Doosan G100XW/XF, Operation & Maintenance Manual

Page 1: ... G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz OPERATION MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine 46689183_en_B_05 19 ...

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Page 3: ...TIONS 55 ENGINE REGULAR INSPECTION 69 ALTERNATOR INSTALLATION MAINTENANCE 107 ALTERNATOR COMPONENTS 123 MAIN BREAKER OPERATION 127 WARRANTY CONDITIONS 123 REFERENCE INFORMATION Write the correct information for YOUR DIPP generator in the spaces below Always use these numbers when referring to your DIPP generator Doosan Bobcat EMEA s r o U Kodetky 1810 263 12 Dobříš Czech Republic www doosanportabl...

Page 4: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 4 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 5: ...s 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 temperature range specified in the GENERAL INFORMATION sectio...

Page 6: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 6 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 7: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 7 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz GENERAL DATA CONTENTS GENERAL DATA 8 ELECTRICAL DATA 8 ...

Page 8: ...100 Weight with fuel kg TBA TBA TBA TBA Weight without fuel kg 2190 2350 2800 2800 UNIT MODEL G80XW XF G115XW XF G150XW XF G200XW XF Prime Power Rating 400V 3Ø 0 8PF 50Hz 118 A 82 00 kVA 65 60 kW 166 A 115 00 kVA 92 00 kW 211 A 146 00 kVA 116 80 kW 284 A 197 00 kVA 157 60 kW Standby Power Rating 400V 3Ø 0 8PF 50Hz 131 A 91 00 kVA 72 80 kW 180 A 125 00 kVA 100 00 kW 235 A 163 00 kVA 130 40 kW 320 A...

Page 9: ...135 XW XF G170XW XF G225XW XF 60Hz SAFETY CONTENTS SAFETY DECALS 10 GRAPHIC FORM AND MEANING OF ISO SYMBOLS 10 SAFETY INSTRUCTIONS 12 EARTHING 13 IF USED AS ALTERNATE POWER SUPPLY 13 HAZARDOUS SUBSTANCE PRECAUTION 14 GENERAL INFORMATION 14 Electricity Materials Battery Radiator Transport ...

Page 10: ... MEANING OF ISO SYMBOLS PROHIBITION MANDATORY INFORMATION INSTRUCTIONS 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 ...

Page 11: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 11 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz Warning Hot Liquid Coolant Drain Engine Oil Drain Flammable Liquid ...

Page 12: ...e to start at any time Follow all safety 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...

Page 13: ... solid earth and is the responsibility 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 ex...

Page 14: ...ll local regulations codes of practice 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 pa...

Page 15: ...el are ingested Consult a doctor if engine 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 ...

Page 16: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 16 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 17: ...ONS 18 COMMISSIONING 18 CONNECTING THE LOAD 18 PRIOR TO STARTING 18 STARTING 19 STOPPING 19 CONTROLLER 20 DESCRIPTION OF CONTROLS 20 CONTROL PUSH BUTTONS 21 MODULE DISPLAY 22 VIEWING THE INSTRUMENT PAGES 30 OPERATION 34 STOP RESET MODE 34 MANUAL MODE 35 AUTOMATIC MODE 36 MAINTENANCE ALARM 37 FAULT FINDING 39 STARTING 39 LOADING 40 ALARMS 40 INSTRUMENTS 41 MISCELLANEOUS 41 ...

Page 18: ...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 bar L1 L2 L3 Mixing phases connections ...

Page 19: ... the engine CAUTION Allow starter to cool for one minute between start attempts If engine shuts down diagnostic lamps will indicate the problem Correct the problem before continuing 6 Allow the engine to warm up for 3 to 5 minutes 7 Check the CONTROL Panel for proper voltages No RED diagnostic lamps should be glowing 8 With main breaker ON power is present and available for use 9 Close side doors ...

Page 20: ... the sequences followed by a module containing the standard factory configuration Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field Control of the module is via push buttons mounted on the front of the module with Stop Reset Mode Manual Mode Test Mode Auto Mode and Start functions For normal operation these are the only cont...

