Doosan G20 SIIIA Operation & Maintenance Manual Download Page 99

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G20, 30, 40 SIIIA Operation & Maintenance Manual

ALTERNATOR INSTALLATION AND MAINTENANCE

CONTENTS

FOREWORD ......................................................................................................................................

100

SAFETY MEASURES ...................................................................................................................

100

WARNING SYMBOLS ..................................................................................................................

100

RECEIPT ...........................................................................................................................................

101

Standards and safety measures ...................................................................................................

101

Inspection .....................................................................................................................................

101

Identification ..................................................................................................................................

101

Storage .........................................................................................................................................

101

Application ....................................................................................................................................

101

Contraindications to use ...............................................................................................................

101

TECHNICAL CHARACTERISTICS - G20, G30 SIIIA TAL040F, TAL042C ........................................

103

Electrical characteristics ...............................................................................................................

103

Mechanical characteristics ............................................................................................................

103

TECHNICAL CHARACTERISTICS - G40 SIIIA LSA42.3 ...................................................................

104

Electrical characteristics ...............................................................................................................

104

Mechanical characteristics ............................................................................................................

104

INSTALLATION...................................................................................................................................

105

Assembly ......................................................................................................................................

105

Checks prior to first use ................................................................................................................

106

Terminal connection diagram G20, G30 SIIIA TAL040F, TAL042C ..............................................

107

Terminal connection diagrams G40 SIIIA LSA42.3 .......................................................................

108

Commissioning ...............................................................................................................................

110

Setting up .......................................................................................................................................

110

SERVICING - MAINTENANCE ............................................................................................................

111

Safety measures.............................................................................................................................

111

Routine maintenance .....................................................................................................................

111

Mechanical defects ........................................................................................................................

112

Electrical faults ...............................................................................................................................

113

Dismantling, reassembly ................................................................................................................

115

Exploded view, parts list and tightening torque ............................................................................

120

Summary of Contents for G20 SIIIA

Page 1: ...nd must be made available to personnel who operate and maintain this machine 46674960_en_C_02 18 G20 30 40 SIIIA OPERATION MAINTENANCE MANUAL Original Instruction G20 SIIIA SERIAL No G02030001 G30 SIIIA SERIAL No G03030001 G40 SIIIA SERIAL No G04030001 ...

Page 2: ......

Page 3: ...TRUCTIONS 21 MAINTENANCE 71 ALTERNATOR INSTALLATION MAINTENANCE 99 REFERENCE INFORMATION Write the correct information for YOUR DIPP generator in the spaces below Always use these numbers when referring to your DIPP generator Generator Serial Number Engine Serial Number NOTES YOUR DIPP DEALER ADDRESS PHONE ...

Page 4: ...4 G20 30 40 SIIIA Operation Maintenance Manual ...

Page 5: ...5 G20 30 40 SIIIA Operation Maintenance Manual FOREWORD CONTENTS FOREWORD 6 DECLARATION OF CONFORMITY 7 ...

Page 6: ...vements to products sold previously The intended uses of this machine are outlined below and examples of unapproved usage are also given however the company cannot anticipate every application or work situation that may arise IF IN DOUBT CONSULT SUPERVISION This machine has been designed and supplied for use only in the following specified conditions and applications Operation within the ambient t...

Page 7: ...EU The Low Voltage Equipment Directive 17 and their amendments 18 Conformity with the Noise Emission Directive 2000 14 EC 19 20 22 Type kW 22 Type kW G20 SIIIA 15 88 6LWA 89LWA G100 SIIIA 80 94 3LWA 95LWA G30 SIIIA 26 89 8LWA 91LWA G150 SIIIA 120 95 6LWA 96LWA G40 SIIIA 32 88 8LWA 92LWA G200 SIIIA 160 95 8LWA 97LWA G60 SIIIA 48 91 5LWA 92LWA G250 205 96 5LWA 97LWA G80 SIIIA 64 93 3LWA 94LWA G400 S...

Page 8: ...equipo Generador portátil 7 Modelo del equipo 8 Nombre comercial 9 Número de serie VIN 9 Número de serie 10 Cumple n con las disposiciones pertinentes de la s siguientes Directiva s de la CE 11 Directiva de máquinas 2006 42 CE 12 Directiva de compatibilidad electromagnética 2004 108 CE 13 Directiva de emisión de ruidos 2000 14 CE 14 Directiva de equipos de presión 97 23 CE 15 Directiva de recipien...

Page 9: ...excluído do âmbito desta directiva É permitido apresentar a marcação CE em conformidade com as restantes directivas aplicáveis da CE 27 Director de Engenharia 28 Emitido em Dobris República Checa 29 Data 30 A documentação técnica da maquinaria está disponível através da Doosan Bobcat EM V U R 8 RGHWN REĜtã HFK 5HSXEOLF 31 2006 95 CE Directiva de Equipamentos de Baixa Tensão ro 7UDGXFHUH D HFODUDĠL...

Page 10: ...10 G20 30 40 SIIIA Operation Maintenance Manual ...

Page 11: ...11 G20 30 40 SIIIA Operation Maintenance Manual GENERAL DATA CONTENTS GENERAL DATA 12 GENERAL INFO 12 ELECTRICAL DATA 12 ...

Page 12: ...CTRICAL DATA UNIT MODEL G20 SIIIA G30 SIIIA G40 SIIIA Engine Speed RPM 1500 1800 1500 1800 1500 1800 Engine Fuel Diesel Diesel Diesel Manufacturer Yanmar Yanmar Yanmar Model 4TNV88 BGGE 4TNV98 ZGGE 4TNV98T ZGGE Number of cylinders Displacement litres 4 2 2 4 3 3 4 3 3 FLUID CAPACITIES Engine Crankcase Lubricant litres 7 4 10 2 11 5 Fuel Tank litres 220 220 180 365 optional Radiator Engine Coolant ...

