mover Correct speed - Check A.V.R. connections
speed (possible AVR failure)
- Exciter field short-circuited
- Rotating diode(s) burnt out.
- Main field rotor short-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 No adjustment of voltage, Voltage between E+ and E- >
voltage measure voltage E+/E- on 12V or AVR faulty
AVR
Voltage oscillations Adjust the stability If no effect: change Check speed for possible cyclic
potentiometer on A.V.R recovery mode normal/ irregularity
rapid (ST2)
Loose connections
R438 or R448 only
Faulty A.V.R
Speed below nominal on load
(or LAM set too high)
Voltage correct on no load Run on no-load and check Voltage between E+ and Check speed (or LAM on R438
too low on load (*) voltage between E+ and E- <6V (DC) set too high)
E- Voltage between E+ and
Faulty rotating diodes faulty
E- >10V (DC)
Short circuit in the main field.
Check resistance.
Faulty exciter armature. Check
resistance.
Voltage collapses during Check the AVR, the surge The output voltage does Exciter winding open circuit
normal operation (**) suppressor, the rotating not return the rated value
Faulty exciter armature
diodes and replace any
defective part Faulty AVR
Main field rotor winding open
circuit or short circuit

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! 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).

Checking the winding

You can check the winding insulation by performing a high voltage test. In this case you must
disconnect all AVR wires.
During this procedure, make sure that the alternator is disconnected from any external load
and inspect the terminal box to check that the connections are fully tightened.
- Stop the unit, disconnect and disconnect 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 battery to the unit.
- Run the unit at its rated speed.
- Connect a voltmeter to the direct hookups and shut the output breaker and the momentarily
shut switch connected to the E+ (5+) lead and check the output voltage on the voltmeter. If the
output voltage of the alternator is greater than its normal value then the machine is in good
working order. The fault therefore comes from the AVR or its associated wiring(i.e. sensing,
auxiliary windings).

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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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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" or 'AREP" 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 bare shaft key wayed
• Drip-proof machine, self-cooled
• Degree of protection: IP 23

Options-Air input filter, air output labyrinth cowling

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AREP Field Excitation System

With 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 the AVR monitoring transistor. This
principle ensures that regulation is not affected by
distortions generated by the load.
R 438 LS Regulator

• Short-circuit current = 3 x IN for 10 seconds

• Short-circuit current = 3 x IN for 10 seconds
• Standard power supply; 2 auxiliary windings
• Shunt power supply; max 4SV -50/60 Hz
• Rated overload current: 8A-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)

• Fuse F2 on output side (E+, E-)
• Voltage detection: 5 VA isolated via transformer. 0-110V terminals = 95 to 140V, 0-
220V terminals = 170 to 260V, 0-380V terminals = 340 to 520V
• Voltage regulation ±%
• 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)
• Guadrature droop adjustment via potentiometer P1
• Underspeed protection (U/f) and LAM: frequency threshold adjustable via
potentiometer P4.
• Max. excitation current adjustment via P5: 4.5 to 10A
• Potentiometer P5 , Max. excitation current adjustment 4.5 to 8A.
• 50/60 Hz selection via strap ST3.

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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. (A 1 k potentiometer can also be used to extend the adjustment
range.)

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LAM Characteristics
The LAM system is integrated as standard in the R438 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" causes the voltage to drop by
approximately 15% and consequently the amount of active load applied is reduced
by approximately 25%, 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" function should be set approximately 2 Hz below the lowest frequency in
steady state.
• LAM: action eliminated by cutting strap ST5.
Typical effects of the “LAM” with a diesel engine (Figure 12).

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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 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)
12. TORX T20 bit
13. TORX T30 bit
14. Puller (eg. Facom: U35)
15. Puller (eg. Facom: U32/350)

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Screw tightening torque

Identification Screw Ø Torque N•m

Field term. block screw M4 4

Field screw M6 10
Diode bridge screw M6 5
Diode nut M5 4
Assembly rod M8 20
Earthing screw M6 5
Balancing bolt M5 4
Disc/shaft screw M10 66
Lifting screw M8 4
Louvre screw M6 5
Cover screw M6 5

Accessing connections and the regulation system

The terminals are accessed by removing the terminal box lid.
To access the adjustment potentiometers on the AVR, the side plate should be removed.

Accessing, checking and replacing diodes

Dismantling
-Remove the terminal box lid].
-Remove the air intake louvre.
-Unscrew the 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.

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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.
-Replace the fixing clamps on the cables and the 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 and fit a new O ring seal.
-Replace the NDE bracket.
-Rest the rotor on one of its poles, then slide it out. Use the tube as a lever arm to assist
dismantling.

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-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. 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 cover should be refitted.

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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. All values are given at ± 10% (for exact values, consult the test report)
and are subject to change without prior warning.
Alternator 4 pole with AREP excitation Resistances at 20°C () -50/60 Hz

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.wind. X1, X2 0,5 0,3 0,3 0,26 0,26 0,23
Auxil.wind Z1,Z2 0,6 0,5 0,5 0,44 0,44 0,41
Field 6 6 6 6 6 6
Armature 0,5 0,51 0,51 0,51 0,51 0,51

Alternator 4 pole with AREP excitation

Field excitation current (i exc (A) -400V -50Hz)
Symbols: “i exc”. excitation current of the exciter field.

Type 42.2 VS2* S4 S5 M6 M7 L9

No-load 0,9 0,9 0,9 0,8 0,8 0,7
At rated load 2,4 2,1 2,3 2 2,3 2,3

(*) Lister type machine

For 60Hz machines the “i exc” values are approximately 5 to 10% less.

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EXPLODED VIEWS

No. Nbr Desc No. Nbr Desc

1 1 Stator assy 59 3 Inspection door
4 1 Rotor assy 120 1 Terminal block suprt
15 1 Fan 124 1 Terminal block
16 6 Fixing screws 198 1 Voltage regulator
28 1 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
323 - Fixing screws
324 1 Clamping washer
325 - Spacer shim
347 1 Surge suppressor

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