Page 21: ...s the changeover device to place the generator on load Close Generator and Delayed Load Output 1 2 3 4 becomes active if used Upon removal of the Remote Start Signal the generator remains on load until either selection of the Stop Reset Mode or Auto Mode AUTO MODE This button places the module into its Auto Mode This mode allows the module to control the function of the generator automatically The...

Page 22: ...hich the backlight is turned off Active Configuration An icon is displayed in the Active Config section to indicate the active configuration within the currently selected within the controller TRANSFER TO GENERATOR This button is only active in the Manual Mode and allows the operator to transfer the load to the generator OPEN GENERATOR This button is only active in the Manual Mode and allows the o...

Page 23: ...een Mains current instrumentation screen 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 sensor instrumentation screen Appears when the event log is being displayed Current time held in the unit The current value of th...

Page 24: ... to show this ICON DETAILS Appears when the engine is at rest and the unit is in Stop Reset Mode Appears when the engine is at rest and the unit in Manual Mode Appears when the engine is at rest and the unit is Test Mode Appears when the engine is at rest and the unit is in Auto Mode Appears when a timer is active for example cranking time crank rest etc Appears when the engine is running and all ...

Page 25: ... 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 and configuration Charge Failure The auxiliary charge alternator voltage is low as measured from the W L terminal Low Fuel Level The level detected by the fuel level sensor is below the low fuel level pre set pre alarm ...

Page 26: ... 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 measured current has risen above the configured trip level for a configured duration Oil Filter Maintenance Alarm Maintenance due for oil filter Air Filter Maintenance Alarm Maintenance due for ai...

Page 27: ...unit The exception to this is the Low Oil Pressure alarm and similar active 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 h...

Page 28: ...IPTION Auxiliary Inputs The module detects that an auxiliary input which has been user configured to create a fault condition has become active Analogue Input The module detects that an input configured to create a fault condition has become active Fail To Start The engine has failed to start after the configured number of start attempts Low Oil Pressure The module detects that the engine oil pres...

Page 29: ...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 30: ...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 ICON DESCRIPTION Generator and mains voltage instrumentation Generator instrumentation Mains instr...

Page 31: ...ph N ph ph Mains Voltage ph N ph ph Generator These pages contain electrical values of the generator measured or derived from the module s voltage inputs Generator Voltage ph N Generator Voltage ph ph Generator Frequency Mains These pages contain electrical values of the mains measured or derived from the module s voltage inputs Mains Voltage ph N Mains Voltage ph ph Mains Frequency It is possible...

Page 32: ...ine Fuel Level Flexible Sensor Engine Maintenance Due Oil Engine Maintenance Due Air Engine Maintenance Due Fuel Info These pages contain information about the controller Module s date and time Scheduler settings Product description and USB identification number Application and Engine Version Event Log This module s event log contains a list of the last 50 recorded events and the engine hours at w...

Page 33: ...isplays the desired event Continuing to press down the up or down buttons cycles through the past alarms after which the display shows the most recent alarm and the cycle begins again To exit the event log press the up and down buttons simultaneously to enter the navigation menu Once entered cycle to the desired instrumentation section Icon to indicate the event log is currently displayed Current ...

Page 34: ...and Frequency must be zero Engine Charge Alternator Voltage must be zero Oil pressure sensor must indicate low oil pressure When the engine has stopped it is possible to send configuration files to the module from DSE Configuration Suite PC software and to enter the Front Panel Editor to change parameters Power Save Mode in the DSE Configuration Suite Software Press the Manual Mode button followed...

Page 35: ...ng sequence press the Start button The fuel relay is energised and the engine is cranked If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the Crank Rest Timer 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 Once th...

Page 36: ...will begin Stopping Sequence The Return Delay timer operates to ensure that the starting request has been permanently removed and isn t just a short term removal Should another start request be made during the cooling down period the set returns on load If there are no starting requests at the end of the Return Delay timer the load is removed from the generator to the mains supply and the cooling ...

Page 37: ...ture from DSE Configuration Suite Software showing the Maintenance Alarm Reset button in the DSE Configuration Suite SCADA I MAINTENANCE 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 l...

