Workshop
Instruction
1. General information
Workshop instruction KWG Generators
Applicable to : F1200C; F1200CS; F1800C; F1800W; SD1800C; SD1800CS; F2500C; F2500CS;
SD2500C; SD2500CS; SD2500W; SD2500WS; SD2550C; SD2550CS (with electric
heating system)
Publication Number : WI-170711-1-LM-HC
Author : Manfred Lammers / Christian Hoppe
2. Document overview
This document describes the following:
1. General information ........................................................................................................................................................ 1
2. Document overview ........................................................................................................................................................ 1
3. Subject ........................................................................................................................................................................... 1
4. Safety instruction ............................................................................................................................................................ 2
5. Needed equipment ......................................................................................................................................................... 2
6. Location of components ................................................................................................................................................. 3
7. Description of digital voltage regulator (DVR)................................................................................................................. 6
8. Description of generator connector block ....................................................................................................................... 7
9. Preparation for measurement ......................................................................................................................................... 8
10. Measurements ................................................................................................................................................................ 9
11. Check generator voltage with external power supply on exciter winding ...................................................................... 14
12. Check of DVR function ................................................................................................................................................. 15
13. Generator temperature sensor test............................................................................................................................... 16
14. Measurement general overview.................................................................................................................................... 16
3. Subject
This workshop instruction is a guideline how to check the generator and the generator controller if these are not delivering
sufficient voltage.
4. Safety instruction
Any failure to follow the safety instructions and safety regulations when operating the
electrical screed heating, leads to a risk of electric shock.
Danger of life
Without exception, all maintenance and repair work on the medium voltage electric system
must be carried out by an electrician.
Ensure that all protective devices and covers are available and appropriately secured!
Immediately repair any noticed damage! Operation must be discontinued in the event of
faults!
5. Needed equipment
- 1x Multimeter (voltage up to 600V; resistance 200Ohm)
- 1x Insulation tester with min. 500V test voltage
- 2x Test adapter (4812005418)
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6. Location of components
F1200C; F1200CS
Switch cabinet of
electric heating
system
Digital voltage
regulator (DVR)
Ground (earth) line
from generator
Phases L1; L2 & L3 Neutral (N)
from generator Micro fuse for
exiter curcuit
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F1800C; F1800W; SD1800C; SD1800W
Switch cabinet of
electric heating
system
Digital voltage
regulator (DVR)
Micro fuse for
exiter curcuit
Phases L1; L2 & L3
from generator
Ground (earth) line
from generator
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Neutral (N)
F2500C; F2500CS; SD2500C; SD2500CS; SD2500W; SD2500WS; SD2550C; SD2550CS
Switch cabinet of
electric heating
system
Digital voltage
regulator (DVR)
Micro fuse for
exiter curcuit
Ground (earth) line
from generator
Neutral (N) Phases L1; L2 & L3
from generator
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7. Description of digital voltage regulator (DVR)
Following pictures and descriptions are based on the generator system of a big paver. Component position at other machine
may be different, but the procedure of checking stays the same.
CAN-Bus connection for CAN4
of paver (end resistor of
“CAN4” on the printed circuit
board of DVR; not visible)
Phases L1; L2 & L3
from generator (pins
3; 4 & 5)
Connection for
temperature sensor
(inside generator)
Power supply exiter
circuit (pins 1-2)
Status LEDs
Micro fuse for Sticker with DVR
exiter curcuit information
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8. Description of generator connector block
Plug connector for
DVR at the generator
Connection terminal for L1;
L2; L3; Neutral (N) and
ground (earth)
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9. Preparation for measurement
- Turn off machine ignition and main battery switch
- Check regulator, micro-fuse, generator and wiring for visible damage. Replace damaged parts.
- Disconnect all plugs from DVR
- Disconnect cables from generator at the electric heating switch cabinet.
Disconnect all AMP-Plugs and main line from DVR.
Attention! Line ends must be protected against short-circuit fault!
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10. Measurements
10.1 Check the exciter-stator with Ohmmeter (Multimeter 200 Ohm range) from Pin 1 to 2 at DVR plug.
DVR Plug
6 5 4 3 2 1
Paver type Pins Range Result
F1200… 30Ω ± 3Ω
F / SD1800… 1–2 15Ω +/- 3Ω
F / SD 25…. 10Ω +/- 3Ω
If values are not ok and wiring to generator is ok, replace Generator with new one.
If values are ok, proceed with next steps.
10.2 Check three phases (L1 – L2 – L3) to each other at DVR plug
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6 5 4 3 2 1
Paver type Pins Range Result
3–4 0.1 – 3 Ω
All 3–5 Values should be
equal with a
4–5 tolerance of +/-10%
If values are not ok and wiring to generator is ok, replace Generator with new one.
