DAGFS-SERIES Silent diesel generator & Digital panel /

Brushless synchronous A.C. Alternators

USER’S MANUAL
[Link]

Manufactured under license of Daewoo International Corporation, Korea

INDEX
1. SAFETY AND WARNING...........................................................................................................................2
2. GENERAL INTRODUCTION.....................................................................................................................6
3. OPERATION INSTRUCTION FOR FIRST START.....................................................................................8
4. MAINTENANCE.......................................................................................................................................14
5. TECHNICAL DATA...................................................................................................................................17
6. DIGITAL PANEL.......................................................................................................................................21
7. EXPLODED VIEW AND PARTS LIST......................................................................................................28
8. EC.............................................................................................................................................................48
9. WARRANTY.............................................................................................................................................49

1
1. SAFETY AND WARNING

The operator of the machine:

Is responsible for and has a duty of care in making sure that the machine is operated safely and
in accordance with the instructions in this user manual.
Should never leave it in a condition, which would allow an untrained or unauthorised person/s
to operate this machine.
Take all due care and diligence for the safety of and with regard to those around whilst using the
machine, to include but not limited to;
Elderly, children, pets, livestock and property.

Some or all of the following PPE, warning signs and symbols may appear throughout this
manual and you must adhere to their warning/s. Failure to do so may result in personal injury.

Personal Protective Equipment (PPE)

Before operation and maintenance for the generator sets, please read carefully about this
manual and make sure a good understanding of this operation manual and other documents
which attached with the engine.
Correct installation of the generator set is the precondition of normal operation. Qualified spare
parts shall be used for maintenance to ensure good running condition and long life expectancy

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The generator set shall be operated only by the staffs who have received training on the
operation and the repair shall be made by the authorized staffs. Operator and maintenance staff
shall be clear about safety and preventive actions and operation maintenance procedure.

The generator sets can only be started under safety conditions. Please do not start the
generator sets when any abnormal condition has been found so that to avoid accidents.
When clean, maintain and repair the generator sets, please shut down the generator set and cut
off the connection of negative polar of the battery or dismantle battery connecting cable, and
place warning label at the relative place so that to avoid accident.

The exhaust air discharged from engine is harmful for people’s health. All of the generator sets
installed indoors shall discharge the exhaust gas to outside doors.

During the period of generator set running, the exhaust pipe and silencer will generate high
temperature. Therefore when the generator set is installed, these parts need to be covered with
insulation materials and be kept far away from inflammable materials. Please ensure good
ventilation and organized environment for the generator set’s installation room. Please do not
place inflammable materials and explosives (liquid) near the engine.

Smoking, spark over, and other fire lighting behaviors are not allowed in the area which is close
to the battery and fuel because the mixture of volatilization from fuel and hydrogen generated by
battery charging process will cause explosion when it meets sparkle or naked flame.

The generator set installation room shall be facilitated with BC and ABC fire extinguisher, and
operators shall be familiar with the knowledge on how to use it.

When fan protection cover or other protection cover has been detached, please do not try to
start the generator set; and when the generator set has to be started, please don’t put your hand
in the area where the protection cover is missing or make repair around these areas. please keep
your palm, arm, long hair, jewelry and loose clothes far away from belt pulley, belt and other
power transmission parts.

When working in the generator set installation room, please ware working clothes, gloves and
hat. After the generator set being started, please don’t try to open the cover of the radiator
before the anti‐freeze fully cooled down, so that to avoid steam (hot water) burst forth to hurt
people. Please don’t swallow or let your skin contact with the harmful materials such as fuel,
anti‐freeze, lubricant and electrolyte.

When you skin is spattered with these kinds of liquids, please use plenty of water to rinse.
Long time stay in high noise level environment will cause harm to your hearing. If you have to
work around the generator set frequently, you’d better ware the device to protect your ear.

When the generator set need to make cable connections to output power, the operation shall
conform to the condition, specification, standard related to power distribution. Qualified cable

3
shall be used to make power distribution.

When the installation of generator set involves with welding, please do not connect to the
ground circuit or make grounding through generator set (engine) so that to avoid the big current
generated from welding operation hurt the electric appliance, bearing and bearing bush etc.
inside of the generator set. Please ensure the safety of generator set and reliable grounding.

SAFETY LABELS INFORMATION

TRANSPORT WARNING

• Never lift the generating set by attaching to the engine

or alternator lifting lugs, instead use the lifting points on the
base frame or canopy.
• Ensure that the lifting rigging and supporting structure is
in good condition and has a capacity suitable for the load.
• Keep all personnel away from the generating set when it
is suspended.

MECHANICAL WARNING

• Do not attempt to operate the generating set with the

safety guards removed. While the generating set is run
ning do not attempt to reach under or around the guards
to do maintenance or for any other reason.
• Keep hands, arms, long hair, loose clothing and jewel
ers away from pulleys, belts and other moving parts.

SAFEGUARD WARNING

• Generating sets that are not equipped with sound att

enuating enclosures can produce noise levels in excess
of 105 dB (A). Prolonged exposure to noise levels above
85 dB (A) is hazardous to hearing.
• Wear protective clothing including gloves and hat whe
n working around the generating set.
• If equipped keep access doors on enclosures closed and locke
d when not required to be open.
• Avoid contact with hot oil, hot coolant, hot exhaust gases, hot
surfaces and sharp edges and corners.

4
CHEMICAL WARNING

• Ensure that the generating set room is properly

ventilated.
• Keep the room, the floor and the generating set clean.
When spills of fuel, oil, battery electrolyte or coolant occur,
they should be cleaned up immediately.
• Never store flammable liquids near the engine.
• Do not smoke or allow sparks, flames or other sources
of ignition around fuel or batteries. Fuel vapors are
explosive. Hydrogen gas generated by charging batteries
is also explosive.
• Never store flammable liquids near the engine.
• Do not smoke or allow sparks, flames or other sources
of ignition around fuel or batteries. Fuel vapors are explosive.
Hydrogen gas generated by charging batteries is also explosive.

ELECTRICAL WARNING

• The generating set should be shutdown with the battery

negative (‐) terminal disconnected prior to attempting to
connect or disconnect load connections.
• Do not attempt to connect or disconnect load connections
while standing in water or on wet or soggy ground.
• Make sure connect generator set to earth.
• Replace the generating set terminal box cover as soon as
connection or disconnection of the load cables is complete.
Do not operate the generating set without the cover securely in
place.
• Connect the generating set only to loads and/ or electrical
systems that are compatible with its electrical characteristics
and that are within its rated capacity
• Keep all electrical equipment clean and dry. Replace any
wiring where the insulation is cracked, cut, abraded or otherwise
degraded. Replace terminals that are worn, discolored or corroded.
Keep terminals clean and tight.
• Do not touch electrically energized parts of the generating
set and/or interconnecting cables or conductors with any
part of the body or with any non insulated conductive object.

5
2. GENERAL INTRODUCTION

7 4
3

6
2 1

GENERATOR SUPPLY SCOPE

Silencer
Engine 6
1 Strong thick pipe with heat insulation
Brand-new engine
materials to reduce noise effectively
and to avoid excessive temperature
11 in canopy inside

Alternator Terminal Box Inside

2 7
Brand new brush Regular internal wire connecting to
less alternator convenient maintain

Access 8 Digital Control Panel

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Large Canopy doors for Branded high quality digital control
convenient maintain and panel rise the reliability and stability
inspection purpose of the genset

Radiator 9
Fuel Tank
4
40°C for open type, Average 8 hours base fuel tank
50°C for soundproof type

Rain Cover
5
Strong materials cover to avoid rain
and dopant in the genset to make
sure generator work regularly

6
A. Product Test logo
Our gensets offered are manufactured strictly accord to the
ISO9001-2000 international quality management system.
Our genset at least 1 hour on load testing from 25%,50%,
75%,100%,110%.

1. MORE 8 HOURS BOTTOM FUEL TANK

WITH FUEL GUAGE
High strength bending base, long-term durability, non-deformation,
anti• corrosion,professional baking paint,large capacity,base tank
height 24-35mm/12-35rnm.

2. HIGH PERFORMANCE SOUND SUPPRESSOR

The high-grade rubber shock absorber between diesel engine,
alternator and frame,it reduce the vibration,reduce the damage for
parts,prolong the service life of the unit, double screw design
more solid and durable and prvent the loose when running,
and to reduce the vibration noise

3. SUPER QUALITY CANOPY & PAINT

2-6 mm thick high quality ATSM standard steel case,
high temperature baking varnish with position pole oxidation
Avoid off paint,More professional

4. TRANSPORTABITY
One-point lifing eye makes it easy to transport all generator.
Special forklift opening are provided in the base of the machine.

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APPLICATION

Continuous service

Used as main power supply to generate electricity for several purposes: motion force, lighting,
heating etc. The generator sets can continue running and allow 10% over load for 1 hour per 12
hours under variable load, which is used for remote area.

Standby service

Used as standby power supply to provide continue electric power for non‐invariable loads. The
generator set is suitable for the area where must ensure continue power supply, such as hospi-
tals, industrial facilities, airports etc. Keep the generator set standby state at any time and st
art to run when the mains supply is abnormal.

Emergency service

Used as auxiliary power supply to solve energy interruptions that may cause serious problems
to people, physical and /or financial damage or to face consumption peaks. The generator set
can start in short order to provide steady electric power for the loads when the mains supply
happen abnormity, and switch to stop after the mains supply becomes normal. Generally the
generator set continues working for several hours.

3. OPERATION INSTRUCTION FOR FIRST START

1) Inject water/oil/diesel

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2) Connect the battery, red wire for anode, black wire for cathode

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3) Press diesel pump, to exhaust air until feel pressure

4) Turn on the emergency stop button

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5) Use the key to turn on the generator, keep it running

6) Operating control panel, in order: STOP Manual Start

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Note: Go to next step if engine starts smoothly. If not, turn back to step 3, press the diese
pump a few more times

Connect city power and output wire, attention: N is null line U V W is firing line

Wire socket above ATS use for city power bottom for output wire

Firing line connect only with U, null line only with N for single phase city power

8) Operating control panel, in order: Stop Auto ( set it to auto mode)

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Final step: Finish set up the generator and then turn on breaker for auto protection

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4. MAINTENANCE

General outline

For different types of generator sets, users need to refer to the matched engine’s operation and
maintenance manual to implement correct maintenance operation.

In order to obtain maximum operation safety and life expectancy of the generator sets, perio-
dic maintenance is very important. Strictly observance of the terms on generator set’s mainte-
nance can ensure generator set’s performance and reduce its damage to environment.

Correctly identify and strictly observe the labels (drawings, words and warnings etc.) On diesel
generator sets can be of great help to correct maintenance and safe operations.

Maintenance of the generator sets shall be made when it has been stopped and the cable
which connect to the negative polar of the battery shall be dis‐connected so that to ensure the
generator set will not mistakenly start.

Engine

Each time before start the engine

• Check lubricant oil level
• Check coolant level
• Check air filter indicator
• Check the ventilation of radiator and ambient environment
• Check engine’s transmission belt
• Check fuel supply status

Generator sets which run frequently need to be checked one time every 6 to 8 hours.
Backup generator sets need to be checked once more after being stopped.
Depends on the new generator set’s running status, when it is necessary, within 100 to 300
Hours, following actions shall be taken:
• Check the valve clearance
• Check the fuel injector

For each 0~50 hours of running

• Discharge the water remained in the oil‐water separator

For each 50~600 hours of running or at least each 12 months

• Change lubricant and lubricant filter
• Because the quality of lubricant oil, sulfur content of the fuel, and lubricant consumption rate
of each engine is different, the interval for lubricant oil change for each generator set will be
different. When change the lubricant oil, at the same time oil filter needs to be changed,
otherwise the change of oil will become meaningless. On the contrary, if the lubricant oil

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remains in good status, we can filter the lubricant much better by change the oil filter.