Page 13: ...AFETY CONTENTS SAFETY DECALS 14 GRAPHIC FORM AND MEANING OF ISO SYMBOLS 14 SAFETY INSTRUCTIONS 16 EARTHING 17 IF USED AS ALTERNATE POWER SUPPLY 17 HAZARDOUS SUBSTANCE PRECAUTION 18 GENERAL INFORMATION 18 Electricity Materials Battery Radiator Transpor ...

Page 14: ...RUCTIONS WARNING WARNING Electrical shock risk WARNING Hot surface Tie down point Lifting point On power Off power Read the Operation Maintenance manual before operation or maintenance of this machine is undertaken Diesel fuel No open flame Crush Warning No Water Coolant Fill Earthing Point Warning Hot Liquid Coolant Drain Engine Oil Drain ...

Page 15: ...15 G20 30 40 SIIIA Operation Maintenance Manual WARNING Flammable liquid ...

Page 16: ...ety recommendations outlined in this manual to avoid injury to personnel DISCONNECT BATTERY BEFORE SERVICING CAUTION Exercise extreme caution when using booster battery To jump battery connect ends of one booster cable to the positive terminal of each battery Connect one end of other cable to the negative terminal of the booster battery and other end to a earth connection away from dead battery to...

Page 17: ...y of the operator when earthing is required by IEC 364 4 41 Protection Against Electric Shock and other local codes as applicable Several methods are employed to externally earth portable generator sets depending on the intended use and code requirements In all cases a continuous length of splice free copper cable no smaller than 10 mm2 shall be used for the external earth conductor when earthing ...

Page 18: ...e and site rules must be observed To ensure that the machine can operate in a safe and reliable manner additional equipment such as gas detection exhaust spark arresters and intake shut off valves may be required dependant on local regulations or the degree of risk involved A weekly visual check must be made on all fasteners fixing screws securing mechanical parts In particular safety related part...

Page 19: ...ngine lubricants or fuel are inhaled Never give fluids or induce vomiting if the patient is unconscious or having convulsions Safety data sheets for engine lubricants and fuel should be obtained from the lubricant supplier Battery Batteries contain corrosive liquid and produce explosive gas Do not expose to naked lights Always wear personal protective clothing when handling When starting the machi...

Page 20: ...20 G20 30 40 SIIIA Operation Maintenance Manual ...

Page 21: ... Buttons Status L E D S VIEWING REAL TIME DATA ACCESSING THE SCREENS 60 CHECKING SOFTWARE VERSION LAMP TEST 62 ADJUSTING THE CONTRAST ON THE DISPLAY SCREEN 62 PARAMETER ADJUSTMENTS VIA KEYPAD 62 SETPOINTS DESCRIPTIONS 63 Basic Settings Engine Parameters Engine Protection Alternator Protection Date Time 3 WAY FUEL VALVE 67 OIL SUMP PUMP 68 SOCKET SET CE 69 GOVERNOR LEVER G20 SIIIA 69 SPEED CONTROL ...

Page 22: ...round and above the machine to permit safe access for specified maintenance tasks Ensure that the machine is positioned securely and on a stable foundation Any risk of movement should be removed by suitable means especially to avoid strain on any rigid discharge piping CONNECTING THE LOAD Make sure the wires are not cracked or damaged in any way Connect the proper phase wire to its corresponding b...

Page 23: ...mal shut down Verify the following 1 All external electrical power loads are turned OFF 2 Main Breaker is OFF 3 Battery Disconnected Switch is ON 4 Reset pull to unlatch Emergency Stop Button 5 Push the controller START Button 6 Wait for preheating if enabled CAUTION Do NOT use engine starting fluids DANGER POWER is present upon cranking the engine CAUTION Allow starter to cool for one minute betw...

Page 24: ...he engine to start at any time without warning Prior to performing any maintenance on the system it is recommended that steps are taken to remove the battery and isolate supplies Control of the module is via push buttons mounted on the front of the module with Stop Reset Mode Auto Mode and Manual Start Mode functions For normal operation these are the only controls which need to be operated Detail...

Page 25: ...rom lowest to highest if used Upon removal of the starting signal the module will remove the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary Close Generator and Delayed Load Output 1 2 3 4 become inactive at once if used The module will then await the next start event For further details please see the more detailed description of Auto op...

Page 26: ...PLAY The module s display contains the following sections A description of each section can be viewed in the sub sections Note Depending upon the module s configuration some display screens may be disabled Figure 2 Example of DSE4510 Home Page Display Figure 3 ...

Page 27: ...n Load power instrumentation screen Engine speed instrumentation screen Hours run instrumentation screen Battery voltage instrumentation screen Oil pressure instrumentation screen Coolant temperature instrumentation screen Flexible sender instrumentation screen Appears when the event log is being displayed Current time held in the unit The current value of the scheduler runtime and duration ECU di...

Page 28: ...OR FPE AUTO RUN ICON ICON DETAILS Appears when the main configuration is selected Appears when the alternative configuration is selected When running in Auto Mode and on the Home Page an icon is displayed in the FPE Auto Run section to indicate the source of the auto start signal ICON AUTO RUN REASON Appears when a remote start input is active Appears when a low battery run is active Appears when ...

Page 29: ...in auto mode Appears when the engine is at rest and the unit is waiting for a manual start Appears when a timer is active for example cranking time crank rest etc Appears when the engine is running and all timers have expired either on or off load The animation speed is reduced when running in idle mode Appears when the unit is in the front panel editor Appears when a USB connection is made to the...

