Ingersoll-Rand INS/ATS User Manual

Users guide and maintenance
manual for the generating sets
Réf. GPAO : 33501185101NE
Model
(
s
)
: G200
Control device : M150
Réf. constructeur : 33501185101
Revised (10-12)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand C
ompany and Doosan
Company or the products of
e
ith
er.

Ingersoll-Rand INS/ATS Specifications

General

Brand	Ingersoll-Rand
Model	INS/ATS
Category	Portable Generator
Language	English

Summary

Users guide and maintenance manual for the generating sets

Model(s) : G200

Control device: M150

Users guide and maintenance manual

Safety instructions

Provides essential safety instructions for operating the generating sets.

1. Preamble

1.3. Safety instructions and regulations

Details crucial safety instructions and regulations for operating the generating sets.

2. INSTALLATION

2.1. Unloading

2.1.3 Instructions for unloading

5. BATTERY MAINTENANCE

PROCEDURE FOR TESTING STARTER BATTERIES

Outlines the procedure for testing starter batteries to ensure proper function.

6. FUEL AND CONSUMABLES

6.1 Circuit capacities – Mitsubishi engines

6.2 Circuit capacities – john Deere engines

6.3 Circuit capacities – Volvo engines

Instructions for use

SAFETY SYMBOLS

Caution : danger

Caution : risk of electric shock

Symbol indicating risk of electric shock.

Caution : toxic substances

Symbol indicating caution regarding toxic substances.

Caution : pressurised fluids

Symbol indicating caution regarding pressurized fluids.

Caution : high temperature (risk of burning)

Symbol indicating caution for high temperatures and burn risk.

Caution : rotating or moving parts (risk of entanglement)

Symbol indicating risk of entanglement with rotating or moving parts.

Caution : risk of corrosion

Symbol indicating caution regarding risk of corrosion.

Caution : risk of explosion

Symbol indicating caution regarding risk of explosion.

Authorised personnel only

Protective clothing required.

Eye and hearings protection necessary

Periodic maintenance required

Check battery charge

Naked flame and non protected lightining forbidden, no smoking

Symbol prohibiting naked flames, non-protected lighting, and smoking.

Do not use water based fire extinguishers

Symbol prohibiting the use of water-based fire extinguishers.

Trailer : link up the earth before starting the generator

Emergency stop

Symbol for the emergency stop function.

A – DESCRIPTION

1 - STARTING AND STOPPING KEY:

2 - OIL PRESSURE WARNING LIGHT (M50-M150):

Explains the oil pressure warning light and its function.

3 - COOLING SYSTEM WARNING LIGH (M50-M150):

Explains the cooling system warning light and its function.

4 - VOLTAGE AND CHARGING ALTERNATOR EXCITATION WARNING LIGHT (M50-M150):

Describes the voltage and charging warning light.

5 - «OVERCHARGE» WARNING LIGHT (M150):

Explains the overcharge warning light function.

6 - WARNING LIGHTS TEST (M150-A50-X200):

7 - EMERGENCY STOP PUSH BUTTON:

Explains the function and use of the emergency stop push button.

9 - CIRCUIT BREAKER (M50 - M150):

11 - AMMETER (M50-M150):

B – USE

Service as Required

Do Not Modify Fuel System

Warns against modifying the fuel system to avoid warranty termination and legal issues.

Adding Coolant

Replacing Single Stage Air Cleaner

Replacing Axial Seal Air Cleaner Filter Element

Replacing Radial Seal Air Cleaner Filter Element

Replacing Fan and Alternator Belts

Checking Fuses

Bleeding the Fuel System (Engines With Electronic Fuel Systems And Bosch VP44 Pump)

Details how to bleed the fuel system for engines with specific electronic fuel systems.

Bleeding the Fuel System (Engines with Electronic Fuel Systems and Stanadyne DE10 Pump)

Details how to bleed the fuel system for engines with specific electronic fuel systems.

Bleeding the Fuel System (Engines with Electronic Fuel Systems and Denso High Pressure Common Rail) (4045HF475, 6068HF475)

Details how to bleed the fuel system for specific engine models with Denso HPCR.

Troubleshooting

General Troubleshooting Information

Provides general information and a diagnostic thought process for troubleshooting engine problems.

Precautions For Welding On Engines Equipped With Electronic Engine Control Unit (ECU)

Outlines essential precautions for welding on engines with an ECU to prevent damage.

Engine Wiring Layout (Electronic Fuel System With Stanadyne DE10 Injection Pump)

Engine Wiring Layout (Electronic Fuel System With Bosch VP44 Injection Pump)

Engine Wiring Layout (Electronic Fuel System With Denso High Pressure Common Rail)

Engine Wiring Diagram (Electronic Instrument Panel)

Engine Wiring Diagram (Electronic Instrument Panel)—Continued

Engine Troubleshooting

Lists common engine problems and their solutions.

Diagnostic Trouble Code Procedure (Using Electronic Instrument Panel)

Explains the procedure for using the electronic instrument panel to diagnose trouble codes.

Displaying Of Diagnostic Trouble Codes (DTCs)

Details how to display and interpret diagnostic trouble codes.

Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Stanadyne DE10 Pump)

Lists DTCs for engines with specific electronic fuel systems.

Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Bosch VP44 Pump)

Lists DTCs for engines with specific electronic fuel systems.