• Change fuel filter, clean or change first stage fuel filter core, oil water separator’s core (some
of the generator sets have), check and organize fuel pipes arrangement.
• The change interval of above fuel filter (core) depends on the quality of fuel (if it contains
many impurity), the fuel adding method is reasonable or not, the fuel tank is cleaned periodica-
lly or not (contaminant discharge). Once the color of engine exhaust air is found to be abnormal
and the output power decrease, first the fuel system needs to be checked.

For each 400 hours of running

• Check and adjust the transmission belt and change it when necessary
• Check and clean radiator core
• Discharge deposit in the fuel tank

For each 800 hours of running

• Check if the turbocharger has leakage
• Check if the air inlet pipes has leakage

For each 1200 hours of running

• Adjust valve clearance

For each 2000 hours of running or at least 24 months

• Change air filter (depend on ambient air quality, decide if this need to be changed earlier)
• Change coolant and coolant filter (some generator sets have)
• Thoroughly clean radiator core and water path
For each 2400 hours of running
• Check fuel injector
• Thoroughly check and clean turbo‐charger
• Comprehensively check engine equipment

For each 2400 hours of running

• Check fuel injector
• Thoroughly check and clean turbo‐charger
• Comprehensively check engine equipment

Alternator
Inside and outside of the alternator shall be cleaned periodically. And the frequency of cleaning
depends on the generator set’s ambient environment. When the cleaning becomes necessary,
following procedures can be followed: cut off all of the powers, wipe off the dirt, contaminant,
oil stain, water or any other liquid from the surface. The ventilation mesh also needs to be
cleaned. The adhesiveness of these materials to the coils will cause the coils overheat or
damage the insulation.

The dirt and contaminant need to be absorbed by dust collector. Please don’t use air blow or

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high pressure water spray to clean the alternator. The humidity of alternator will decrease
insulation resistance. The alternator shall be dried. Please refer to Alternator’s Operation and
Maintenance Manual for the method of drying and detailed maintenance.

Control panel
Daily maintenance for the control panel shall ensure the cleanness of its surface, make the
indicator more clear and easy for reading, and the operation button flexible and reliable.
During the generator set’s running period, vibration will cause the shift of “0” position in the
instrument of control panel and loose of tightened parts, and therefore periodically check the
instrument of the control panel and parts and cable’s connections are very important.
Repair for the control panel can only be done after thorough learning of the principle of this
control panel (please refer to Control Panel Operation Manual for details)

Start battery
Batteries which have been stored in a long time shall be properly charged before being used,
so that to ensure normal capacitance of the battery. (Densimeter can be used to check the
actual capacitance of the battery)

Normal operation and battery charging will cause some water inside of the battery being
vaporized. And therefore constant fluid infusion is needed. Before fluid infusion, first the conta-
minant around the adding hole shall be cleaned so that to avoid them falling into the battery.
Then open the adding hole, add proper amount of distilled water or purified water. Do not add
too much (shall be according to the indicating line in the battery polar plate), Otherwise the
inside electrolyte will overflow from the adding hole when the battery is under discharge or
charging, which will cause contamination to the ambient material and environment.
Please do not use the battery to start the generator set under low temperature because the
battery capacitance can not output normally under low temperature, and long time discharge
may cause battery malfunction(crake or explode).

Warning:
• The battery of the backup generator set shall be periodically maintained and charged. It is
suggested that users can buy floating charger for the battery.

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5. TECHNICAL DATA

DAGFS-15
SILENT TYPE DIESEL GENERATOR SET
Model DAGFS-15 Power 12 kW
Engine Model ZH2105D Power 15 KVA
Alternator Model VG-164D Standby Power 13.2 kW
Frequency 50 Hz Standby Power 14.52 KVA
Phase/Voltage 3 phase/ 380 V Net weight 650 kg
Rated Current 23 A Size 1700x900x1150 mm

DETAILS OF ENGINE

Engine Model ZH2105D Cylinder N° 4

Displacement 1.8 L Bore and Stroke 100 x 115 mm
Rated Power 18 kW Volume of Oil 13 L
Rated Power 22,5 KVA Combustion Vortex Design
Fuel Consumption 236 g/kw.h Aspiration Type Natural Aspirated
Governor Machinery Governor Radiator Water Tank 50°C
4-stroke, V In-line Water
Type Cool,Electric start Diesel tank capacity 59 L
DETAILS OF ALTERNATOR

Alternator Model VG-164D A.V.R. SX460

Type Brushless sel-excited Protection IP23
Prime Power 15 Insulation Class H
Winding Lead 12 Factor 0.8
ATS 100 A Wire 100% copper wire
Efficient 90%

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DAGFS-25
SILENT TYPE DIESEL GENERATOR SET
Model DAGFS-25 Power 20 kW
Engine Model K4100D Power 25 KVA
Alternator Model VG-184FS Standby Power 22 kW
Frequency 50 Hz Standby Power 28 KVA
Phase/Voltage 3 phase/ 380 V Net weight 710 kg
Rated Current 38 A Size 2000x850x1150 mm

DETAILS OF ENGINE
Engine Model K4100D Cylinder N° 4
Displacement 3,61 L Bore and Stroke 100 x 115 mm
Rated Power 30 kW Volume of Oil 13 L
Rated Power 38 KVA Combustion Vortex Design
Fuel Consumption 7 L/H on 75% loading Aspiration Type Natural Aspirated
Governor Machinery Governor Radiator Water Tank 50°C
4-stroke, V In-line Water
Type Cool,Electric start Diesel tank capacity 70 L
DETAILS OF ALTERNATOR
Alternator Model VG-184FS Efficient 90%
Type Brushless sel-excited A.V.R. SX460
Prime Power 25 Protection IP23
Winding Lead 12 Insulation Class H
ATS 100 A Factor 0.8

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DAGFS-35
SILENT TYPE DIESEL GENERATOR SET
Model DAGFS-35 Power 28 kW
Engine Model K4102D Power 35 KVA
Alternator Model VG-184G Standby Power 30.8 kW
Frequency 50 Hz Standby Power 38.5 KVA
Phase/Voltage 3 phase/ 380 V Net weight 710 kg
Rated Current 53 A Size 2000x850x1150 mm

DETAILS OF ENGINE
Engine Model K4102D Cylinder N° 4
Displacement 3,61 L Bore and Stroke 100 x 115 mm
Rated Power 36 kW Volume of Oil 13 L
Rated Power 45 KVA Combustion Vortex Design
Fuel Consumption 8.2 L/H on 75% loading Aspiration Type Natural Aspirated
Governor Machinery Governor Radiator Water Tank 50°C
4-stroke, V In-line Water
Type Cool,Electric start Diesel tank capacity 72 L
DETAILS OF ALTERNATOR
Alternator Model VG-184G Efficient 90%
Type Brushless sel-excited A.V.R. SX460
Prime Power 35 Protection IP23
Winding Lead 12 Insulation Class H
ATS 100 A Factor 0.8

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DAGFS-50
SILENT TYPE DIESEL GENERATOR SET
Model DAGFS-50 Power 40 kW
Engine Model ZH4105ZD Power 50 KVA
Alternator Model VG-224D Standby Power 44 kW
Frequency 50 Hz Standby Power 55 KVA
Phase/Voltage 3 phase/ 380 V Net weight 900 kg
Rated Current 76 A Size 2150x920x1200 mm

DETAILS OF ENGINE
Engine Model ZH4105ZD Cylinder N° 4
Displacement 3,76 L Bore and Stroke 100 x 115 mm
Rated Power 50 kW Volume of Oil 13 L
Rated Power 62.5 KVA Combustion Vortex Design
Fuel Consumption 11.2 L/H on 75% loading Aspiration Type Natural Aspirated
Governor Machinery Governor Radiator Water Tank 50°C
4-stroke, V In-line Water
Type Cool,Electric start Diesel tank capacity 99 L
DETAILS OF ALTERNATOR
Alternator Model VG-224D Efficient 90%
Type Brushless sel-excited A.V.R. SX460
Prime Power 50 Protection IP23
Winding Lead 12 Insulation Class H
ATS 100 A Factor 0.8

20
DAGFS-80
SILENT TYPE DIESEL GENERATOR SET
Model DAGFS-80 Power 64 kW
Engine Model R4108IZD Power 80 KVA
Alternator Model 224GS Standby Power 70,4 kW
Frequency 50 Hz Standby Power 88 KVA
Phase/Voltage 3 phase/ 380 V Net weight 1250 kg
Rated Current 121 A Size 2350x1000x1350 mm

DETAILS OF ENGINE
Engine Model R4108IZD Cylinder N° 4
Displacement 4,95 L Bore and Stroke 108 x 125 mm
Rated Power 75 kW Volume of Oil 13 L
Rated Power 93,75 KVA Combustion Vortex Design
Fuel Consumption 15 L/H on 75% loading Aspiration Type Natural Aspirated
Governor Machinery Governor Radiator Water Tank 50°C
4-stroke, V In-line Water
Type Cool,Electric start Diesel tank capacity 130 L
DETAILS OF ALTERNATOR
Alternator Model 224GS Efficient 90%
Type Brushless sel-excited A.V.R. SX460
Prime Power 80 Protection IP23
Winding Lead 12 Insulation Class H
ATS 160 A Factor 0.8

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DAGFS-100
SILENT TYPE DIESEL GENERATOR SET
Model DAGFS-100 Power 80 kW
Engine Model R6105AZD Power 100 KVA
Alternator Model 274C Standby Power 88 kW
Frequency 50 Hz Standby Power 110 KVA
Phase/Voltage 3 phase/ 380 V Net weight 1400 kg
Rated Current 142 A Size 2700x1050x1430 mm

DETAILS OF ENGINE
Engine Model R6105AZD Cylinder N° 6
Displacement 7,1 L Bore and Stroke 105 x 135 mm
Rated Power 84 kW Volume of Oil 13 L
Rated Power 105 KVA Combustion Vortex Design
Fuel Consumption 17 L/H on 75% loading Aspiration Type Natural Aspirated
Governor Machinery Governor Radiator Water Tank 50°C
4-stroke, V In-line Water
Type Cool,Electric start Diesel tank capacity 135 L
DETAILS OF ALTERNATOR
Alternator Model 274 C Efficient 90%
Type Brushless sel-excited A.V.R. SX460
Prime Power 100 Protection IP23
Winding Lead 12 Insulation Class H
ATS 160 A Factor 0.8

22
6. DIGITAL PANEL

KEY FUNCTION DESCRIPTION

CONTROLLER DIMENSION

PARAMETER EDITING

After controller powered on,press to enter ito the parameters setting menu,the menu item
as shown:
1) Press @ key to enter the menu interface after controller started,choose 1. (See Fig 1 );
2) Press ID key to enter parameter configuration password confirm interface (See Fig 2);
When 1234 is put, part of the parameters can be set; when 0318 is input, all the parameters
can be set;
3) Press e or 8 key to increase or decrease values;Press ID key to shift cursor and
confirm setting;
4) If password is [Link] into parameter interace; Press e key or 8 key to choose

23
parameter items; Press key to enter into current arameter setting menu;
5) If parameter within the range. the setting can be saed in internal FLASH of controller. If
out of range, it can.