Page 30: ...the appropriate icons to indicate each alarm which is active Example If the DSE controller was sensing a charge alternator failure alarm delay over current alarm and an AC under voltage alarm at the same time it would cycle through all of the icons to show this Figure 4 In the event of a warning alarm the LCD only displays the Alarm Icon In the event of an electrical trip or shutdown alarm the mod...

Page 31: ...igured As Digital The analogue inputs can be configured to digital inputs The module detects that an input configured to create a fault condition has become active Fail To Stop The module has detected a condition that indicates that the engine is running when it has been instructed to stop NOTE Fail to Stop could indicate a faulty oil pressure sensor If engine is at rest check oil sensor wiring an...

Page 32: ... timer has expired Generator Over Frequency The generator output frequency has risen above the pre set pre alarm setting CAN ECU Fault The engine ECU has detected an alarm CAN Data Fail The module is configured for CAN operation and does not detect data on the engine Can data link Immediate Over Current The measured current has risen above the configured trip level Delayed Over Current The measure...

Page 33: ... from safety on alarms as the oil pressure is low with the engine at rest Electrical trips are latching alarms and to remove the fault press the Stop Reset Mode button on the module ICON FAULT DESCRIPTION Auxiliary Inputs The module detects that an auxiliary input which has been user configured to create a fault condition has become active Analogue Input Configured As Digital The analogue inputs c...

Page 34: ... auxiliary input which has been user configured to create a fault condition has become active Analogue Input Configured As Digital The analogue inputs can be configured to digital inputs The module detects that an input configured to create a fault condition has become active Fail To Start The engine has failed lo start after the configured number of start attempts Low Oil Pressure The module dete...

Page 35: ...n kW Overload The measured kW has risen above the configured trip level for a configured duration CAN ECU Fault The engine ECU has detected an alarm CHECK ENGINE LIGHT Contact Engine Manufacturer for support CAN Data Fail The module is configured for CAN operation and does not detect data on the engine Can data link Emergency Stop The emergency stop button has been depressed This fail safe normall...

Page 36: ...To select the required icon press the Up button to cycle right or the Down button to cycle left until the desired instrumentation section is reached Once the desired icon is at the top press the Auto Mode button to enter that instrumentation section If the Auto Mode button is not pressed the display automatically returns to the Home Page after the configured setting of the LCD Scroll Timer ...

Page 37: ...eration Maintenance Manual NAVIGATION MENU ICONS ICON DESCRIPTION Generator instrumentation Current and load instrumentation Engine instrumentation Module information Engine DTCs Diagnostic Trouble Codes if active Event log ...

Page 38: ...gh the display to view different pages of information by repeatedly operating the Up or Down navigation buttons And so on until the last page is reached A further press of the navigation Down button returns the display to the Home Page Once selected the page will remain on the LCD display until the user selects a different page or after an extended period of inactivity Page Delay Timer the module ...

Page 39: ...e module fascia buttons It also contains the voltage reading of the generator and mains that is measured from the module s voltage inputs Figure 9 Generator Voltage ph N ph ph Mains Voltage ph N ph ph DSE4520 only GENERATOR These pages contain electrical values of the generator measured or derived from the module s voltage inputs Figure 10 Generator Voltage ph N Generator Voltage ph ph Generator F...

Page 40: ... measured or derived from the module s inputs some of which may be obtained from the engine ECU Figure 11 Engine Speed Engine Run Time Engine Battery Volts Engine Coolant Temperature Engine Oil Pressure Engine Fuel Level Flexible Sensor Engine Maintenance Due Oil Engine Maintenance Due Air Engine Maintenance Due Fuel ...

Page 41: ... Operation Maintenance Manual INFO These pages contain information about the controller Figure 12 Module s date and time Scheduler settings Product description and USB identification number Application and Engine Version ...

Page 42: ...DTC Figure 13 To view the engine DTC s press both Up and Down buttons simultaneously the navigation menu is then displayed Once entered cycle to the DTC section and enter To view the active DTC s alarms repeatedly press the Up or Down buttons until the LCD screen displays the alarm Continuing to press the Up or Down buttons will cycle through the alarms To exit the active DTC s alarm section press...

Page 43: ...figured low oil pressure alarm level Under Speed The engine ECU has detected that the engine speed has fallen below its configured under speed alarm level Over Speed The engine ECU has detected that the engine speed has risen above its configured over speed alarm level Charge Failure The engine ECU has detected that the engine s charge alternator output has fallen below its configured alarm level ...

Page 44: ...bserved by any particular module in the field QUICKSTART GUIDE This section provides a quick start guide to the module s operation STARTING THE ENGINE Figure 14 Note For further details see the section entitled OPERATION elsewhere in this manual STOPPING THE ENGINE Figure 15 Note For further details see the section entitled OPERATION elsewhere in this manual Press the Manual Start button to crank ...

Page 45: ...software and to enter the Front Panel Editor to change parameters Figure 16 Note For further details of module configuration refer to DSE Publication 057 172 DSE45xx Configuration Software Manual Stop Reset Mode is activated by pressing the Stop Reset Mode button The Stop Reset icon is displayed to indicate Stop Reset Mode operations In Stop Reset Mode the module removes the generator from load if...

Page 46: ...d of the start delay timer the fuel relay is energised and the engine is cranked Note If the unit has been configured for CAN compatible ECUs receive the start command via CAN and transmit the engine speed to the DSE controller ENGINE RUNNING The generator is placed on load if configured to do so Note The load transfer signal remains inactive until the Oil Pressure has risen This prevents excessiv...

Page 47: ...s been configured for CAN compatible ECUs receive the start command via CAN If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made Should this sequence continue beyond the set number of attempts the start sequence is terminated and the display shows Fail to Start When the engine fires the ...