Page 38: ...uns do not occur when the module is in Test Mode waiting for a start request Scheduled 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 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 Depend...

Page 39: ...Auto Mode Check that there is no signal 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 tha...

Page 40: ...ine temperature fault operates after 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 ...

Page 41: ...e 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 Generator voltage full scale is 415V ph N accuracy...

Page 42: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 42 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 43: ...TION 44 DANGER WARNING CAUTION AND NOTE 45 GENERAL INFORMATION 45 GENERAL INSTRUCTIONS 45 PRECAUTIONS IN STARTING THE ENGINE 46 CAUTIONS FOR INSPECTION AND REPAIR 46 GENERAL REPAIR 47 OTHER SAFETY INSTRUCTIONS AND ENVIRONMENTAL POLLUTION 47 USE OF GENUINE PARTS 48 ENGINE MAINTENANCE 48 PREVENTION OF DAMAGE AND ABRASION 48 PREVENTION OF POLLUTION 49 HANDLING OF ENGINE OIL 49 ...

Page 44: ...t be replaced only genuine parts as defined by the parts list PARTS BOOK should be used Doosan shall not be held liable for any critical damage or faults which may be caused by the use of unauthorized or remanufactured parts The maintenance methods stated in this Operation and Maintenance Manual are the most efficient and safest work procedures Some work procedures require special tools For questi...

Page 45: ...rences for operators easy understanding GENERAL INSTRUCTIONS 1 In order to maintain the best long term performance and safety please read and understand this manual and execute routine inspections and regular inspections 2 We have divided the content of this manual into causes of bodily injury and damage to assets and causes of pollution WARNING If skin contact with corrosive acids fuel or hot oil...

Page 46: ...e allowed to handle engines 4 Do not get close to moving or rotating parts while the engine is in operation 5 Do not touch the hot engine during operation 6 Exhaust gas is poisonous Fully ventilate before starting engine If the space is enclosed ensure that it is well ventilated 7 Keep vicinity of engine ladders and stairways free of oil and grease Accidents caused by slipping can have serious con...

Page 47: ...unauthorized or remanufactured parts may cause critical damage and faults in engine performance 7 Replace parts such as cotter pins gaskets O rings seal rings oil seals and washers with new ones during repairs Reuse of parts may be the cause of engine faults and engine may not operate properly 8 Group and store disassembled parts in disassembling order As bolts and nuts vary in strength shape and ...

Page 48: ... solve the cause to prevent the critical faults in advance Use of genuine parts is recommended Using unauthorized or remanufactured parts may cause critical damage and faults to engine for which Doosan shall not be held liable Consider the following while managing engines 1 Use clean specified and qualified fuel only Use fuel recommended in this Operation and Maintenance Manual CAUTION Using inapp...

Page 49: ...erving the regulations HANDLING OF ENGINE OIL Prolonged and repeated contact of skin with engine oil may cause skin to dry out and contract causing dermatitis Engine oil includes substances toxic to the human body Handle engine oil by observing the following safety rules 1 Do not expose skin to used engine oil for a long time 2 Always wear working clothes and gloves 3 If skin comes in contact with...

Page 50: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 50 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 51: ...GINE 53 BREAK IN PERIOD OF THE ENGINE 53 GENERAL INFORMATION 53 BREAK IN PERIOD OF A NEW ENGINE 53 CHECK POINTS 53 COLD START OPERATION 53 INSPECTION AFTER STARTING THE ENGINE 53 OPERATION IN WINTER 54 COLD START 54 PREVENTING COOLANT FROM FREEZING 54 PREVENTING OVERCOOLING OF THE ENGINE 54 ENGINE OIL 54 INSPECTION AND REPAIR OF THE ENGINE 54 CHECKING ENGINE PARTS AFTER PROLONGED OPERATION 54 INSP...

Page 52: ...overhauled engine or after long periods without use press shutdown lever in stop position and operate starter motor for a few seconds max 10 until oil pressure is indicated Ensure that the engine can not be started by unauthorized persons RUNNING IN It is recommended that new or overhauled engines should not be operated at a load higher than approximately 75 of the maximum load during the first fe...