A. Note: Pressing @ key at any time can exit the editor and return to main menu

1. Parameter Selting

PARAMETER RANGE AND DEFINITION

24
25
26
27
TYPICAL APPLICATIONS

28
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7. EXPLODING VIEW AND PARTS LIST (applies to all models)

CYLINDER BLOCK ASSEMBLY

30
NUMBER PART NAME QUANTITY
1 Bolt M8X45 3
2 Nut M8 3
3 Spring washerφ8 3
4 Washerφ8 3
5 Gasket of fuel pump 1
6 Gear housing 1
7 Bolt M8X25 8
8 Spring washerφ8 8
9 Washerφ8 8
10 Gasket of gear housing cover 1
11 Gear housing cover 1
12 Bolt M10X70 8
13 Spring washerφ10 8
14 Washerφ10 8
15 Front oil seal FB55X85X12 1
16 Bolt M8X22 4
17 Spring washerφ8 4
18 Washerφ8 4
19 Advanced device cover 1
20 Gasket of advanced device cover 1
21 Bolt M10X25 4
22 Spring washerφ10 4
23 Gasket of gear housing 1
24 Bolt M10X100 1
25 Nut M10 1
26 Spring washerφ10 1
27 Washerφ10 1
28 Water sealing ring 8
29 Bolt M8X25 3
30 Spring washerφ8 3
31 Washerφ8 3
32 Bracket of generator assembly 1
33 Cylinder liner 4

31
NUMBER PART NAME QUANTITY
34 Cylinder head gasket 1
35 Cylinder head bolt long 14
36 Cylinder head bolt short 4
37 Drain cock 1
38 Rear cover sealing 2
39 Rear cover 2
40 Oil screw ZG3/8 2
41 Cylinder block assembly 1
42 Stud M8X40 4
43 Combined seal washer 4
44 Roof nut M10 4
45 Oil dipstick 1
46 Bolt M8X20 14
47 Spring washer 8 14
48 Washer 8 14
49 Gasket of front cover 2
50 Front cover 1 1
51 Front cover 2 1
52 Oil screw ZG1/8 7
53 Locating pin B10X25 2
54 Plug of camshaft φ55 1
55 Gasket of flywheel housing 1
56 Bolt M8X16 2
57 Spring washerφ8 2
58 Washerφ8 2
59 Dust proofed shell 1
60 Flywheel housing 1
61 Rear oil seal FB100X125X12 1
62 Bolt M12X30 8
63 Spring washerφ12 8
64 Thrust plate 1
65 Locating pin B10X25 2
66 Main bearing 5

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CYLINDER HEAD ASSEMBLY

33
NUMBER PART NAME QUANTITY
1 Bolt M8X45 8
2 Nut M8 8
3 Spring washerφ8 8
4 Washerφ8 8
5 Gasket of inlet manifold 4
6 Inlet manifold 1
7 Gasket of inlet pipe 1
8 Inlet pipe 1
9 Stud M8X50 2
10 Spring washerφ8 2
11 Washerφ8 2
12 Cylinder head assembly 1
13 Gasket of exhaust manifold 4
14 Exhaust manifold 1
15 Bolt M8X25 8
16 Spring washerφ8 8
17 Washerφ8 8
18 Gasket of exhaust pipe 1
19 Bolt M8X25 4
20 Spring washerφ8 4
21 Part of oil-added cover 1
22 Tube for ventilator 1
23 Hoopφ 1
24 Cylinder head cover 1
25 Sealed gasket of cylinder head cover 1
26 Gasket of side cover 1
27 Side cover 1
28 Bolt M8X45 8
Nut M8 8
29
Spring washerφ8 8
30
Bolt M8X22
31 5
Spring washerφ8
32 5
Washerφ8
33 5

34
NUMBER PART NAME QUANTITY
34 Host ring 2
35 Bolt M10X20 4
36 Spring washerφ10 4

35
CRANK AND CONNECTING-ROD MECHANISM

36
NUMBER PART NAME QUANTITY
1 Bolt of crankshaft pulley 1
2 Crankshaft pulley washer 1
3 Crankshaft pulley 1
4 Crankshaft pulley 1
5 Key C10X50 1
6 Connecting-rod 4
7 Piston 4
8 Snap ring 28 8
9 Piston rings 4
10 Piston pin 4
11 Crankshaft 1
12 Oil baffle disc 1
13 Locating pin B10X25 1
14 Connecting-rod bearing 4
15 Flywheel 1
16 Flywheel bolt 6

37
VALVE ACTUATING MECHANISM

38
NUMBER PART NAME QUANTITY
1 Idle gear shaft 1
2 Idle gear 1
3 Idle gear washer 1
4 Bolt M8X22 1
5 Spring washerφ8 1
6 Bolt M8X30 1
7 Spring washerφ8 1
8 Camshaft washer 1
9 Camshaft gear 1
10 Thrust plate of camshaft 1
11 Bolt M8X25 2
12 Spring washerφ8 2
13 Key C8X22 1
14 Camshaft 1
15 Valve tappet 8
16 Push rod 8
17 Rock-arm assembly 1
18 Rock-arm bolt 4
19 Roof nut M8 4
20 Combined seal washerφ8 4
21 Nut M10 4
22 Spring washerφ10 4
23 Seat of valve spring 8
24 Split of valve spring 8
25 Valve spring (outer) 8
26 Valve spring (inner) 8
27 Valve oil seal 8
28 Exhaust valve 4
29 Inlet valve 4

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FUEL SUPPLY SYSTEM

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NUMBER PART NAME QUANTITY
1 Bolt M8X25 2
2 Spring washerφ8 2
3 Washerφ8 2
4 Bolt M8X25 2
5 Spring washerφ8 2
6 Washerφ8 2
7 Nut M8 2
8 Fuel-in joint 1
9 Bracket for fuel filter 1
10 Fuel filter 1
11 Complex pipe for Income and return 1
12 Fuel pump gear 1
13 High pressure fuel pipe 1
14 Injector assembly S529 4
15 Fuel pump assembly BH4Q90R9 1
16 Transport pipe out fuel pump 1
17 Transport pipe to fuel filter 1

41
LUBRICATING SYSTEM

42
NUMBER PART NAME QUANTITY
1 Bolt M8X16 3
2 Spring washerφ8 3
3 Washerφ8 3
4 Oil sump 3
5 Gasket of oil sump 1
6 Bolt M8X25 1
7 Spring washerφ8 8
8 Washerφ8 8
9 Oil filter assembly JX0810 8
10 Bolt M8X45 1
11 Spring washerφ8 1
12 Washerφ8 8
13 Bolt M8X25 8
14 Spring washerφ8 8
15 Washerφ8 1
16 Oil returned cover for turbo 4
17 Gasket of oil returned cover for turbo 4
18 Gasket of oil filter assembly 4
19 Connected cover for oil filter 1
20 Gasket of connected cover for oil filter 1
21 Bolt M8X35 4
22 Spring washerφ8 4
23 Washerφ8 1
24 Bolt M8X16 1
25 Spring washerφ8 1
26 Oil pipe 1
27 Hollow bolt M18X1.5 1
28 Bronze washerφ18 8
29 Bolt M6X20 3
30 Spring washerφ6 3
31 O ring 18X2.4 3
32 Bolt M8X22 1
33 Spring washerφ8 4

43
NUMBER PART NAME QUANTITY
34 Washerφ8 2
35 Oil pump driven gear 1
36 Oil pump gear 1
37 Bolt M8X40 1
38 Spring washerφ8 1
39 Oil pump assembly 1
40 O ring 24X2.4 1
41 Oil strainer 1

44
COOLING SYSTEM

45
NUMBER PART NAME QUANTITY
1 Radiator assembly 1
2 Nut M12 2
3 Combined padding block for radiator 2
4 Spring washerφ12 2
5 Washerφ12 2
6 Bracket of radiator 2
7 Front foot 2
8 Bolt M12X25 4
9 Spring washerφ12 4
10 Nut M14 4
11 Bolt M8X35 4
12 Spring washerφ8 4
13 Washerφ8 4
14 Fan 1
15 V Belt 1168 1
16 Padding block for fan 1
17 Bolt M8X45 4
18 Spring washerφ8 4
19 Washerφ8 4
20 Water pump assembly 1
21 Gasket of water pump 1
22 Bolt M8X85 1
23 Spring washerφ8 1
24 Washerφ8 1
25 Water temperature sensor 1
26 Water Temperature Induction Plug Joint 1
27 Combined sealed washer 1
28 Bolt M8X25 3
29 Spring washerφ8 3
30 Washerφ8 3
31 Thermostat housing 1
32 Gasket of thermostat housing 1
33 Gasket of thermostat housing cover 1

46
NUMBER PART NAME QUANTITY
34 Bolt M8X50 2
35 Spring washerφ8 2
36 Washerφ8 2
37 Thermostat housing cover 1
38 Hoopφ26 2
39 Connected tube 1
40 Inlet tube 1
41 Outlet tube 1
42 Hoopφ38 4

47
ELECTRIC SYSTEM

48
NUMBER PART NAME QUANTITY
1 Bolt M12X30 2
2 Spring washerφ12 2
3 Starting motor assembly 1
4 Generator assembly 1
5 Bolt M8X30 1
6 Spring washerφ8 1
7 Washerφ8 1
8 Adjusted bracket of generator assembly 1
9 Bolt M8X25 1
10 Spring washerφ8 1
11 Washerφ8 1

49
EC DECLARATION OF CONFORMITY
FUJIAN EPOS ELECTRIC MACHINERY [Link]

Model: DAGFS-15, DAGFS-25, DAGFS-35, DAGFS-50, DAGFS-80, DAGFS-100

Brand:

We GBR Corp. LTD, Room 1002, 10/F., David House, 8-20 Nanking Street, Jordan, Kowloon, Hong
Kong, China, declare under our sole responsibility that this product is in conformity and
accordance with the following standards and regulations.

The undersigned is responsible for the compilation of technical documentation.

With this declaration of compliance we certify that articles :FUJIAN EPOS ELECTRIC MACHINERY
[Link] are complying the rules of Machinery Directive EN 60204-1:2018; EN ISO 12100:2010; EN
ISO 8528-13:2016EN 55012:2007/A1:2009; EN IC 61000-3-2:2019 EN 61000-3-3:2013+A1:2019; EN
55012:2007/A 1:2009
The DAEWOO Products authorized representative declares that these products described under
"technical data" are in compliance with:
Machinery Directive EN 60204-1:2018; EN ISO 12100:2010; EN ISO 8528-13:2016EN
55012:2007/A1:2009; EN IC 61000-3-2:2019 EN 61000-3-3:2013+A1:2019; EN 55012:2007/A 1:2009

Signature and Stamp on undersigned responsible.

Date: 28-4-2022
GBR Corporation Ltd.
15/F. 100 Queen´s Road Central, Central, Hong Kong Signature
WARRANTY CARD

Product model Date of sale

Serial number Company

Username Client's signature

The product is in good conditions and fully complete. Read and agree the terms of the warranty.

GUARANTEE
The warranty period starts from the date of sale of the products and covers 2 years for all power products.

During the warranty period, free failures caused due to the use of poor-quality materials in the production and manufacturer
workmanship admitted fault are removed. The guarantee comes into force only when warranty card and cutting coupons are
properly filled. The product is accepted for repair in its pure form and full completeness.

WARRANTY DOES NOT COVER

• Mechanical damage (cracks, chips, etc.) and damage starter, chucks, collets, removable batteries, filters and
caused by exposure to aggressive media, foreign objects safety elements, grease, removable devices, equipment,
inside the unit and air vents, as well as for damage occurred knives, drills, etc.);
as a result of improper storage (corrosion of metal parts); • Electrical cables with mechanical and thermal damage;
• Failures caused by overloading or product misuse, use of • Product opened or repaired by a non-authorized service
the product for other purposes. A sure sign of overload center.
products is melting or discoloration of parts due to the high • Prevention, care products (cleaning, washing, lubrication,
temperature, simultaneous failure of two or more nodes, etc.), installation and configuration of the product;
teaser on the surfaces of the cylinder and the piston or • Natural wear products (production share);
destruction of piston rings. Also, the warranty does not • Failures caused by using the product for the needs related
cover failure of the automatic voltage regulator due to to business activities;
incorrect operation; • If the warranty card is empty or missing seal (stamp) of the
• Failure caused by clogging of the fuel and cooling Seller;
systems; • The absence of the holder's signature on the warranty card.
• Wearing parts (carbon brushes, belts, rubber seals, oil
seals, shock absorbers, springs, clutches, spark plugs,
mufflers, nozzles, pulleys, guide rollers, cables, recoil

Product Product Product

Model Model Model

Company Company Company

Date Date Date

of sale of sale of sale
INDEX
1. SAFETY PRECAUTIONS.........................................................................................................................51
2. INTRODUCTION......................................................................................................................................52
3. PRINCIPLE OPERATION........................................................................................................................53
4. APPLICATION OF THE GENERATOR....................................................................................................53
5. INSTALLATION-PART 1..........................................................................................................................58
6. INSTALLATION-PART 2..........................................................................................................................65
7. ACCESORIES..........................................................................................................................................67
8. SERVICE AND MAINTENANCE..............................................................................................................70

50
1. SAFETY PRECAUTIONS

Before operating the generating set, read the generating set operation manual and this
generator manual and become familiar with it and the equipment. The following symbols are
used in the user manual or on the product:

SAFE AND EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE EQUIPMENT IS

CORRECTLY OPERATED AND MAINTAINED.