Page 48: ...NG SEQUENCE In Manual Start mode the set will continue to run until either Once the engine is running and all starting timers have expired the animated Engine Running icon is displayed Press the Auto Mode button to return to automatic mode The set observes all auto mode start requests and stopping timers before beginning the Auto Mode Stopping Sequence Press the Stop Reset Mode button to remove lo...

Page 49: ...rning set continues to run or shutdown running the set is not possible Resetting the maintenance alarm is normally actioned by the site service engineer after performing the required maintenance The method of reset is either by Activating an input that has been configured to Maintenance Reset Alarm x where x is the type of maintenance alarm Air Fuel or Oil Pressing the maintenance reset button in ...

Page 50: ...ENANCE section SCHEDULER The controller contains an inbuilt exercise run scheduler capable of automatically starting and stopping the set Up to 8 scheduled start stop sequences can be configured to repeat on a 7 day or 28 day cycle Scheduled runs may be on load or off load depending upon module configuration Example Figure 21 Screen capture from DSE Configuration Suite Software showing the configu...

Page 51: ...eduled runs operate ONLY if the module is in Auto Mode with no Shutdown or Electrical Trip alarm present If the module is in Stop Reset Mode or Manual Start Mode when a scheduled run begins the engine is not started However if the module is moved into Auto Mode during a scheduled run the engine will be called to start Depending upon configuration by the system designer an external input can be use...

Page 52: ...gure the module through its display without the use of the DSE Configuration Suite PC Software Use the module s fascia buttons to traverse the menu and make value changes to the parameters Figure 22 Next Section 101 201 301 Previous Section 301 201 101 Previous Parameter 103 102 101 Next Parameter 101 102 103 Edit or Save Parameter ...

Page 53: ...e Stop Reset Mode and Auto Mode buttons together to enter the editor mode Press the Up or Down navigation buttons to cycle through the front panel editor to select the required page in the configuration tables Press Manual Start Mode button to select the next parameter or Stop Reset Mode button to select the previous parameter within the current page When viewing the parameter to be edited press t...

Page 54: ...al present on the Remote Start input Check configured polarity is correct Check the mains supply is available and within configured limits Generator fails to start on receipt of Remote Start signal Check Start Delay timer has timed out Check signal is on Remote Start input Confirm correct configuration of input is configured to be used as Remote Start Check that the oil pressure switch or sensor i...

Page 55: ...engine has fired Check engine temperature Check switch sensor and wiring Check configured polarity if applicable is correct i e Normally Open or Normally Closed or that sensor is compatible with the module Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD display Check configuration of input Electrical Trip fault operates Check relevant switch and wiring of fault i...

Page 56: ...re that CTs are connected to the correct phase errors will occur if CT1 is connected to phase 2 Remember to consider the power factor kW kVA x powerfactor The controller is true RMS measuring so gives more accurate display when compared with an averaging meter such as an analogue panel meter or some lower specified digital multimeters Accuracy of the controller is better than 1 of full scale Gener...

Page 57: ...is low or not being charged 7 Engine Speed Indicates engine overspeed 8 Engine Operating Indicates engine is cranking or operating 9 Preheat Indicates preheating is on 10 Engine Communication Indicates the controller has communication with the engine ECU 11 Engine Fault Indicates that engine service may be required 12 Engine Start Switch 13 Engine Stop Reset Switch Stops engine and resets diagnost...

Page 58: ... time for maintenance Monitor Switches 8 Amperage Output Selects the line phase amperage to be displayed on the AC Ammeter 9 Voltage Adjust Potentiometer Turn to adjust generator output voltage Protection Regulation 10 3 Phase Direct Hookup Connections L1 L2 L3 N neutral PE Protective Earth Not shown 11 Fuse Holders Fuses for voltage output meter Not shown 12 Residual Current Release Device RCD Pr...

Page 59: ...an also be viewed The parameters include but are not limited to kW KVA kVAr power factor oil pressure coolant temperature engine speed and diagnostic history Figure 25 IDENTIFYING KEYPAD BUTTONS AND INDICATORS Operation Buttons Press this button to START the generator set Press this button to STOP the generator set Press this button to deactivate the horn Press this button to clear inactive faults...

Page 60: ...tional screen which identifies the status of the generator set along with the generator kW power factor and engine RPM Figure 27 This screen displays electrical values of the generator set These values include frequency line voltages phase voltages and current per phase Figure 28 This screen displays the engine operational data of the generator set Use this button to scroll the display between the...

Page 61: ...shown here The ECU Yellow Lamp indicates an engine warning and the ECU Red Lamp indicates an engine shutdown Figure 32 This screen is ONLY shown on engines utilising J1939 engine communications The data is sent from the engine ECU Figure 33 BIN I000000 Rem Start Stop I Low Coolant 0 Emergency Stop 0 Low Fuel 0 Full Basin 0 Voltage Select 0 VSS Door 0 BOUT 0000I00 Starter 0 Fuel Solenoid 0 Fuel Pul...

Page 62: ...ays the alarm shutdown list of the generator set Inactive faults can be cleared by pressing the Fault Reset button Up to eight faults can be displayed on this screen and are first in first out CHECKING SOFTWARE VERSION LAMP TEST To check the software version and to test the operation of the LEDs on the control panel simultaneously press and ADJUSTING THE CONTRAST ON THE DISPLAY SCREEN To adjust th...

Page 63: ...ltage in LOW WYE Parallel connection Nominal Voltage 2 Line to neutral voltage in HI WYE series connection Gear Teeth Number of teeth on the engine gear for the pick up Set to zero if no pick up is used Engine speed is counted from the generator frequency Electronic engines get the speed signal from the engine controller Alternator Frequency Frequency of the battery alternator when the controller ...

