alternator 01183626 11203064 01182167.01182403 01183443 01182403 for ATLAS COPCO Bommer D1D 4.3

Pre-installation Preparation

Site and Foundation Preparation

• For indoor installation: Ensure good ventilation and keep the generator away from flammable and explosive materials.

• For outdoor installation: Select a flat, rainproof area and reserve at least 1 meter of maintenance space.

• For heavy generators: Pour a suitable concrete foundation or use a stable steel frame for support to withstand operational vibrations. Calibrate the foundation level with a level gauge.

Equipment and Tool Verification

• Inspect the generator: Check for no transportation damage, ensure the rotor rotates smoothly without jamming, and verify that the voltage rating (12V/24V) on the nameplate matches the usage requirements.

• Prepare tools and accessories: Include lifting equipment (a hoist for small units, a crane for large units), wrenches, a level gauge, a megohmmeter, a multimeter, as well as compatible cables, insulating tape, anchor bolts, etc.

• Cable selection: Use thinner-gauge cables for 12V models; 24V models require thicker cables due to current characteristics to prevent overheating from overload.

Safety Preprocessing

• Disconnect all surrounding power supplies and wear insulating gloves and protective goggles.

• Test insulation resistance: Use a megohmmeter to measure the generator's insulation resistance, which should not be less than 0.5MΩ in cold conditions. Dry the generator first if the resistance is too low.

• Check the battery: Equip 12V models with a 12V storage battery; 24V models with a 24V storage battery or two 12V batteries in series. Ensure no battery leakage.

Generator Fixation and Mechanical Assembly

Hoisting and Positioning

• Hoist using the generator's dedicated lifting rings; never wrap ropes around the shaft, end cover, or pipelines.

• Place the generator stably on the foundation, align with the anchor bolt holes, and insert the bolts without fully tightening to leave room for adjustment.

Leveling and Fastening

• Place shims on both sides of the base and calibrate the generator level axially and horizontally with a level gauge.

• After calibration, evenly tighten the anchor bolts in batches in a diagonal sequence. For portable models, secure them via the built-in wheel frame to prevent displacement during operation.

• For generators with pulleys or couplings: Ensure alignment with the center plane of the driven machinery's wheel to avoid transmission deviations.

Pipeline and Circuit Connection

Auxiliary Pipeline Connection

• For fuel-powered generators: Connect the fuel pipeline with leak-proof seals and install a fuel filter.

• For water-cooled generators: Connect the cooling pipeline, fill with suitable coolant, and check for no blockages.

Circuit Wiring

• Wiring logic is consistent for 12V and 24V models, with only voltage-matching components required:

1. Connect the generator's positive terminal (B+) to the battery's positive terminal using a compatible cable. Use a small fuse for 12V models and an upgraded fuse for 24V models.

2. Connect the negative terminal to the battery's negative terminal or the generator's chassis ground, ensuring a secure connection to avoid poor contact.

3. Connect control lines (e.g., start control line, monitoring line) to corresponding interfaces.

• After wiring: Wrap joints with insulating tape and clean terminal oxide layers with a cleaning agent.

System Debugging and Trial Operation

No-load Debugging

• Manually rotate the rotor to confirm no jamming. After power-on, perform a jog start to check the rotation direction, then conduct no-load operation for at least 1 hour.

• Measure output voltage with a multimeter: Normal range is 13.5-14.5V for 12V models and 27-29V for 24V models. Monitor for no sharp noises or severe vibrations.

Load Testing

• Gradually apply the load to avoid instant full load.

• Monitor voltage and current stability, check for no cable overheating or loose joints.

• For models with a control panel: Verify normal display of parameters (e.g., oil level, water temperature, voltage) and no fault alarms.

Calibration and Finalization

• For models equipped with an AVR (Automatic Voltage Regulator): Fine-tune via the control panel to ensure stable voltage output.

• Test the 12V/24V DC output interface to confirm it meets load power requirements.

• Organize cables to avoid wrapping around rotating components.

Post-installation Inspection

• After stopping the generator: Recheck the tightness of anchor bolts, pipeline interfaces, and cable joints.

• Retest insulation resistance with a multimeter to eliminate leakage hazards.

• Clean the installation site, organize tools and remaining materials, and record installation parameters and trial operation data for future maintenance reference.

1. Safety Operation Red Lines

• Disconnect all surrounding power supplies throughout the process. For battery-equipped models, first disconnect the positive and negative cables to avoid short-circuit sparks during wiring. Keep the installation area away from flammable and explosive substances such as fuel and dust, and ensure good ventilation to prevent the accumulation of exhaust gas or battery hydrogen.

• Operators must wear insulating gloves and protective goggles. Use dedicated lifting rings for hoisting; never wrap ropes around the machine shaft, end cover, or pipelines to avoid component damage or falling risks.

• For fuel-powered generators: Conduct a tightness test after connecting the fuel pipeline, and only power on if there is no leakage. For water-cooled models: Bleed air from the pipeline after adding coolant to prevent overheating during operation.

2. Mechanical Installation Precision Requirements

• The foundation must be flat and stable. For large units, pour a concrete foundation or fix it with a stable steel frame, controlling the level deviation within the allowable range to avoid base deformation caused by operational vibration.

• When installing transmission components (pulleys/couplings), ensure alignment with the center plane of the driven machinery’s wheel. The coaxiality error must be ≤0.1mm. For belt-driven models, adjust the belt tension appropriately—too loose may cause slipping, while too tight will accelerate bearing wear.

• Tighten anchor bolts evenly in a diagonal sequence according to the specified torque, using bolts that meet strength requirements to prevent loosening during operation. For portable models, lock the wheel frame to prevent displacement.

• References：
  

• The core sources of the precautions for installing Atlas Copco 12V and 24V generators are the official operation manuals for the corresponding Atlas Copco generator models. Additionally, some general precautions align with universal industry standards. Detailed explanations are as follows:

• Official Manuals for Specific Models

• Official operation manuals for models such as the Atlas Copco QAS series and QIX220-540 serve as the primary source of installation precautions. For example, the Chinese operation manual for the QIX220-540 details key requirements including hoisting specifications, ventilation demands, electrical grounding, and exhaust gas emission guidelines for generator set installation. The manual for the QAS 275-325 also specifies wiring gauge, color codes, and circuit protection-related installation details. These contents constitute model-specific specifications tailored to the installation of corresponding 12V and 24V units.

• Brand’s Official Service Guidelines

• While the FAQ section on Atlas Copco’s official website does not directly list a complete set of installation precautions, it outlines core principles such as the requirement for installation to be performed by certified technicians and adherence to calibration standards. These principles act as important prerequisites for installation, serving as supplementary sources that clarify personnel qualifications and process requirements.

• Universal Industry Installation Standards

• General precautions mentioned earlier—such as the need for a well-ventilated and dry installation environment, reliable chassis grounding, and standardized exhaust pipe layout—are consistent with universal generator set installation standards compiled by platforms like Elecfans.com and Douyin Encyclopedia. These industry-wide guidelines are widely followed across the generator sector and serve as important references for the installation of Atlas Copco generators, complementing the model-specific requirements outlined in official manuals.