Many accidents occur because of failure to follow fundamental rules and precautions.

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

• Ensure installation meets all applicable safety and lacal electrical codes. Have all installa-
tions performed by a qualified electrician.
• Do not operate the generator with protective covers, access covers or terminal box covers
removed.
• Disable eng ine start circuits before carrying out maintenance.
• Disable closing circuits and/or place warning notices on any circuit breakers normally used
for connection to the mains or other generators, to avoid accidental closure.

Observe all IMPORTANT, CAUTION, WARNING, AND DANGER notices, defined as:

IMPORTANT! Important, refers to hazard or unsafe method or practice which can result
in product damage or related equipment damage.
CAUTION! Caution, refers to hazard or unsafe method or practice which can result in
product damage or injury to personnel.
Warning! Warning refers to a hazard or unsafemethod or practice that can result
severe injury to personnel, possibly death.
Danger! Danger, refers to immediate hazards which will result in severe injury or
death to personnel.

Due to our policy of continuous improvement, details in th is manual which were correct at
time of printing, may now be due for amendment. Information included must herefore not be
regarded as binding.

Photograph
The Front Cover photograph is representative only.

51
2. INTRODUCTION

2.1 INTRODUCTION

The generator is of brushless rotating field design, available up to 660V at 50Hz or 60Hz. The
design, build and text procedures meet a range of British, European and international stan-
dards including, BS 5000, BS EN 60034 and ISO 60034, Where applicable. The generators are
fitted with the PMG Pilot exciter system and an automatic voltage regulator (AVR). The MX 341
or the MX 321 can be fitted.

2.2 SERIAL NUMBER LOCATION

Each generator has ns unique serial number stamped int. the upper section of the drive end
frame end-ring. Inside the term inal box two adhesive rectangular labels have been fixed, each
carrying the generator's unique identity number. One label has been fixed to the inside of the
terminal box sheet metal-work, and the second label fixed to the main frame of the generator.

2.3 DESIGNATION

52
3. PRINCIPLE OPERATION

3.1 EXCITED-AVR CONTROLLED GENERATORS

The main stator provides power for excitation of the exciter field via the SX440 AVR which is
the controlling device governing the level of excitation provided to the exciter field. The AVR
responds to a voltage sensing signal derived from the main stator winding By controlling the
low power of the exciter field, control of the high power requirement of the main field is achie-
ved through the rectified output of the armature.

The SX440 AVR senses average voltage on two phases ensuring close regulation. In addition it
detects engine speed and provides voltage fall off with speed. Below a pre-selected speed
(Hz) setting, preventing over-excitation at low engine speeds and softening. The effect of load
switching to relieve burden on the engine.

4. APPLICATION OF THE GENERATOR

The generator is supplied as a component part for installation in a generating set. It is not,
therefore, practicable to fit all the necessary warning/hazard labels during generator
manufacture. The additional labels required are packaged with this manual, together with a
drawing identifying their locations.(see below).

It is the responsibility of the generating set manufacturer to ensure that the correct labels are
fitted, and are clearly visible.

53
The generators have been designed for use in a maximum ambient temperature of 40°C, and
altitude less than 1000 metres above sea level in accordance with Bs5000. Ambient in excess
of 40°C, and altitudes above 1000 metres can be tolerated with reduced ratings-refer to the
factory.

The generators are of air-ventilated scteen protected dripproof design and are not suitable for
mounting outdoors unless adequately protected by the use of canopies. Anticondensation
heaters are recommended during storage and for standby duty to ensure winding insulation is
maintained in good condition.

When installed in a closed canopy it must be ensured that the ambient temperature of the
cooling air to the generator does not exceed that for which the generator has been rated. The
canopy should be designed such that the engine air intake to the canopy is separated form the

54
generator intake, particularly where the radiator cooling fan is required to draw air into the
canopy. In addition the generator air intake to the canopy should be designed such that the
ingress of moisture is prohibited. Preferably by use of a two stage filter.

The air intake/outlet must be suitable for the air flow given in the following table with additional
pressure drops less than or equal to those given in table 1 below:

The generators may be fitted with air f ilters. These are oil charged wire gauze filters and require
charging during installation.

IMPORTANT! Reduction in cooling airflow or inadequate protection to the generator can

result in damage and/or failure of windings

Dynamic balancing of the generator rotor assembly has been carried out during manufacture in
accordance with BS 6861 Part 1 Grade 2.5 to ensure vibration limits of the generator are
in accordance with BS 4999 Part 142.

The main vibration frequencies produced by the component generator are as follows:

The standard terminal box is arranged for cable entry on the right hand side looking from the
end of generator. If specified at the time of order cable entry may be arranged on the opposite
side.

The terminal box is constructed with removable panels for easy adaptation to suit specific
glanding requirements. With in the terminal box there are insulated terminals for line and
neutral connections and provision for earthing. Additional earthing points are provided on the
generator feet.

The neutral, as supplied from the factory, is NOT connected to the frame.

55
Warning! No earth connections are made on the generator and reference to site regulations
for earthing must be made. In correc tearthing or protection arrangements can
result in personal injury or death.

Fault current curves (decrement curves), together with generator reactance data, are available
on request to assist the system designer to select circuit breakers. Calculate fault currents and
ensure discrimination within the load network

4.1 VIBRATION

Vibrations generated by the engine are complex and contain harmonics of 1.5,3,5 or more
times the fundamental frequency of vibration. The generator will be subjected to this vibration,
Which will result in the generator being subjected to vibration levels higher than those derived
from the generator itself.
The generators are designed to withstand the vibration levels encountered on generating sets
built to meet the requirements of ISO 8525-9 and BS5000-3. (Where ISO 8525 is taken to be
broad band measurements and Bs 5000 refers to the predominant frequency of any vibrations
on the generating set.)

Definition of BS 5000-3
Generators shall be capable of continuously with standing linear vibration levels with amplitu-
des of 0.25 mm between 5 Hz and 8Hz and velocities of 9.0mm/s rms between 8 Hz and 200
Hz when measured at any point directly on the carcass or main frame of the machine. These
limits refer only to the predominant frequency of vibration of any complex waveform.

Definition of ISO 8528-9

ISO 8528-9 refers to a broad band of frequencies, the broad band is taken to be between 2
Hertz and 300 Hertz. The table below is an example from ISO 8528-9 (value 1 ). This simplified
table lists the vibration limits by KVA range and speed for acceptable genset operation.

It is the responsibility of the generating set designer to ensure the alignment of the gen set,
stiffness of the bed-frame and mountings are such that the Vibration limits as defined above
are met.

If the Vibration levels of the generating set are not within the parameters quoted above:

56
1. Consult the genset builder. The genset builder should address the genset design to reduce
the vibration levels as much as possibie.
2. Discuss, with
3. The impact of not meeting the above levels on both bearing and generator life expectancy.

IMPORTANT! Important, refers to hazard or unsafe method or practice which can result
in product damage or related equipment damage. Exceeding either of the
above specifications will have a detrimental effect on the generating bea
rings.
IMPORTANT! (See section on bearings). This will invalidate the generator warranty. If you
are in any doubt, contact newage International Linmted

In standby applications where the running time is limited and reduced life expectancy is accep-
ted, higher levels than specified. in BS5000 can be tolerated, up to a maximum of 18mm/sec.

Two bearing generators require a substantial bedplate with Engine/generator mounting pads to
ensure a good base for accurate alignment. Close Coupling of engine to generator can increa-
se the overall rig idity of the set. A flexible coupling designed to Suit the Specific engine/gene-
rator combination, is recommended to minimise torsional effects.

Alignment of single bearing generators is critical and vibration can occur due to the flexing of
the flanges between the engine and generator. A substantial bedplate with engine/generator
mounting pads is required.

The maximum bending moment of the engine flange must be checked with the engine manu-
facturer.

Torsional vibrations occur in all engine-driven shaft systems and may be of a magnitude to
cause damage at cerrain critical speeds. It is therefore necessary to consider the torsional
vibration effect on the generator shaft and couplings.

It is the responsibility of the generator set manufacturer to ensure compatibility, and for this
purpose drawings showing the shaft dimensions and rotor inertia are available for customers to
forward to the enginesupplier. In the case of single bearing generator coupling details are
included.

IMPORTANT! Torsional incompatibility and/or excessive vibration levels can cause

damage or failure of generator and/or engine components

57
5. INSTALLATION-PART 1

5.1 LIFTING

Warning! Incorrect lifting or inadequate lifting capacity can result In severe personal injury
or equipment damage MINIMUM LIFTING CAPACITY REQUIRED IS AS INDICA
TED ON THE LIFTING LABEL. Generator lifting lugs should not be used for lifting
the complete

Two lifting lugs are provided for use with a shackle and pin type lifting aid, A spreader with
chains, to ensure that the lift is vertical, of suitable length and lifting capacity must be used.
Lifting points are designed to position the craneage possible, but due to design restrictions it is
not possible to guarantee that the generator frame will remain horizontal while lifting, Care is
therefore needed to avoid personal injury or equipment damage, The correct lifting arrange-
ment is shown on the label attached to the lifting lug. (See sample below).

Single bearing generators are supplied fitted with a rotor retaining bar at the drive end of the
shaft. Single bearing generators are also fitted with wooden wedges supporting the fan for
transit purposes.

Once the bar is removed to couple the rotor to engine, the rotor is free to move in the frame,
and care is needed during coupling and alignment to ensure the frame is kept in the horizontal
plane.

5.2 ENGINE TO ASSEMBLY GENERATOR COUPLING

During the assembly of the generator to the engine it will be necessary to firstly carefully align,
the rotate, the combined Generator rotor - Engine crankshaft assembly, as part of the cons-
truction process, to allow location, insertion and tightening of the coupling bolts. This require-
ment to rotate the combined assemblies exists for both single and two beating units.

During the construction of single bearing units it is necessary to align the generator's coupling
holes with the engine flywheel holes. It is suggested that two diametrically opposite

58
Location dowel pins are fitted to the engine flywheel. The coupling can then slide into final
location on the engine flywheel recess. The dowels must be removed and replaced by coupling
bolts before the final bolt tightening sequence.

While fitting and tightening the coupling bolts it will be necessary to rotate the engine cranks-
haft - Generator rotor assembly. Care should be taken to ensure that rotation is carried out in
an approved manner that ensures safe working practice when reaching inside the machine to
insert or tighten coupling bolts, and that no component of the assembly is damaged by
non-approved methods of assembly rotation.

Engine Manufacturers have available a proprietary tool designed to enable manual rotation of
the crankshaft assembly. This tool must always be used, having been engineered as an appro-
ved method of assembly rotation, by engaging the manually driven pinion with the engine
flywheel starter ring-gear.

Danger! Before working inside the generator, during the aligning and fitting of coupling
bolts, care should be taken to lock the assembly to ensure there is no possibility.
Of assembly rotational movement.

5.2.1 TWO BEARING GENERATORS

A flexible coupling should be fitted and aligned in accordance with the coupling manufacturer's
instruction.

If a close coupling adaptor is used the alignment of machine faces must be checked by offe-
ring the generator up to the engine. Shim the generator feet if necessary. Ensure adaptor
guards are fitted after generator/engine assembly is complete.

Open coupled sets require a suitable guard, to be provided by the set builder.

Axial loading of the generator beatings should be avoided. Should it be unavoidable contact
the factory for advice.

CAUTION! Incorrect guarding and/or generator a lignment can result in personal injury and/or
equipment damage.