Page 64: ...After Cool Time This function is not used Factory default setting 0 Stop Time When genset stop sequence is initiated fuel solenoid output cannot activate during this time Fuel Solenoid Determines behavior of the Binary output FUEL SOLENOID DIESEL Output closes together with Binary output STARTER The output opens if Emergency stop comes or Cooled generator set is stopped or in pause between repeate...

Page 65: ...Fuel Level Del Delay for low fuel level Batt Overvolt Warning threshold for high battery voltage Batt Undervolt Warning threshold for low battery voltage Battvolt del Delay for low battery voltage alarm NextServTime h Counts down when engine running If reaches zero an alarm appears ALTERNATOR PROTECTION Overload Threshold for generator overload in of nominal power Overload Wrn Threshold for genera...

Page 66: ...ATE TIME Time Stamp Per Fixed time interval when history of all parameters is recorded Factory Default Setting 0 Summer Time Mod Automatic time adjustment for daylight savings time Time Time of day setting Date Date setting Timer 1 Repeat Selection of day days when exercise Timer 1 will run Timer 1 on Time Selection of time of day when Timer 1 will start the genset Timer 1 Duration Selection of le...

Page 67: ...d is 3 8 BSPP Figure 39 3 way fuel valve Move the lever to the external fuel tank position Figure 40 Valve lever position Clean up any spilled fuel Connecting to external fuel connection preparation Stop the engine Connect the external fuel supply and return hoses to the external fuel connection Thread is 1 2 BSPP Figure 41 3 way fuel valve external connections Move the lever to the external fuel ...

Page 68: ... hose on the engine oil outlet connection Figure 43 Open the engine oil pan drain valve Drain the engine oil using the hand pump Figure 44 Hand pump Recycle or dispose of used oil in an environmentally safe manner Close the engine oil pan drain valve WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil Keep heat flames sparks or lighted tobacco away from fuel and oil Failure to use ca...

Page 69: ...nd shorten its life If adjustment is ever required contact your authorized YANMAR industrial engine dealer or distributor The governor lever 1 controls the engine speed The lever is linked to the engine speed control device in the driven machine The high idle speed limit screw 2 restricts the maximum engine speed when the engine is operated without a load The low idle speed limit screw 3 sets engi...

Page 70: ...containing the materials safely Do not dispose of any pressure vessel that is not clearly marked with its relevant data plate information or rendered unusable by drilling cutting etc Do not allow lubricants or coolants to be released into land surfaces or drains Do not dispose of a complete machine without documentation relating to instructions for its use LONG TERM STORAGE RECOMMENDATIONS 6 MONTH...

Page 71: ...IA 4TNV98T ZGGE 80 ENGINE IDENTIFICATION 81 ENGINE AFTER SERVICE 81 EMISSION CONTROL LABEL 82 ENGINE LABEL FOR EPA 82 FUEL LUBRICANTS AND COOLANT 83 FUEL 83 LUBRICANT 85 COOLANT 86 ENGINE OPERATION 87 CHECK BEFORE OPERATION 87 CHECKS AND OPERATION AFTER START UP 89 OPERATION AND CARE OF A NEW ENGINE 89 COLD START DEVICE 90 ENGINE STOPPING 90 LONG TERM STORAGE 90 PERIODICAL INSPECTION AND MAINTENAN...

Page 72: ...llow its operating and maintenance recommendations This will ensure many years of trouble free and economical engine operation Should your engine require servicing please contact your nearest branch or distributor All information illustrations and specifications contained in this Manual are based on the latest product information available at the time of publication The company reserves the right ...

Page 73: ...g refuelling there is a risk of fire and explosion The engine must be switched off and smoking is prohibited Hazardous gases WARNING Only start the engine in a well ventilated area The exhaust gases contain carbon monoxide and nitrogen oxides which are toxic If it is run in an enclosed space there should be an effective device to extract exhaust gases and crankcase gases Starter lock CAUTION If th...

Page 74: ... to health in approved containers marking them clearly and storing them where they are inaccessible to unauthorised persons Environment Always hand in leftover and used chemicals to an authorised waste disposal contractor SAFETY PRECAUTIONS FOR MAINTENANCE AND REPAIR Switch off the engine Always switch off the engine before carrying out maintenance and repair work unless otherwise indicated Make i...

Page 75: ...nect thee batteries Lubrication system WARNING Hot oil can cause burns and skin irritation Wear protective gloves and goggles when changing hot oil Make sure that there is no pressure in the lubrication system before starting work on it The oil filler cap must always be in place when starting and running the engine to prevent oil being ejected Environment Always hand in used oil to an authorised w...

Page 76: ... oil 2 10 Fuel injection pump 11 Engine oil cooler 3 12 Engine oil filter 13 Dipstick engine oil 14 Governor lever 15 Intake manifold 16 Fuel filter 17 Fuel inlet 18 Fuel return to fuel tank 19 Top filler port Engine oil 20 Rocker arm cover 21 Air intake port From air cleaner 22 Flywheel 23 Starter motor 24 Exhaust manifold 25 Alternator 1 Only applies to 4TNV84T Z 4TNV98T Z 2 Engine oil drain plu...

Page 77: ...mp 11 Engine oil cooler 3 12 Engine oil filter 13 Dipstick engine oil 14 Eco governor 15 Intake manifold 16 Fuel filter 17 Fuel inlet 18 Fuel return to fuel tank 19 Top filler port Engine oil 20 Rocker arm cover 21 Air intake port From air cleaner 22 Flywheel 23 Starter motor 24 Exhaust manifold 25 Alternator 26 EGR valve 27 EGR cooler 4 28 EGR pipe 1 Only applies to 4TNV84T Z 4TNV98T Z 2 Engine o...