Page 53: ... oil level gauge rotate the oil level gauge to 180 degrees insert in the guide tube and then withdraw to check 2 If the oil indicator lamp on the apparatus is turned on or blinks the oil pressure may be insufficient In this case check the oil level and replenish oil if required When replenishing engine oil do not exceed the maximum on the oil level gauge If the oil level is normal check other rela...

Page 54: ...f engine elements and assemblies may occur causing lowered performance of engine parts To maintain high engine performance check the engine after prolonged operation to enhance durability of the engine Unexpected faults may occur in some weak engine parts after normal operation of the engine when operation time is prolonged In this case it is difficult to maintain high engine performance by simply...

Page 55: ...D1146 PU086 59 FRONT REAR D1146 PU086 59 LEFT RIGHT D1146 PU086 59 EXTERIOR VIEW DRAWING OF THE ENGINE D1146T PU086T 60 FRONT REAR D1146T PU086T 60 LEFT RIGHT D1146T PU086T 60 EXTERIOR VIEW DRAWING OF THE ENGINE DP086TA 61 FRONT REAR DP086TA 61 LEFT RIGHT DP086TA 62 TOP DP086TA 63 EXTERIOR VIEW DRAWING OF THE ENGINE P086TI 64 FRONT REAR P086TI 64 LEFT RIGHT P086TI 65 TOP P086TI 66 ENGINE IDENTIFIC...

Page 56: ...sion ring 2 oil ring 1 No of cylinder bore x stroke mm 6 111 139 Total piston displacement cc 8 071 Compression ratio 17 6 1 16 8 1 16 7 1 Engine dimension length x width x height mm 1 224 x 830 x 974 1 224 x 830 x 1 082 1 242 x 746 x 1 113 1 242 x 1 122 x 1 113 Engine weight kg 720 780 780 780 790 Rotation Counter clockwise Viewed from flywheel Fuel injection order 1 5 3 6 2 4 Fuel injection timi...

Page 57: ...ull forced pressure feed type Oil pump type Gear type driven by camshaft Oil filter type Full flow cartridge type Lubricating oil capacity litres Max 15 5 Min 12 Oil specification Oil class API Above API CD or CE SAE 15W40 Oil cooler type Water cooled Water pump Centrifugal type driven by belt Cooling Method Fresh water forced circulation Cooling water capacity litres 14 11 engine only Thermostat ...

Page 58: ...05PS 77kW 116PS 85kW 60Hz 1 800 rpm 130PS 96kW 143PS 105kW D1146T Standard 50Hz 1 500 rpm 145PS 107kW 160PS 118kW 60Hz 1 800 rpm 170PS 125kW 187PS 138kW P086T P086T Power Up 50Hz 1 500 rpm 186PS 137kW 207PS 152kW 60Hz 1 800 rpm 228PS 168kW 254PS 187kW P086TI Standard 50Hz 1 500 rpm 205PS 151kW 240PS 177kW 270PS 199kW 60Hz 1 800 rpm 253PS 186kW 279PS 205kW 303PS 223kW P086TI 1 50Hz 1 500 rpm 203PS ...

Page 59: ...uel injection pipe 4 Water pump 5 Mounting bracket 6 Oil level gauge 7 Flywheel 8 Flywheel housing LEFT RIGHT D1146 1 Cooling fan 2 Alternator 3 Thermostat 4 Oil filter 5 Oil filler cap 6 Exhaust manifold 7 Vibration damper 8 Oil cooler 9 Cooling water pipe 10 Oil pan 11 Oil drain valve 12 Starter 13 Intake stake 14 Intake manifold 15 Fuel filter 16 Fuel injection pump 1 2 3 4 5 5 6 7 8 1 7 8 9 10...

Page 60: ...r head cover 4 Air pipe 5 Water pump 6 Mounting bracket 7 Flywheel 8 Flywheel housing LEFT RIGHT D1146T 1 Cooling fan 2 Alternator 3 Thermostat 4 Oil filler cap 5 Cylinder head cover 6 Exhaust manifold 7 Breather 8 Vibration damper 9 Oil filter 10 Cooling water pipe 11 Oil cooler 12 Oil drain valve 13 Intake manifold 14 Fuel filter 15 Starter 16 Fuel injection pump 6 6 5 1 2 3 4 7 8 12 11 10 8 9 1...