5.2.2 SINGLE BEARING GENERATORS

For transit and storage purposes the generator frame spigot and rotor coupling plates have
been coated with a rust preventative This MUST BE removed before assembly to engine.
A practical method for removal of this coating is to clean the mating surface areas with a
degreasing agent based on a petroleum solvent.

59
CAUTION! Care should be taken not to allow any cleaning agent to come into prolonged
contact with skin.

Alignment of single bearing generators is critical. If necessary shim the generator feet to ensure
alignment of the machined surfaces.

The sequence of assembly to the engine should generally be as follows:

1. On the engine check the distance from the coupling mating-face on the flywheel to the-
flywheel housing mating face. This should be within 0.5mm of nominal dimension. This is
necessary toensure that a thrust is not applied to the ac generator bearing or engine bearing.
2. Check that the bolts securing the flexib le plates to the coupling bub are tight and locked
into position. Refer to section 7. Subsection [Link] for tightening torques.
3. Remove covers from the drive end of the generator to gain access to coupling and adaptor
bolts, check coupling joint interfaces are clean and inbrucant free.
4. Check that coupling discs are concentric with adaptor spigot. This can be adjusted by the
use of tapered wooden wedges between the fan and adaptor. Alternatively the rotor can be
suspended by means of a rope sling through the adaptor opening. Offer the generator to
engine and engage both coupling discs and housing spigots at same time, pushing generator
towards engine until coupling discs are against flywheel face, and housing spigots located.
5. Fit housing and coupling bolts taking care to use heavy gauge washers between coupling
bolt head and coupling disc. Tighten bolts evenly around assembly sufficiently to ensure
correct alignment.
6. Tighten housing bolts.
7. Tighten coupling disc to flywheel bolts. Refer to engine manufacturers manual for correct
tightening torque.
8. Remove rotor - aligning aids either wooden wedges, or the two M 10 set screws and sheet
metal wear plates.

Incorrect guarding and/or generator alignment can result in personal injury and/or equipment
damage.

5.3 EARTHING

The generator frame should be solidly bonded to the generating set bed-plate. If anti-vibration
mounts are fitted between the generator frame and its bed-plate a suitably rated earth conduc-
tor (normally one half of the cross sectional area of the main line cable) should bridge across
the anti - vibration mount. Refer to local regulations to ensure that the correct earthing proce-
dure has been followed.

5.4 PRE-RUNNING CHECKS

60
5.4.1 INSULATION CHECK

Insulation tests should be carried out before running the generator set, both after assembly
and after installation on site. (see Section 7.1)

IMPORTANT! The windings have been H.V. Tested during manufacture and further H.V.
Testing may degrade the in sulation with consequent reduction in operating
life. Should It be necessary to demonstrate H.V. Testing, for customer
acceptance, the tests must be carried out at reduced voltage levels I.e.
Test Voltage=0.8(2 X Rated Voltage+1000)

5.4.2 DIRECTION OF ROTATION

The standard direction of rotation is clockwise, as viewed from the drive end. This matches the
predominant direction of rotation used by diesel engine manufacturers. The generator can be
driven in the opposite direction with a small reduction in efficiency and an increased noise
level. The phase rotation will also be effected.

[Link] PHASE ROTATION

Phase rotation is fixed for the standard direction of rotation, clockwise as viewed from the drive
end. If the generator is to be rotated in the counter - clockwise direction it will be necessary to
connect the customer output cables accordingly. Refer to the factory for 'reverse rotation
wiring diagram'.

5.4.3 VOLTAGE AND FREQUENCY

Check that the voltage and frequency that are required for the generating set application is as
indicated on the generator nameplate. If it is necessary to reconnect the stator for the voltage
required , refer to diagrams in the back of this manual.

5.4.4 AVR SETTINGS

To make AVR selections and adjustments remove the AVR cover and refer to depending upon
type of AVR fitted. Reference to the generator nameplate will indicate AVR type. Most of the
AVR adjustments are factory set in positions that will give satisfactory per formance during
initial running tests. Subsequent adjustment may be required to achieve Optimum performance
of the set under site operating conditions. Refer to 'Load Testing' section for details.

[Link] TYPE SX440 AVR

The following 'jumper' connections on the AVR should be checked to ensure they are correctly
set for the generating set application.

61
Refer to Fig.5 a for location of selection links.

1. Frequency seclection
4 pole 50Hz operation LINK C-50
4 pole 60Hz operation LINK C-60

2. Stability selection terminals

below 90kW LINKA-C
below 550kW LINK B-C

3. Stability selection terminals LINK 2-3

LINK4-5
LINK 6-7

4. Excitation Interruption Link LINK K1-K2

5.5 GENERATOR SET TESTING

Warning! During testing It may be necessary to remove covers to adjust controls exposing
'live' terminals or components. Only personnel qualified to perform electrical
service should carry out testing

62
5.5.1 TEST METERING/CABLING

Connect any instrument wiring and cabling requited for initial test purposes with permanent or
spring-clip type connectors Minimum instrumentation for testing should be line to line or line to
neutral voltmeter, Hz meter, load current meteting and kW meter. If reactive load is used a
power factor meter is desitable.

IMPORTANT! When fitting power cables for load testing purposes, ensure cable voltage
rating is at least equal to the generator rated voltage. The load cable termi
nation should be placed on top of the winding lead termination and clam
ped between the two nuts provided.

CAUTION! Check that all wiring terminations for internal or external wiring are secure,
and fit all terminal box covers and guards. Failure to secure wiring and/or
covers may result In personal Injury and/or equipment failure.

5.6 INITIAL START-UP

Warning! During testing it may be necessary to remove covers t o adjus t controls expo
sing 'live' terminals or components
Only personnel qualified to perform electrical service should carry out testing
and/or adjustments. Replace all access covers after adjustments are completed.

On completion of generating set assembly and before starting the generating set ensure that
all engine manufacturer's pre-running procedures have been completed, and that adjustment
of the engine governor is such that the generator will not be subjected to speeds in excess of
125% of the rated speed.

IMPORTANT! Over-speeding of the generat or is never advisable as this can result in

damage to the generator rotating components special care is necessary
during Initial setting of the speed governor.

In addition remove the AVR access cover and turn VOLTS control fully anti - clockwise. Start
the generating set and run on no - load at nominal frequency. Slowly turn VOLTS control
potentiometer clockwise until rated voltage is reached, refer to fig. 5 for control potentiometer
location.

IMPORTANT! Do not increase the voltage above therated generator voltage shown on
the generator nameplate.

This STABILITY control potentiometer will have been pre-set and should normally not require
adjustment, but should this be required, usually identified by oscillation of the voltmeter, refer
to Fig. 5 for control potentiometer location and proceed as follows:

63
1. Run the generating set on no-load and check that speed is correct and stable.

2. Turn the STABILITY control potentiometer clockwise, then turn slowly anti-clockwise until the
generator voltage starts to become unstable.

The correct setting is slightly clockwise from this position ( i. E. Where the machine volts are
stable but close to the unstable region).

5.7 LOAD TESTING

Warning! During test ing it may be necessary to remove covers to adjust controls exposing
'live’ terminals or components
Only personnel qualified to perform electrical service should carry out testing
and/or adjustments. Refit all access covers after adjustments are completed.

5.7.1 AVR ADJUSTMENTS

Refer to Fig. 5 for control potentiometer locations. Having adjusted VOLTS and STABILITY
during the initial start-up procedure, other AVR control functions should not normally need
adjustment. If instability on load is experienced, recheck stability setting. Refer to subsection
4.6.
If however, poor voltage regulation on-load or voltage collapse is experienced, refer to the
following paragraphs on each function to
A) Check that the symptoms observed do ind icate adjustment is necessary.
B) make the adjustment correctly.

[Link] UFRO (UNDER FREQUENCY ROLL OFF)

The AVR incorporates an under speed protection circuit that gives a voltage/speed (Hz)charac-
teristic as shown:

64
The UFRO control potentiometer sets the "knee Point". Symptoms of incorrect setting are a)
the light emitting diode (LED) indicator, just above the UFRO control potentiometer, being
permanently lit when the generator is on load, and b) poor voltage regulation on load, i.e. ope-
ration on the sloping part of the characteristic

Clockwise adjustment lowers the frequency (speed) setting of the "knee point" and extingui-
shes the LED. For Optimum setting the LED should illuminate as the frequency falls just below
nominal frequency, i.e. 4Hz on a 50Hz generator or 57Hz on a 60Hz generator.

IMPORTANT! If the LED is i lluminated and no output voltage is present, refer to EXC
TRIP and/or OVER/V sections below.

5.8 ACCESSORIES

Refer to the "ACCESSORIES" Section of this manual for setting up procedures related to gene-
rator mounted accessories.
If there are accessories for control panel mounting supplied with the generator refer to the
specific accessory fitting procedures inserted inside the back cover of this book. Replace AVR
access cover after all adjustments are completed.

Warning! Failure to refit covers can result in personal injury or death.

6. INSTALLATION-PART 2

6.1 GENERAL

The extent of site installation will depend upon the Generating set build, e. g. if the generator is
installed in a canopied set with integral switchboards and circuit breaker, on site installation will
be limited to connecting up the site load to the generating set output terminals. In this case
reference shou ld be made to the generating set manufacturer's instruction book and any
pertinent local regulations.

If the generator has been installed on a set without Switchboard or circuit breaker the following
points relating to connecting up the generator should be noted.

6.2 GLANDING

IMPORTANT! To avoid the possibility of swarf e ntering any electrical components in the
terminal box, panels must be removed for drilling.

65
The terminal box is arranged for glanding on the right hand side (or if specifically ordered on
the left-hand side) viewed from the end. Both panels are removable for drilling/punching
to suit glands/or glanding boxes. If single core cables are taken through the terminal box side
panel an insulated or non-magnetic gland plate should be fitted.

At entry to the terminal box incoming cables should be Supported by a recognized glanding
method such that minimum unsupported weight, and no axial force, is transferred to the termi-
nal assembly.

Incoming cables external to the terminal box. should be supported. The supports should allow
for an adequate radius at each bend, and allow for the vibration of the generating set without
putting excessive stress on the cables. Before making final connections, test the insulation
resistance of the windings. The AVR should be disconnected during this test and RTD leads
grounded.

A 500V Megger or similar instrument should be used. Should the insulation resistance be less
than 5MO the windings must be dried out as detailed in the Service and Maintenance section
of this manual.

6.3 TORQUE SETTINGS FOR TERMINAL CONNECTIONS

Pre treatment: Clean plated surfaces with a degreasing agent, then lightly abrade them to
remove any tarnish. Don't score the surface.

The generator torque settings for all generator connections, links, CT's, accessories, cables,
etc. is 45 Nm.

The customer output cables should be connected to the terminals using 8.8 grade steel bolts
and associated antivibration hardware. The following table is for your guidance when connec-
ting the customer output cables.

Carry out periodic checks to ensure that the torque settings are correct.

6.4 EARTHING

The neutral of the generator is not bonded to the generator frame as supplied from the factory.
An earth terminal is provided inside the terminal box adjacent to the main terminals. Should it
be required to operate with the neutral earthed a substantial earth conductor (normally equiva-
lent to one half of the section of the line conductors) must be connected between the neutral
and the earth terminal inside the terminal box. It is the responsibility of the generating set
builder to ensure the generating set bedplate and generator frame are all bonded to the main
earth terminal in the terminal box.

66
CAUTION! Reference to local electricity regulations or safety rules should be made go
ensure correct earthing procedures h ave been followed.

6.5 PROTECTION

It is the responsibility of the end user and his contractors/subcontractors to ensure that the
overall system protection meets the needs of any inspectorate, local electricity authority of
safety rules, pertaining to the site and it's location. To enable the system designer to achieve
the necessary protection and / or discrimination, fault current curves are available on request
from the factory, together with generator reactance values to enable fault current calculations
to be made.

Warning! Incorrect inst allation and/or protective systems can result in personal injury
and/or equipment damage. Installers must be qualified to perform electrical
installation work.