Page 78: ... 9 42 5 44 2 45 8 48 1 High idling min 1 1600 25 1895 25 2180 25 2290 25 2400 25 2510 25 2590 25 2700 25 2810 25 2920 25 2995 25 3210 25 Engine weight dry with flywheel housing 1 183 kg 170 kg PTO position Flywheel end Direction of rotation Counter clockwise viewed from flywheel end Governor Mechanical governor all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced...

Page 79: ...0 59 5 62 0 64 5 67 0 69 5 High idling min 1 1530 25 1830 25 2150 25 2250 25 2350 25 2450 25 2550 25 2650 25 Engine weight dry with flywheel housing 1 248 kg 235 kg PTO position Flywheel end Direction of rotation Counter clockwise viewed from flywheel end Governor Electronic governor all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced lubrication with trochoid p...

Page 80: ... 5 78 8 82 0 85 0 High idling min 1 1530 25 1830 25 2350 25 2450 25 2550 25 2650 25 Engine weight dry with flywheel housing 1 258 kg 245 kg PTO position Flywheel end Direction of rotation Counter clockwise viewed from flywheel end Governor Electronic governor all speed governor Cooling system Liquid cooled with radiator Lubricating system Forced lubrication with trochoid pump Normal oil pressure R...

Page 81: ...ervice or parts ordering CAUTION Conduct confirmation of engine serial number with the engine stopped To avoid being injured do not check it while the engine is still hot ENGINE AFTER SERVICE Please feel free to contact your dealer for periodical inspection and maintenance Doosan Genuine Parts Genuine Doosan parts are identical with those used in the engine production and accordingly they are warr...

Page 82: ...R EPA Emission control label is attached on the top of rocker arm cover The location of emission control label attached on the engine may vary depending on the engine specification The following is the sample of a label required for engine emission control information along with location ...

Page 83: ...njection pump injector or other parts of the fuel system and engine can be damaged if you use any fuel or fuel additive other than those specifically recommended by Doosan If any fuel other than the one specified is used engine operation will be impaired Engine failure or malfunction resulting from use of such improper fuel will not be warranted by Doosan To help avoid fuel system or engine damage...

Page 84: ...ain excess water NOTE Be sure you do not overfill the fuel tank Heat such as from the engine can cause the fuel to expand If the tank is too full fuel could be forced out This could lead to a fire and the risk of personal injury and or equipment damage WARNING The water diesel fuel mixture is flammable and could be hot To avoid personal injury and or property damage do not touch the fuel coming fr...

Page 85: ...e oil viscosity affects engine startability performance oil consumption wear and the potential for seizure etc Always ensure that lubricants with the correct viscosity for the operating temperature are used Refer to figure below NOTE Using a mixture of different brands or quality of oils will adversely affect the original oil quality therefore never mix different brand or different type oils Do no...

Page 86: ...out LLC cooling water will freeze and expand to break the cooling line Be sure to use the mixing ratios specified by the LLC manufacturer for your temperature range Do not mix different types brand of LLC chemical reactions may make the LLC useless and engine trouble could result Replace the cooling water every once a year WARNING When handling Long Life Coolant Antifreeze wear protective rubber g...

Page 87: ... level against the marks on the dipstick The oil level must be between the upper level mark and the lower level mark as illustrated Remove filler cap yellow coloured on the rocker arm cover side of engine Fill with engine oil up to the upper limit on the dipstick Manually tighten the filler cap Do not use a tool such as pliers to tighten it Engine oil pan capacity G20SIIIA 4TNV88 BGGE 7 4 litres G...

Page 88: ...ne starting or insufficient battery charge The battery cables must be tightened securely Never reverse and terminals when reconnecting cables after disconnection Even a short period of reverse connection will damage the electrical parts Battery Electrolyte level The amount of electrolyte in the batteries will be reduced after repeated discharge and recharge Check the electrolyte level in the batte...

Page 89: ...y tested and adjusted in the factory however further run in is necessary Avoid any harsh engine operation within the initial 100 operating hours Do not operate the unit at full load until the engine is warmed up Do not allow the engine to run unloaded for extended periods so as to minimise the risk of cylinder bore glazing During operation pay attention to the following points if the engine shows ...

Page 90: ...ne operation Periodical machine maintenance is scheduled on the operation hours indicated on the hourmeter 4 Liquid and Exhaust Smoke Leakage Make regular checks for lubricant fuel coolant and exhaust smoke leakage 5 Abnormal Engine Noise In the event of any abnormal engine noise please consult your local branch or dealer 6 State of the Exhaust Smoke Check for any abnormal exhaust smoke color COLD...

Page 91: ...ilter mounting face 6 Moisten the new engine oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface and tighten it further to 3 4 of a turn with the filter wrench Tightening torque 19 6 23 5N m 2 0 2 4kgf m Applicable engine oil filter Part No CCN 46697111 7 Fill with the new engine oil until i...

Page 92: ...e of each injection pump and then to the leak off pipe of each injector nozzle so that any air in the fuel system bleeds off automatically to the fuel tank NOTE Although the fuel system can bleed air automatically when the key switch is in the ON position air can also be manually bled by use of the primer pump facility in the filter separator assembly By unscrewing the plastic primer pump head A a...

Page 93: ...e correct seating of the sealing ring Fill the element bowl assembly with clean fuel oil then apply a light coat of clean engine oil to the new element seal ring Screw the new element onto the head firmly by hand Follow the fuel system air bleeding procedure INSPECTION EVERY 1000 HOURS OPERATION a Replacing cooling water Cooling water contaminated with rust or water scale reduces the cooling effec...