Listing of Diagnostic Trouble Codes (DTCs) (Engines With Electronic Fuel Systems And Denso High Pressure Common Rail)

Lists DTCs for engines with specific electronic fuel systems.

Intermittent Fault Diagnostics (With Electronic Controls)

Provides methods for diagnosing intermittent electronic faults.

Storage

Engine Storage Guidelines

Preparing Engine for Long Term Storage

Outlines the steps for preparing an engine for long-term storage.

Removing Engine from Long Term Storage

Details the procedure for removing an engine from long-term storage.

Specifications

General OEM Engine Specifications

Lists general OEM specifications for the engines.

Engine Power Ratings¹ And Fuel System Specifications²

Provides engine power ratings and fuel system specifications.

Engine Crankcase Oil Fill Quantities

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Lubrication and Maintenance Records

Using Lubrication and Maintenance Records

Daily (Prestarting) Service

500 Hour/12 Month Service

Details the maintenance tasks required at 500-hour or 12-month intervals.

2000 Hour/24 Month Service

Details the maintenance tasks required at 2000-hour or 24-month intervals.

Service as Required

GENERATOR PARTS LISTS

GENERATOR MODEL G200

Identifies the generator model as G200, for which parts lists are provided.

Leroy Somer Alternators LSA 46.2 / 47.1

SAFETY MEASURES

Provides essential safety measures for the installation and maintenance of alternators.

WARNING SYMBOLS

Explains the various warning symbols included with the manual for safety alerts.

1 - RECEIPT

1.1 - Standards and safety measures

Outlines compliance with international standards and general safety measures.

1.2 - Inspection

1.3 - Identification

1.3.1 - Nameplate

1.4 - Storage

2 - TECHNICAL CHARACTERISTICS

2.1 - Electrical characteristics

Details the electrical characteristics of the alternators, including winding and excitation systems.

2.2 - Mechanical characteristics

Details the mechanical characteristics of the alternators.

2.3 - Excitation system

2.3.1 - R448 AVR characteristics

Provides detailed characteristics of the R448 Automatic Voltage Regulator (AVR).

2.3.2 - R 448 power supply connection

2.3.3 - Frequency compared with voltage (without LAM)

2.3.4 - LAM characteristics

2.3.5 - R 448 AVR options

3 - INSTALLATION

3.1 - Assembly

3.1.1 - Handling

3.1.2 - Coupling

3.1.2.1 - single bearing alternator

3.1.2.2 - two-bearing alternator

3.1.3 - Location

3.2 - Inspection prior to first use

3.2.1 - Electrical checks

Details essential electrical checks, including isolation resistance and drying procedures.

3.2.2 - Mechanical checks

3.3 - Terminal connection diagrams

3.3.1 - Terminal connection : LSA 46.2/47.1 - 12-wire

3.3.3 - Option connection diagram

3.3.4 - Connection checks

3.3.5 - Electrical checks on the AVR

Outlines electrical checks for the AVR, including strap settings and potentiometer adjustments.

3.4 - Commissioning

3.5 - Settings

Explains the adjustments and settings that must be made by a qualified engineer.

3.5.1 - R 448 settings

Provides the settings and adjustments for the R 448 AVR.

Adjustments in standalone operation

Adjustments in parallel operation

3.5.2 - Max. excitation setting (excitation ceiling)

Explains how to set the maximum excitation current (ceiling).

Adjustment of the current limit

Guides on adjusting the current limit for alternator protection.

Checking the internal protection :

3.5.3 - Special type of use

- Field weakening

4 - SERVICING - MAINTENANCE

4.1 - Safety measures

Provides essential safety measures for servicing and troubleshooting alternators.

4.2 - Regular maintenance

4.2.1 - Checks after start-up

4.2.2 - Cooling circuit

4.2.3 - Bearings

4.2.4 - Electrical servicing

4.2.5 - Mechanical servicing

4.3 - Fault detection

4.4 - Mechanical defects

Lists common mechanical defects and their possible causes and actions.

4.5 - Electrical faults

4.5.1 - Checking the winding

Explains how to check the winding insulation using a high voltage test.

4.5.2 - Checking the diode bridge

4.5.3 - Checking the windings and rotating diodes using separate excitation

Details how to check windings and rotating diodes using separate excitation.

4.6 - Dismantling, reassembly

4.6.2 - Screw tightening torque

4.6.3 - Access to diodes

4.6.4 - Access to connections and the regulation system

4.6.5 - Replacing the NDE bearing on single bearing machines

Details the process for replacing the NDE bearing on single-bearing alternators.

4.6.6 - Replacing the DE bearing on two-bearing machines

4.6.7 - Complete dismantling

4.6.8 - Reassembling the end shields

4.6.9 - Reassembling the rotor

4.6.10 - Dismantling and reassembly of the filters

4.7 - Installation and maintenance of the PMG

4.7.1 - Mechanical characteristics

4.7.2 - Electrical connection

Details the electrical connections for the PMG to the AVR.

4.8 - Table of characteristics

4.8.1 - Average values for LSA 46.2

Provides average values and resistances for LSA 46.2 alternators.

4.8.2 - Average values for LSA 47.1

Provides average values and resistances for LSA 47.1 alternators.

4.8.3 - Voltage of auxiliary windings at no load

5 - SPARE PARTS

5.1 - First maintenance parts

5.3 - Accessories

5.4 - Exploded view, parts list

5.4.1 - Single bearing

Provides an exploded view and parts list for single bearing alternators.

5.4.2 - Two-bearing