6.6 COMMISSIONONG

Ensure that all external cabling is correct and that all of the generating set manufacturer's
pre-running checks have been carried out before starting the set.

Generators fitted with air filters should have the filters charged with oil prior to commissioning.
Refer to Service section for charging procedure (subsection 7.3.2)

The generator AVR controls will have been adjusted during the generating set manufacturer's
tests and should normally not require further adjustment.

Should malfunction occur during commissioning refer to Service and Maintenance section
'Fault Finding' procedure (subsection? A)

7. ACCESSORIES

Generator control accessories may be f itted, as an option, in the generator terminal box. If
fitted at the time of supply, the wiring diagram(s) in the back of this book shows the connec-
tions. When the options are supplied separately, fitting instructions are provided with the
accessory.

7.1 REMOTE VOLTAGE ADJUST

A remote voltage adjust(hand trimmer) can be fitted.

The remote voltage adjustment potentiometer is connected across AVR terminals 1&2.

These terminals are normally linked.

67
When the remote voltage adjust potentiometer is used the link across terminals 1 & 2 must be
removed.

On SX440 the link 1&2 is on an adjacent terminal block.

7.2 PARALLEL OPERATION

IMPORTANT! Failure to meet conditio ns 1, 2 and 3 when closing the circuit breaker, will
generate excessive mechan ical a nd el ectrical stresses, resulting in
equipment damage.

Understanding of the following notes on parallel operation is useful before attempting the
fitting or setting of the droop kit accessory. When operating in parallel with other generators
or the mains, it is essential that the phase sequence of the incoming generator matches that of
the busbar and also that all of the following conditions are met before the circuit breaker of the
incoming generator is closed on to the busbar (or operational generator).

1. Frequency must match within close limits.

2. voltages must match within close limits.
3. phase angle of voltages must match within close limits.

A variety of techniques, varying from simple synchronising lamps to fully automatic synchroni-
sers, can be used to ensure these conditions are met. Once connected in parallel a minimum
instrumentation level per generator of voltmeter, ammeter, wattmeter (measuring total power
per generator), and frequency meter is required in order to adjust the engine and generator
controls to share KW in relation to engine ratings KVAr in relation to generator ratings.
It is important recognize that:

1. kW are derived from the engine, and speed governor characteristics determine the kW
sharing between sets and.
2. KVAr are derived from the generator, and excitation control characteristics determine the
KVAr sharing.

Reference should be made to the generating set manufacturer's instructions for setting the
governor controls.

7.2.1 DROOP

The most commonly used method of KVAr sharing is to create a generator voltage characteris-
tic that fa lls with a decreasing power factor (increasing KVAr). This is achieved with a current
transformer (C.T.) that provides a signal dependent on current phase angle (i.e. power factor) to
the AVR. The current transformer has a burden resistor on the AVR board, and a percentage of
the burden resistor voltage is summed into the AVR circuit. In creasing droop is obtained by
turning the DROOP control potentiometer clockwise.

68
The diagrams below indicate the effect of droop in a simple two generator system:

Generally 5% droop at full load current zero power factor is sufficient to ensure KVAr sharing.
If the droop accessory has been supplied with the generator it will have been tested to ensure
correct polarity and set to a nominal leve of droop. The final level of droop will be set during
generating set commissioning. Although nominal droop setting may be factory set it is advisa-
ble to go through the setting procedure below.

[Link] SETTING PROCEDURE

Depending upon available load the fol lowing settings should be used, laa are based on rated
current level.

0.8 P. F. load (at full load current) set droop to 3%

Zero P. F. load (at full load current ) set droop to 5%

Setting the droop with low power factor load is the most accurate.

Run each generator as a single unit at rated frequency or rated frequency +4% depending
upon type of governor and nominal voltage. Apply available load to rated current of the

69
generator. Adj ust 'DROOP' control potentiometer to give droop in line with above table. cloc-
kwise rotation increases amount or droop. Refer to Fig. 5a of 5b for potentiometer locations.

Note 1)
Reverse polarity of the C. T. will raise the generator voltage with load. The polarities S1&S2
shown on the wiring diagrams are correct for clockwise rotation of the generator looking at the
drive end. Reversed rotation requires S1&S2 to be reversed.

Note 2)
The most important aspect is to set all generators equal. The precise level of droop is less
critical.

Note 3)
A generator operated as a single unit with a drop circuit set at rated load 0.8 power factor is
unable to maintain the usual O.S% regulation. A shorting switch can be connected across
S1&S2 to restore regulation for single running.

IMPORTANT! LOSS OF FUEL to an engine can cause Its generator to motor with conse
quent damage to the generator windings. Reverse power relays should be
fitted to trip main circuit breaker.

IMPORTANT! LOSS OF EXCITATION to the generator can result in large c urrent oscilla
tions with consequent damage to generator winndings. Excitation loss
detection equipment should be fitted to trip main circuit breaker.

IMPORTANT! When using this connection arrangement a shorting switch is required

across each C.T. Burden (terminals S1&S2.) The switch must be closed a)
when a generating set is not running and b) when a generating set is selec
ted for single running.

Should 'Asiatic' control of the generator be required, request the diagrams from the factory.
The setting procedure is exactly the same as for DROOP. (Subsection [Link])

8. SERVICE AND MAINTENANCE

As part of routine maintenance procedures. Periodic attention to winding condition (particularly

when generators have been idle for a long period ) and bearings is recommended. (Refer to
subsections 8.1 and 8.2 respectively).

When generators are fitted with air filters regular inspection and filter maintenance is required.
(Refer to subsection 8.3).

8.1 WINDING CONDITION

70
Danger! Service and fault finding procedures present hazards that can result in severe
personal injury or death. Only personnel qualified to perform electrical and me
chanical service should carry out these procedures. Ensure engine start circuits
are disabled before commencing service or maintenance procedures. Isolate any
anti-condensation heater supply.

Guidance or Typical Insulation Resistance [IR]

Values he following is offered as general information about IR values. The aim is to provide
guidance about the typical IR Values for generator from new through to the point of refurbish-
ment.

New machine
The generators Insulation Resistance, along with many Other critical factors, will have been
measured during the alternator manufacturing process. The generator will have been transpor-
ted with an appropriate packaging suitable for the method of delivery to the Generating Set
assemblers works, where we expect it to be stored in a suitable location protected from adver-
se conditions.

However, absolute assurance that generator will arrive at the Gen-set production line with IR
values still at the factory test levels of above 100MΩ cannot be guaranteed.

At Generating Sat Manufacturers Works The generator should have been transported and
stored such that it will be de livered to the assembly area in a clean dry condition. If held in
appropriate storage conditions the generator IR value should typically be 25MΩ If the unused/-
new generator's IR values fall below 10MΩ then a drying out procedure should be implemented
by one of the processes outlined below before being dispatched to the end customer's site.
Some investigation should be undertaken into the storage conditions of the generator while on
site.

Generators in Service
Whilst It is known that a generator will give reliable service with an IR value of just 10MΩ. For a
relatively new generator to be so low it must have been subjected to inappropriate operating or
storage conditions.

Any temporary reduction in IR values can be restored to expected values by following one of
the drying out procedures.

8.1.1 WINDING CONDITION ASSESSMENT

CAUTION! The AVR should be disconnected and the Resistance Temperature Detec tor
(R.T.D.) leads grounded during this test.

71
The condition of the windings can be assessed by measurement of insulation resistance [IR]
between phase to phase, and phase to earth. Measurement of winding insulation should be
carried out:-

1. As part of a periodic maintenance plan.

2. After prolong periods of shutdown.
3. When low insulation is suspected, e.g. Damp or wet windings.

Care should be taken when dealing with windings that are suspected of being excessively
damp or dirty. The initial measurement of the [IR] insulation Resistance should be established
using a low voltage (SOOV) megger type instrument. If manually powered the handle should
initially be turned showly so that the full test voltage will not be applied, and only applied for
long enough to very quickly assess the situation if low values are suspected or immediately
indicated.

Full megger tests or any other form of high voltage test should not be applied until the windings
have been dried out and if necessary cleaned.

Procedure for insulation Testing

Disconnect all electronic components, AVR, electronic protection equipment etc. Ground the
[RTD'S] Resistance Temperature Detection devices if fitted. Short out the diodes on the rotating
diode assembly. Be aware of all components connected to the system under test that could
cause false readings or be damaged by the test voltage.

Carry out the insulation test in accordance with the 'operating instructions' for the test equip-
ment. The measured value of insulation resistance for all windings to earth and phase to phase
should be compared with the guidance given above for the various 'life stages' of a generator.
The minimum acceptable value is 10MΩ.

If low winding insulation is confirmed, one or more of the methods, given below, for drying the
windings should be carried out.

8.1.2 METHODS OF DRYING OUT GENERATORS

Cold Run
Providing a generator in good condition but has not been run for some time. It is possible that
simply running the genset, without excitation, will raise the IR sufficiently (greater than 10MΩ) to
allow the unit to be put into service. Run the generator for approximately 10 minutes with AVR
terminals

K1 and K2 open. Visually check that the windings appear dry and carry out an insulation resis-
tance test to prove that the minimum (1.0MO) insulation value has been achieved. If this method
fails, use one of the traditional methods outlined below.

72
Blown Air Drying
Remove the covers from all apertures to allow the escape of the water-laden air. During drying,
air must be able to flow freely through the generator in order to carry off the moisture.

Direct hot air from two electrical fan heaters of around 1-3 KW into the generator air inlet aper-
tures. Ensure the heat source is at least 300mm away from the windings to avoid over heating
and damage to the insulation.

Apply the heat and plot the insulation value at half hourly intervals. The process is complete
when the parameters covered in the section entitled, 'Typical Drying Out Curve', are met.

Remove the heaters, replace all covers and re-commission as appropriate.

If the set is not to be run immediately ensure that the anticondensation heaters are energized,
and retest prior to running.

Shirt Circuit Method

NOTE: This process shou ld only be performed by a competent engineer familiar with safe
operating practices within and around generator sets of the type in question. Ensure the gene-
rator is safe to work on, initiate all mechanical and electrical safety procedures pertaining to the
genset and the site.

Bolt a short ci rcuit of adequate current carrying capacity, across the main terminals of the
generator. The shorting link should be capable of taking full load current.

Disconnect the cables from terminals "X" and "XX" of the AVR.

Connect a variable de supply to the "X" (positive) and "XX" (negative) field cables. The de
supply must be able to provide a current up to 2.0 Amp at 0-24Volts.

Position a suitable ac ammeter to measure the shorting link current.

Set the de supply voltage to zero and start the generating set. Slowly increase the de voltage to
pass current through the exciter field winding. As the excitation current increases, so the stator
current in the shorting link will increase. This stator output current level must be monitored, and
not allowed to exceed 80% of the generators rated output current.

After every 30 minutes of this exercise: Stop the generator and switch off the separate excita-
tion supply, and measure and record the stator winding IR values, and plot the results.
The resulting graph should be compared with the classic shaped graph. This drying out proce-
dure is complete when the parameters covered in the section entitled 'Typical Drying Out
Curve' are met.

73
Once the insulation Resistance is raised to an acceptable level minimum value 10MΩ - the de
supply may be removed and the exciter field leads "X" and "XX" re-connected to their terminals
on the AVR.

Rebuild the genset, replace all covers and re-commission as appropriate.

If the set is not to be run immediately ensure that the anticondensation heaters are energised,
and retest the generator prior to running.

Typical Drying Out Curve

Whichever method is used to dry out the generator the resistance should be measured every
half-hour and a curve plotted as shown.(Fig 9)

The illustration shows a typical curve for a machine that has absorbed a considerable amount
of moisture. The curve indicates a temporary increase in resistance, a fall and then a gradual
rise to a steady state. Point 'A', the steady state, must be greater than 1.0MΩ (If the windings
are only slightly damp the dotted portion of the curve may not appear).

For general guidance expect that the typical time to reach point 'A' will be approximately 3
hours for a LV 6 generator.

Drying should be continued after point "A" has been reached for at least one hour.