Page 94: ... service d Inspect and Clean EGR Lead Valve The EGR lead valve is located in the passage of recirculated gas To prevent carbon accumulation in or clogging of the lead valve inspect and clean the lead valve at regular intervals Consult your local Portable Power dealer for this service e Clean EGR Cooler The EGR cooler is apt to be contaminated with rust and scale that deteriorate the cooling perfor...

Page 95: ...o maintain proper contact of the valves and seats d Checking and adjusting the fuel injection timing As this maintenance requires specialized knowledge and skill consult your Portable Power dealer e Checking and adjusting the EPA emission related parts The inspection and servicing require specialized knowledge and techniques Consult your Portable Power dealer or distributor EPA allows to apply mai...

Page 96: ...l tank Clogged fuel filter element Air in the fuel system Control rack is stuck at no fuel position Fuel is injected but engine does not fire Incorrect preheating operation Faulty air heater Incorrect injection timing Low cylinder compression pressure Engine fires but stalls immediately Air in the fuel system Unstable engine running Unstable low idling Crack in injection pipe Injection nozzle fail...

Page 97: ...er and strainer Clean and or replace Worn bearings and oil pump Replace Faulty relief valve Replace Low engine output Incorrect injection pump adjustment Incorrect injection timing Too far advanced Too far retarded Injection nozzle malfunction Incorrect injection pressure Incorrect spray condition Insufficient fuel supply to the injection pump Lack of fuel in tank Air in injection pump Fuel filter...

Page 98: ...ing Excessive injection volume Injection pump defective Excessive mechanical loads Improper exhaust Excessive black smoke Clogged air cleaner Damaged injector nozzle Faulty EGR Valve Injection timing incorrect Excessive injection volume Incorrect fuel Excessive white smoke Water mixing in fuel Low compression pressure Injection timing incorrect Low coolant temperature Faulty turbocharger Battery o...

Page 99: ...characteristics 103 Mechanical characteristics 103 TECHNICAL CHARACTERISTICS G40 SIIIA LSA42 3 104 Electrical characteristics 104 Mechanical characteristics 104 INSTALLATION 105 Assembly 105 Checks prior to first use 106 Terminal connection diagram G20 G30 SIIIA TAL040F TAL042C 107 Terminal connection diagrams G40 SIIIA LSA42 3 108 Commissioning 110 Setting up 110 SERVICING MAINTENANCE 111 Safety ...

Page 100: ...warning symbols used CAUTION Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment WARNING Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel WARNING SYMBOLS We wish to draw your attention to the following 2 safety measures which must be complied with a During operation do not allow anyone to stand in fr...

Page 101: ...he nameplate on the machine conforms to your order Nameplate So that you can identify your machine quickly and accurately we suggest you write its specifications on the nameplate below STORAGE Prior to commissioning machines should be stored Away from humidity 90 after a long period of storage check the machine insulation See Electrical checks on page 106 To prevent the bearings from becoming mark...

Page 102: ...o load A D E bearing N D E bearing Altitude m kVA kW A V kVA kW A Weight kg r p m P F Hz RATINGS Voltage Phase Conn Contin P R B R 40 C Std by 27 C Date TAL ALTERNATORS R C US IEC 60034 1 5 NEMA MG1 32 33 www leroy somer com 1 025 002 a Made in ISO 8528 3 166631 IP LSA N Th class A V R Excit Excit values full load V A at no load A D E bearing N D E bearing Altitude m kVA kW A V kVA kW A Weight kg ...

Page 103: ...ICAL CHARACTERISTICS Steel frame End shields in cast iron Greasable ball bearings Mounting arrangement MD 35 single bearing with standard feet and SAE flanges coupling discs Drip proof machine self cooled SHUNT EXCITER MAIN FIELD Armature Exciter field Rotating rectifiers T1 U1 T4 U2 T2 V1 T5 V2 For delta connection 1PH 3PH use terminals N and U connect N and N1 red black T3 W1 T6 W2 STATOR 6 wire...

Page 104: ... Drip proof machine self cooled Options Direct power output by non reconnectable cables regulator fitted outside the alternator Protection against harsh environmentsh Air input filter air output labyrinth cowling Alternators fitted with air inlet filters should be derated by 5 power To prevent excessive temperature rise caused by clogged filters it is advisable to fit the stator winding with therm...

Page 105: ... handling the machine using the lifting ring snap on the plastic cover provided in the maintenance manual wallet Single bearing coupling Before coupling the machines check that they are compatible by undertaking a torsional analysis of the transmission checking the dimensions of the flywheel and its housing the flange coupling discs and offset CAUTION When coupling the alternator to the prime move...

Page 106: ...l as turning over the machine from time to time Space heaters are only really effective if they are working continuously while the machine is stopped WARNING Ensure that the alternator has the degree of protection matching the defined environmental conditions When the alternator s power output is ensured directly through cables these must be connected before start up Mechanical checks Before start...

Page 107: ...r cables on the terminals The winding code is specified on the nameplate 6 wires connection Connection 3 PH Star T1 T4 T6 T3 T5 T2 L2 V L3 W L1 U green yellow blue to R120 to R120 to R120 T4 T5 T6 T3 T2 T1 W L3 V L2 U L1 N 1 PH Delta T1 T4 T6 T3 T5 T2 yellow blue T4 T5 T6 T3 T2 T1 L L 3 PH Delta T1 T4 T6 T3 T5 T2 yellow blue T4 T5 T6 T3 T2 T1 W L3 V L2 U L1 D C C ...