If values are ok, proceed with next steps.
10.3 Preparation of Insulation resistance measurement
For the insulation resistance measurement different tools are available named insulation meter, insulation gauge, insulation
measuring device etc. Different names = same kind of device.
This device are not the same as an ohmmeter, there is a big different.
An ohm meter make a measurement with very low voltage round 2 V.
An isolation meter make a measurement with 500 or 1000 V. It means when you have a leak in the isolation from the copper
coil from the generator to the frame from the generator you can make a measurement from this with high voltage.
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Before performing the insulation resistance measurement please study the operating manual of the measuring device.
The insulation measurement will be performed directly at the cables to the generator (see picture below).
Phases L1; L2 & L3
Neutral (N) Ground (Earth)
10.4 Insulation resistance measurement
The measurement can be performed wire by wire against earth or L1; L2; L3 and N together against earth.
10.4.1 Wire by wire insulation resistance measurement
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Paver type Pins Range Result
L1 against Earth
L2 against Earth ≥ 1MΩ
All (If value is < 1MΩ and
L3 against Earth wiring to generator is ok
exchange generator)
N against Earth
Device (bridge)
to connect all 4
lines together
10.4.2 Insulation resistance measurement with L1; L2; L3 and N together against earth.
Paver type Pins Range Result
≥ 1MΩ
All L1 – L2 – L3 - N (If value is < 1MΩ and
against Earth wiring to generator is ok
exchange generator)
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10.5 Insulation resistance measurement exciter winding
For the insulation test of the generator exciter winding both lines at the DVR plug has to be connected to the same insulation
measuring device connector.
Device (bridge)
to connect both
lines
Paver type Pins Range Result
≥ 1MΩ
All (If value is < 1MΩ and
1 against 2
wiring to generator is ok
exchange generator)
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11. Check generator voltage with external power supply on exciter winding
Before proceeding reconnect the main wiring from the generator and the DVR plugs except the 6 pin plug.
Provide an external voltage of 12V to the exciter winding as shown in picture below.
Start diesel engine (min. 1100rpm; max. 1200rpm) and perform following measurements at the screed heating main switch
cabinet (2x Test adapter 4812005418 needed).
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Paver type Pins Range Result
L1 – N
All L2 – N 170 – 230V
L3 – N
If values are not ok and wiring to generator is ok, replace Generator with new one.
If values are ok, proceed with next steps.
12. Check of DVR function
Reconnect 6 pin plug to DVR
Start engine and check voltage regulator. Green and red LED should be inactivated, the yellow LED should light up. If green
and red LED are lightened up replace the DVR. Activate the screed heating. The yellow LED should inactivate. If not
regulate the engines revolution up to 1100 rpm If the yellow LED is still lighted, replace the regulators circuit board.
Status LEDs
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13. Generator temperature sensor test
Connection for
temperature sensor
(inside generator)
Paver type Pins Range Result
All Appr. 40kΩ
1 against 2
(at 20°C)
14. Measurement general overview
Check the exciter-stator with Ohmmeter (Multimeter 200 Ohm range) from Pin 1 to 2 at DVR plug (chapter 10.1)
Paver type Pins Range Result
F1200… 30Ω ± 3
F / SD1800… 1–2 15Ω +/- 3
F / SD 25…. 10Ω +/- 3
Check three phases (L1 – L2 – L3) to each other at DVR plug (chapter 10.2)
Paver type Pins Range Result
3–4 0.2 – 3 Ω
All 3–5 Values should be
equal with a
4–5 tolerance of +/-10%
Insulation resistance measurement (chapter 10.4.1)
Paver type Pins Range Result
L1 against Earth
L2 against Earth ≥ 1MΩ
All (If value is < 1MΩ and
L3 against Earth wiring to generator is ok
exchange generator)
N against Earth
Insulation resistance measurement with L1; L2; L3 and N together against earth (chapter 10.4.2)
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Paver type Pins Range Result
≥ 1MΩ
All L1 – L2 – L3 - N (If value is < 1MΩ and
against Earth wiring to generator is ok
exchange generator)
Insulation resistance measurement exciter winding (chapter 10.5)
Paver type Pins Range Result
≥ 1MΩ
All (If value is < 1MΩ and
1 against 2
wiring to generator is ok
exchange generator)
Check generator voltage with external power supply on exciter winding (chapter 11)
Paver type Pins Range Result
L1 – N
All L2 – N 170 – 230V
L3 – N
Generator temperature sensor test (chapter 13)
Paver type Pins Range Result
All Appr. 40kΩ
1 against 2
(at 20°C)
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