It should be noted that as winding temperature increases, values of insulation resistance may
significantly reduce. Therefore, the reference values for insulation resistance can only be esta-
blished with windings at a temperature of approximately 20°C.

After drying out, the insulation resistances should be rechecked to verify minimum resistances
quoted above are achieved. On re-testing it is recommended that the main stator insulation
resistance is checked as fol lows:

-Separate the neutral leads.

Ground V and W phase and megger U phase to ground
Ground U and W phase and megger V phase to ground
Ground U and V phase and megger W phase to ground.

74
If the minimum value of 1.0MΩ is not obtained, drying out must be continued and the test
repeated.
If the minimum value of 1.0MΩ for all components cannot be achieved rewinding or refurbish-
ment of the generator will be necessary.

The generator must not be put into service until the minimum value, Of 1.0MΩ for all compo-
nents, can be achieved.

8.2 BEARINGS

All bearings are supplied from the factory pre-packed with Kluber Asonic GHY 72 grease.
Do not mix kluber Asonic GHY 72 with any grease of different specifications. Mixing grease of
differing specifications will reduce bearing life. The specification for Kluber Asonic FHY 72 is
available on request from the factory.
Sealed for life bearings are fitted with integral seals and are not re-greasable.

BEARING LIFE

IMPORTANT! The life of a bearing in service is subject to the working conditions and the
environment.
IMPORTANT! High levels of vibration from the engine or misalignment of the set will
stress the bearing and reduce its service life. If the vibration limits set out
im BS 5000-3 and ISO 8528-9 are exceeded bearing life will be reduced.
Refer to 'vibration’ below.
IMPORTANT! Long stationary periods in an environment where the generator is subject
to vibration can cause false brinneling, which puts flats on the ball and
grooves on the races, leading to premature failure.
IMPORTANT! Very humid atmospheric or wet conditions can emulsify the grease causing
corrosion and deterioration of the grease, leading to premature failure of
the bearings.

HEALTH MONLTORING OF THE BEARINGS

It recommends that the user check the bearing condition, using monitoring equipment, to
determine the state of the bearings. The 'best practice' is to take initial readings as a base line
and periodically monitor the bearings to detect a deteriorating trend. It will then be possible to
plan a bearing change at an appropriate generating set or engine service interval.

VLBRATION

The generators are designed ti withstand the vibration levels encountered on generating sets
built to meet the requirements of ISO 8528-9 and BS5000-3. (Where ISO 8528 is taken to be
broad band measurements and BS5000 refers to the predominant frequency of any vibrations
on the generating set.)

75
Definition of BSS000-3
Generators shall be capable of continuously withstanding linear vibration levels with amplitudes
of 0.25 mm between 5 Hz and velocities of 9.0 mm/s. Between 8 Hz and 200 Hz when measu-
red at any point directly on the carcass or main frame of the machine. These limits refer Only to
the predominant frequency of v ibration of any complex waveform.

Definition of ISO 8528-9

ISO 8528-9 refers to a broad band of frequencies, the broad band is taken to be between 2
Hertz and 300 Hertz. The table below is an example from ISO 8528-9 (value 1 ). This simplified
table lists the vibration limits by kVA range and speed for acceptable genset operation.

IMPORTANT! Exceeding either o f the above specifications will have a detrimental effect
on the life of the bearing. This will invalidate the generator warranty. If you
are in any doubt, contact Newage International limited.

If the vibration levels of the generating set are not within the parameters quoted above.
1. consult the genset builder. The genset builder should address the genset design to reduce
the vibration levels as much ad possible.
2. Discuss the impact of not meeting the above levels on both bearing and generator life
expectancy.

Where requested, or deemed necessary, Newage will work with the genset builder in an
attempt to find a satisfactory solution.

BEARING 'SERVICELIFE' EXPECTANCY

Bearing manufacturers recognize that the "service life" of their bearings is dependent upon
many factors that are not in their control, they cannot therefore quote a "service life".
Although "service life" cannot be guaranteed, it can be maximized by attention to the genera-
ting set design. An understanding of the genset application will also help the user to maximize
the service life expectancy of the bearings. Particular attention should be paid to the alignment,
reduction of vibration levels, environmental protection, maintenance and monitoring procedu-

76
res. We does not quote life expectancy figures for bearings, but suggests practicable replace-
ment intervals based on the L 10 life of the bearing, the grease and the recommendations of
the bearing and grease manufacturers. For general-purpose applications, provid ing the vibra-
tion levels do not exceed the levels stated in ISO8528-9* and BS5000-3* and the ambient
temperature does not exceed 50°C the following approximations can be applied when *
(See section on vibration)

Sealed for life Bearings. - Approximately 30,000hours.

Re-greaseable bearings.- Approximately 40,000hours.

This is provided the correct maintenance is carried out, and only Kluber Asonic GHY 72 grease
(or equivalent) is used in all bearings. It is important to note that bearings in service. Under
good operating conditions, can continue to run beyond the remembered re placement period.
It should also be remembered that the r isk of bearing failure increases with time.

8.3 ALR FILTERS

Air filters for the removal of airborne particulate matter (dus) are offered as an addition to the
standard build option. Filters on it's need to be ordered with the generator. Air filters need to
be charged with oil before the genset is put to work (see 8.3.2) The frequency of fi lter mainte-
nance will depend upon the severity of the site conditions. Regular inspection of the elements
will be required to establish when cleaning is necessary.

Danger! Removal of filter elements enables access to LIVE parts. Only remove elements
with the generator out of service.

8.3.1 CLEANING PROCEDURE

Remove the filter elements from the filter frames. Immerse of flush the element with a suitable
degreasing agent until the element is cleas.

As an alternative procedure a high-pressure water hose with a flat nozzle can be used. Sweep
the water spray back and forth across the element from the clean side (fine mesh side of
element) holding the nozzle firm ly against the element surface. Cold water may be adequate
depending upon type of contamination although hot water is preferable.

The element can be inspected for cleanliness by looking through the filter towards the light.

When the roughly clean, no cloudy areas will be seen. Dry elements thoroughly before attemp-
ting to carry out the recharging procedure.

77
8.3.2 RECHARGING (GHARGING) AIR FILTERS

Charging is best done by totally immersing the dry element into a dip tank containing "Filterko-
te Type k" or commercial lubricating oil SAE 20/50. oils of higher or lower viscosity are not
recommended.

Allow elements to completely drain before refitting the elements into the frames and putting
into service.

8.4 FAULT FINDING

IMPORTANT! Before commencing any faultfinding procedures, examine all wiring for
broken or loose connections.

Two types of AVR can be fitted to the WH generator. The Refer to the generator nameplate for
type of AVR fitted.

8.4.1 MX341 AVR, FAULT FINDING

8.5 SEPARATE EXCITATION TEST PROCEDURE

The generator windings, diode assembly and AVR can be checked using the appropriate
following sections.

78
8.5.1 GENERATOR WINDINGS, ROTATING DIODES and PERMANENT MAGNET GENERA-
TOR (PMG)

IMPORTANT! The resistances quoted apply to a standard winding. For generators

having windings or voltages other than those specified refer to fac-
tory for details. Ensure all disconnected leads are isolated and free
from earth.
IMPORTANT! Incorrect speed setting will give proportional error in voltage out put.

Checking Generator Windings and Rotating Diodes

This procedure is carried out w ith lead X and XX disconnected at the AVR or transformer
control rectifier bridge and using a 12 volt d. c. Supply to leads X and XX.

Start the set and run at rated speed.

Measure the voltages at the main output terminals U, V and W. if voltages are balanced and
within +/-10% of the generator nomial voltage, refer to 7 .5.1.1.

Check voltages at AVR terminals 6, 7 and 8. These should be balanced and between 170-250
volts.

If voltages at main terminals are balanced but voltage at 6, 7

and 8 are unbalanced, check continuity of leads 6,7 and 8.

If voltages are unbalanced , refer to 7 .5.1.2.

[Link] BALANCED MAIN TERMINAL VOLTAGES

If all voltages are balanced within 1 % at the main terminals, it can be assumed that all exciter
windings, main windings and main rotating diodes are in good order ,and the fault is in the
AVR or transformer control. Refer to subsection 7 .3.2 for test procedure.

If voltages are balanced but low, there is a fault in the main excitation windings or rotating
diode assembly. proceed as follows to identity:-

Rectifier Diodes

The diodes on the main rectifier assembly can be checked with a multimeter. The flexible leads
connected to each diode should be disconnected at the terminal end, and the forward and
reverse resistance checked. A healthy diode will indicate a very high resistance ( infinity) in the
reverse direction, and a low resistance in the forward direction. A faulty diode will give a full
deflection reading in both directions with the test meter on the 10,000 ohms scale, or an
infinity reading in both directions. On an electronic digital meter a healthy diode will give a low

79
reading in one direction, and a high reading in the other.

Replacement of Faulty Diodes

The rectifier assembly is split into two plates, the positive and negative, and the main rotor is
connected across these plates. Each plate carries 3 diodes, the negative plate carrying negati-
ve biased diodes and the positive plate carrying positive biased diodes. Care must be taken to
ensure that the correct polarity diodes are fitted to each respective plate. When fitting the
diodes to the plates they must be tight enough to ensure a good mechanical and electrical
contact, but should not be over-tightened. The recommended torque tightening is 4.06-4.74
Nm (36-42Ib in).

Surge suppressor

The surge suppressor is a metal-oxide varistor connected across the two rectifier plates to
prevent high transient reverse voltages in the fie ld winding from damaging the diodes. This
device is not polarized and will show a virtually infinite reading in both directions with an ordi-
nary resistance meter. If defective this will be visible by inspection, since it will normally fail to
short circuit and show signs of disintegration. Replace if faulty.

If after establishing and correcting any fault on the rectifier assembly the output is still low
when separately excited, then the main rotor, exciter stator and exciter rotor winding resistan-
ces should be checked (see Resistance charts ), as the fault must be in one of these windings.
The exciter stator resistance is measured across leads X and XX. The exciter rotor is conne.
Main Excitation Windingscted to six studs that also carry the diode lead t erminals. The main
rotor winding is connected across the two rectifier plates. The respective leads must be
disconnected before taking the readings.

[Link] UNBALANCED MAIN TERMINAL VOLTAGES

If voltages are unbalanced, this indicates a fault on the main stator winding or main cables to
the circuit breaker. NOTE: Faults on the stator winding or cables may also cause noticeable
load increase on t he engine when excitation is applied. Disconnect the main cables and sepa-
rate the winding leads U1-U2,(U5-U6),V1-V2,(V5-V6),W1-W2,(W5-W6) to isolate each winding
section. Note: -leads suffixed 5 and 6 apply to 12 wire windings only.

Measure each section resistance values should be balanced and within+/- 10% fo the value.

Measure insulation resistance between sections and each section to earth.

Unbalanced or incorrect winding resistances and/or low insulation resistances to earth indica-
te rewinding of the stator will be necessary. Refer to removal and replacement of component
assemblies' subsection 8.5.3.

80
8.5.2 AVR FUNCTION TEST

All types of AVR's can be tested with this procedure:

1. Remove exciter field leads X & XX (F1 &F2) from the AVR terminals X & XX (F1 &F2).
2. Connect a 60W 240V household lamp to AVR terminals X & xx (f1 &f2).
3. Set the AVR VOL TS control potentiometer fully clockwise.
4. Connect a 12V, 1.0A DC supply to the exciter field leads X & XX (F1 &F2) with X (F1 )to the
positive.
5. Start the generating set and run at rated speed.
6. Check that the generator output voltage is within +/- 10% of rated voltage.

The lamp should glow for approximately 8 seconds and then turn off. Failure to turn off indica-
tes faulty protection circuit and the AVR should be replaced. Turning the "VOLTS"control
potentiometer ful ly anti-clockwise should turn off the lamp with all AVR types.

Should the lamp fail to light the AVR is faulty and should be replaced.

IMPORTANT! After this test turn VOLTS control potentiometer fully anti-clockwise.