Page 108: ...L1 U L3 W L2 V D F L1 U M L3 W T1 T7 T12 T10 T4 T9 T3 T6 T11 T5 T2 T8 L2 V Tension LM 1 2 tension LL LM voltage 1 2 LL voltage R 220 voltage sensing 0 T8 110 V T11 R 438 voltage sensing 0 T3 220 V T2 N L1 U L2 V L3 W NDE T9 T8 T7 T12 T10 T11 T4 T3 T2 T1 T5 T6 Winding 60 Hz 50 Hz 380 415 380 480 440 460 380 416 6 7 8 R 220 voltage sensing 0 T8 110 V T11 R 438 voltage sensing 0 T3 380 V T2 NDE N L1 ...

Page 109: ...ng 60 Hz 50 Hz 220 240 220 240 250 260 200 220 240 6 7 8 R 220 voltage sensing 0 T8 110 V T11 R 438 voltage sensing 0 T3 220 V T2 M L L NDE T9 T8 T7 T12 T10 T11 T4 T3 T2 T1 T5 T6 1 phase or 3 phases L1 U L2 V L3 W L L Winding 60 Hz 50 Hz 110 120 120 110 120 120 130 6 7 8 R 220 voltage sensing 0 T8 110 V T11 R 438 voltage sensing 0 T3 110 V T2 NDE T9 T8 T7 T12 T10 T11 T4 T3 T2 T1 T5 T6 L L L3 W T1 ...

Page 110: ...nnected to the electrical earth circuit The earth terminal ref 28 is connected to the frame The connections inside the terminal box must never be subjected to stress due to cables connected by the user COMMISSIONING WARNING The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The machine is tested and set up a...

Page 111: ...trical servicing Commercially available volatile degreasing agents can be used CAUTION Do not use trichlorethylene perchlorethylene trichloroethane or any alkaline products WARNING These operations must be performed at a cleaning station equipped with a vacuum system that collects and flushes out the products used The insulating components and the impregnation system are not at risk of damage from...

Page 112: ...ve the ambient temperature Air flow intake outlet partially clogged or hot air is being recycled from the alternator or engine Alternator operating at too high a voltage 105 of Un on load Alternator overloaded Vibration Excessive vibration Misalignment coupling Defective mounting or play in coupling Rotor balancing fault Engine Alternator Excessive vibration and humming noise coming from the machi...

Page 113: ... P2 before running at the correct speed Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Voltage oscillations Adjust the AVR stability potentiometer If no effect try normal or fast stability modes ST2 Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or AVR LAM set too high Voltage correct at no load and to...

Page 114: ...ely 50 ohms 300 W and a diode on both exciter field wires 5 and 6 Assembly A Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation power of the machine see the nameplate 3 Run the unit at its rated speed 4 Gradually increase the exciter field current by a...

Page 115: ...ng the feet on the housing and immobilising the stator must not be removed bolt of the stator lower Access to connections and the regulation system The terminals and AVR are accessed directly by removing the terminal box lid 41 AVR is accessed directly by removing the terminal box lid Accessing checking and replacing the diode bridge Dismantling Remove the terminal box lid 41 Cut the fixing clamps...

Page 116: ...support made according the following bellow Rest the rotor on one of its poles then slide it out Use the tube as a lever arm to assist dismantling After extraction be careful with the fan It is necessary to replace the fan in case of disassembling After extracting the rotor be careful not to damage the fan and place the revolving field on special V blocks NOTE If intervention is required on the ma...

Page 117: ...oad with separate field excitation All values are given to 10 for exact values consult the test report and are subject to change without prior warning For 60 Hz operation the resistance values are the same and the excitation current i exc is approximately 5 to 10 weaker Three phase 4 pole AREP excitation Resistances at 20 C Ω Resistance of auxiliary windings at 20 C Ω Field excitation current i ex...

Page 118: ...mbly 79 1 Preloading wavy washer 15 1 Fan M5 4 90 1 Wound exciter field 28 1 Earth terminal 91 4 Field fixing screw M6 10 30 1 DE flange 100 1 Exciter armature 33 1 Air outlet grille M5 4 124 1 Terminal plate 36 1 NDE bracket 198 1 Regulator AVR 37 4 Tie rod M8 20 322 1 Coupling disc 40 1 Plastic cap 323 6 Fixing screw M10 66 41 2 Terminal box lid 324 1 Clamping washer 49 4 Cover screw M5 3 6 343 ...

Page 119: ...her 15 1 Fan M5 4 90 1 Wound exciter field 28 1 Earth terminal 91 4 Field fixing screw M6 10 30 1 DE flange 100 1 Exciter armature 33 1 Air outlet grille M5 4 124 1 Terminal plate M5 6 36 1 NDE bracket 198 1 Regulator AVR M5 4 0 5 37 4 Tie rod M10 34 322 1 Coupling disc 40 1 Plastic cap 323 6 Fixing screw M10 66 41 2 Terminal box lid 324 1 Clamping washer 49 Terminal box screw M5 3 6 0 4 343 2 Dir...

Page 120: ...box lid 49 Terminal box screw M5 3 6 0 4 53 1 Plug 59 1 Access flap M5 3 6 0 4 70 1 NDE bearing 79 1 Preloading wavy washer 90 1 Wound exciter field 91 4 Field fixing screw M6 10 100 1 Exciter armature 120 1 Terminal plate support M5 6 124 1 Terminal plate M5 6 198 1 Regulator AVR M5 4 0 5 199 Interference suppression module M5 6 343 2 Direct diode assembly M5 4 349 1 0 ring seal 1 AVR fuses ...

Page 121: ......

Page 122: ...Doosan Bobcat EMEA s r o U Kodetky 1810 263 12 Dobříš Czech Republic www doosanportablepower eu ...

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