8.5.3 REMOVAL AND REPLACEMENT OFCOMPONENT ASSEMBLIES

METRIC THREADS ARE USED THROUGHOUT

CAUTION! When lifting single bearing generators, care is needed to ensure the generator
frame is kept in the horizontal plane. The rotor is free to move in the frame and
can slide out if not correctly lifted. Incorrect lifting can cause serious injury to
personnel.

[Link] ANTI-CONENSATION HEATERS

Danger! The external mains electricity supply used to power the anti-condensation heater
must be switched off and safely isolated before attempting any work adjacent to
the heater, or removal of the non drive end bracket on which the anticon heater is
mounted. Ensure that the engine is inhibited prior to work in generator.

[Link] REMOVAL OF BEARINGS

IMPORTANT! Position the main rotor so that a full pole face of the main rotor core is at
the bottom Remove PMG of the stator bore if fitted.

The generators in this manual will be fitted with one of two different bearing arrangements.
There may be two different arrangements on a two-bearing generator.

81
Removal of the bearing may be effected either after the rotor assembly has been removed or
more simply by removal of endbracket (s).

Be sure to note the location of all components during removal to assist during the assembly
process.

BEARING REPLACEMENT

Environment

Every effort must be made to establish a clean area around the generator when removing and
replacing bearings. Contamination is a major cause of bearing failures.

Equipment

Suitable cleaning solvent

Bearing puller, two or three leg
Thin protective gloves
Lint free cleaning cloth
Induction heater.

Preparation

Remove the lubrication pipework if fitted .

Position the rotor so that the full pole face of the main rotor is
at the bottom of the stator bore.
Remove the end bracket, see [Link] for procedure.

NOTES:
• It is not necessary to remove the rotor.
• Ensure that the bearing contact surface shows no sign of wear or corrosion prior to fitting the
bearing.
• Never refit used bearings, Wave washer or 'O' rings.
• Never refit used bearings, grease flinger, wave washer or 'O' rings.
• Only the outer race should be used to transmit load during assembly (NEVER use the inner
race).

REMOVAL OF REGREASABLE BEARINGS

The bearings are a press fit on the shaft and can be removed with standard tooling , i.e. 2 or 3
legged manual or hydraulic bearing pullers.

To remove bearings proceed as follows:

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1. Remove 4 screws holding bearing cap.
2. Remove cap.
3. Non drive end remove wave washer and circlip (single bearing only).
4. Remove bearing cartridge housing complete with bearing (and grease f linger if fitted).
5. Remove bearing form cartridge.
6. Discard the old bearing 'O' rings and wave washer where fitted.

The bearing cap(s) and cartridge(s) must be thoroughly flushed out with clean solvent and-
checked for wear or damage, before re-assembly. Damaged components should be replaced
before refitting the bearing.

ASSEMBLY OF REASABLE BEARINGS

NOTE: Gloves must be worn at all tines when handling the bearings, grease and solvent.

1. Wipe clean the a ssembly surface, using cleaning solvent on lint free cloth.
2. Wipe clean: Bearing Cartridge. Wave Washer, Bearing Cap, greas flinger, all re-lubrication
pipes and fittings (internal and external), Visually inspect all components after cleaning, for
contamination.
3. Place all components on the clean assembly surface. Do not use an air line to blow off
excess fluid .
4. Thoroughly clean the external surface of the grease gun nozzle using lint free cloth.

Bearing preparation

1. Remove the veering from its packaging.

2. Wipe off the preservative oil from the surface of the inner and outer rings using lint free cloth
only.
3. Place the bearing on the clean assembly surface, with the bearing designation marking
facing down.

Bearing Assembly (Lubrication, see TABLE 17)

Cartridge:
1. Apply the specified cartridge grease fill quantity to the back face of the bearing housing.
2. Apply a small amount of grease to the grooved sealing surface in the bearing housing.
3. Apply anti-fretting lubricant (MP14002-Kluber Altemp Q NB 50) to the beating housing
circumference. Apply paste in a thin coherent layer by use of a lint free cloth (DO NOT rub in)
(use clean protective gloves).
4. Non-drive end fit new 'O' Rings into the 'O' Ring grooves in the bearing housing circumfe-
rence.

Bearing

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1. Apply half the specified bearing grease fill quantity (see table 16) to the upper face of the
bearing (opposite side to the bearing designation markings).
2. Thumb the applied grease into the bearing, ensuring good penetration into the raceways/-
balls (use clean protective gloves).

Assemble Bearing into Cartridge

1. Heat the bearing cartridge to 25°C above ambient with an induction heater (Do not exceed
100°C)
2. With greased face of the bearing facing the cartridge bore, assemble the bearing into the
bearing housing. Ensure the bearing outer race contacts the location shoulder.

Assemble Bearing onto Shaft

Bearing Cartridge
1. Heat the Bearing and Cartridge assembly to ao·c above ambient with an induction heater.
(use induction heater,no other heat source is suitable)
2. Slide the Bearing and Cartridge assembly to over the shaft, pushing it firmly against the
bearing seating shoulder.
3. Rotate the assembly (including inner race) 45°C in either direction, to provide correct align-
ment. The bearing must be held firmly in place until I s cool enough to positively locate.
NOTE: Ensure cartridge is at ambient temperature before assembling bracket.

Cap/ Flinger:

Apply the specified cap grease fill quantity to the I nside face of the cap (see table 16).

1. Fill the grease exhaust slot with grease.

2. Apply a small amount of grease to the grooved sealing surface in the cap.
3. Fit circlip. (single bearing only).
4. Heat flinger to 12o·c an place on shaft up to the bearing inner race. Hold firmly until positi-
vely located.
5. Place wave washer in cap, fit cap to bearing cartridge.

REMOVAL OF SEALED FORLIFE BEARINGS

With Bearing Cartridge

The bearings are a press fit on the shaft and can be removed with standard tooling, i.e. 2 or 3
egged manual or hydraulic bearing pullers.

To remove bearings proceed as follows:

1. Remove 4 screws holding bearing cap.
2. Remove cap.
3. At the end, remove wave washer and circlip (single bearing only).

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4. Remove bearing cartridge housing complete with bearing.
5. Remove bearing from cartridge.
6. Discard the old bearing, 'O' rings and wave washer where fitted.

The bearing cap(s) and cartridge(s) must be thoroughly flushed out with clean solvent and
checked for wear or damage, before re-assembly. Damaged components should be replaced
before refitting the bearing.

Assembly of Sealed for life bearings with Cartridge

Pre - assembly, cleaning.

NOTE: Gloves must be worn at all times when handling the bearings, grease and solvent.
1. Wipe clean the assembly surface, using cleaning solvent on lint free cloth.
2. Wipe clean: Bearing Cartridge and bearing cap (internal and external). Visually inspect all
components after cleaning, for contamination.
3. Place all components on a clean assembly surface. Do not use an air line to blow off excess
fluid.
4. Thoroughly clean the external surface of the grease gun nozzle using lint free cloth.

Bearing preparation:

1. Remove the bearing from its packaging.

2. Wipe off the preservative oil from the surface of the inner and outer r ings using lint free
cloth only.
3. Place the bearing on the clean assembly surface, with the bearing designation marking
facing down.

Bearing Assembly

Cartridge:
1. Apply anti-fretting lubricant (MP 14002 kluber Altemp Q NB 50) to the bearing housing
circumference. Apply paste in a thin coherent layer by use of a lint free cloth (DO NOT rub
in)(use clean protective gloves).
2. Fit 'O' Rings into the 'O' Ring grooves in the bearing housing circumference. Assemble

Bearing into Cartridge

1. Heat the bearing cartridge to 25·c above the ambient temperature (with an induction heater,
do not exceed 100°C) and assemble the new bearing into the cartridge.
Ensure that the bearing designation is visible after assembly.
2. With greased face of the bearing facing the cartridge bore, assemble the bearing into the
bearing housing. Ensure the bearing outer race contacts the location shoulder.
NOTE: Only the outer race should be used to transmit load during assembly (NEVER use the
inner race).

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Assemble Bearing and Cartridge onto the shaft

1. Heat the Bearing and Cartridge assembly to ao·c above ambient. (use induction heater, no
other heat source is suitable)
2. Slied the Bearing and Cartridge assembly over the shaft, pushing it firmly against the bea-
ring seating shoulder.
3. Rotate the assembly (including inner race) 45 in either direction, go provide correct align-
ment. The bearing must be held firmly in place until it is cool enough to positively self locate.
4. Non drive end only fit circl ip (single bearing only) and wave washer.
5. Fit the bearing cap.
6. Rotate the bearing assembly on the shaft to check for free movement.

Note: Ensure cartridge is at ambient temperature before

assembling bracket.

7. Refit the end bracket and PMG where fitted.

[Link] MAIN ROTOR ASSEMBLY

Single Bearing Machine

NOTE: On single bearing machines, before removal from, or re-assembly to the prime mover,
position the rotor, if possible, such that a fu ll pole face is at bottom dead centre.
1. Remove all access covers and terminal box lid.
2. Ensure that these leads are free to come away with the non-drive endbracket when remo-
ved.
3. Remove the 8 bolts holding the drive and adaptor to the frame.
4. With a rope sling around drive end adaptor, tap adaptor out of its spigot location; guide over
fan and remove.
5. If the generator is fitted with a cartridge. Remove the 4 bolts retaining the end bearing
cartridge in the non drive end endbracker (outer 4 bolts). (This includes all regreasable options)
6. Remove the 8 bolts securing the non drive end bracket to the frame.
7. Supporting the non-drive end bracket with a hoist, insert two M10 bolts in the two holes
provided for 'jacking' purposes (on the end bracket horizontal centre line). Screw in the bolts
until the end bracket spigot is clear of the locating recess, lower the whole assembly until the
main rotor is resting in the stator bore. Still supporting the non drive eng bracket, tap the
bracket off the non drive end bearing cartridge (taking care that the exciter stator does not foul
exciter rotor windings) and remove.
8. To withdraw the rotor from the stator the stator the rotor must be supported by a rope at the
drive end and eased out of the stator core until half the main rotor is protruding out of the
stator. At this point it is safe to release the weight from the rope sling.
9. Tightly bind a rope sling around the rotor core, and supporting the non-drive end of the
rotor, guide it clear of the stator.

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Warning! The rope sling may not be at the center of gravity of the rotor and guidance at the
ends of the rotor is essential. THE FULL WELGHT OF THE ROTOR GIVEN IN
THE TABLE BELOW MUST BE SUPPORTED BY THE CRANE AND SLING. If the
rotor core is allowed to drop more than a few millimeters at this point, it will make
contact with the stator windings and may damage them.

RE-ASSEMBLY IS A REVERSAL OF THE ABOVE PROCEDURE.

Before assembly of a single bearing rotor into stator housing check that the drive discs are not
damaged or cracked or showing any other signs of fatigue. Also check that holes in the discs
for drive fixing screws are not elongated.

Damaged components must be replaced.

TWO BEARING MACHINES

NOTE:
Position rotor, if possible, such that a full pole face is at bottom dead center.
The procedure for removal of a two bearing rotor is similar to that outlined for single bearing
machines with the exception of Steps 4 and 5 relating to the drive end adaptor.
For removal of this item proceed as follows:-
1. Remove the 8 bolts holding drive end adaptor to frame and 4 olts retaining bearing cartridge
in drive end bracket (outer 4 bolts), if fitted./
2. With rope sling around the shaft extension, supporting the roto weight tap the drive end
bracket spigot out of its locating recess and lower rotor assembly to rest in the stator bore.
3. Take the weight of the drive end bracket on the sling and tap the bracket off the drive end
bearing cartridge. guide over the and remove.

Re-assembly is a reversal of the above procedure.

8.6 RETURNING TO SERVICE

After rectification of any faults found, remove all test connections and reconnect all control
system leads. Restart the set and adjust VOLTS control potentiometer on AVR BY slowly
turning clockwise until rated voltage is obtained. Refit all terminal box covers/access covers
and reconnect heater supply.
Failure to refit all guards, Access covers and terminal box covers can result in personal injury
or death.

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[Link]
Manufactured under license of Daewoo International Corporation, Korea