Page 61: ...TENANCE MANUAL 61 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz EXTERIOR VIEW DRAWING OF THE ENGINE DP086TA FRONT REAR DP086TA 1 Fuel filter 2 Oil filter 3 Cooling fan pulley 4 Crankshaft pulley 5 Oil drain plug 6 Oil pan 7 Flywheel housing 8 Flywheel EK00345A ...

Page 62: ...W XF G225XW XF 60Hz LEFT RIGHT DP086TA 1 Cooling pan 2 Alternator 3 Thermostat 4 Turbocharger 5 Exhaust manifold 6 Starter 7 Vibration damper 8 Cooling water pipe 9 Oil cooler 10 Oil pan 11 Oil drain valve 12 Intake manifold 13 Fuel filter 14 Fuel injection pump 15 Oil level gauge 16 Oil filter EK00346A ...

Page 63: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 63 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz TOP DP086TA 1 Oil cap 2 Breather EK00347A ...

Page 64: ...NANCE MANUAL 64 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz EXTERIOR VIEW DRAWING OF THE ENGINE P086TI POWER UP FRONT REAR P086TI 1 Fuel filter 2 Oil filter 3 Oil pan pulley 4 Crankshaft pulley 5 Oil drain plug 6 Oil pan 7 Flywheel housing 8 Flywheel EK00348A ...

Page 65: ...W XF G225XW XF 60Hz LEFT RIGHT P086TI 1 Cooling pan 2 Alternator 3 Thermostat 4 Turbocharger 5 Exhaust manifold 6 Starter 7 Vibration damper 8 Cooling water pipe 9 Oil cooler 10 Oil pan 11 Oil drain valve 12 Intake manifold 13 Fuel filter 14 Fuel injection pump 15 Oil level gauge 16 Oil filter EK00349A ...

Page 66: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 66 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz TOP P086TI 1 Oil cap 2 Breather EK00350A ...

Page 67: ...odel name 4 7 digits B Production Year 1 digit C Serial Number 5 digits D After engine model SUFFIX 2 digits Type 3 A Sales Model name 5 digits B Engine output 3 digits C Production Year 1 digit D Serial Number 5 digits E After engine model SUFFIX 2 digits Type 4 A New representative specification 9 digits B Production Year 1 digit D Serial Number 5 digits Type 5 A Sales Model name 4 7 digits B Pr...

Page 68: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 68 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 69: ...NG THE COOLANT 75 CLEANING THE COOLING CIRCUIT 76 INTER COOLER 77 LUBRICATION SYSTEM 78 GENERAL INFORMATION 78 ENGINE OIL STANDARDS 78 ENGINE OIL CAPACITY 79 CHECKING THE ENGINE OIL 79 REPLACEMENT OF ENGINE OIL 80 REPLACEMENT OF ENGINE FILTER 80 FUEL SYSTEM 80 GENERAL INFORMATION 80 FUEL STANDARDS 81 WATER DRAINING FROM FUEL FILTER 82 REPLACING FUEL FILTER 82 PREVENTING FUEL CONTAMINATION 83 FUEL ...

Page 70: ...BOCHARGER 89 ROUTINE CHECK AND SERVING THE TURBOCHARGER 89 DISASSEMBLY AND CLEANING A TURBOCHARGER 89 CYLINDER BLOCK HEAD 90 VALVE CLEARANCE 90 HOW TO ADJUST THE VALVE CLEARANCE 90 ADJUSTING THE VALVE CLEARANCE 91 CYLINDER COMPRESSION PRESSURE 92 ELECTRICAL SYSTEM 92 BATTERY 92 STARTER 92 OTHERS DRIVING SYSTEM 93 V BELT 93 DIGITAL SPEED CONTROLLER DSC 1000 95 PRODUCT OVERVIEW AND GENERAL SPECIFICA...

Page 71: ...tion in a well ventilate space unless it is absolutely necessary do not perform inspection under an engine When carrying out engine inspection or maintenance ensure there are no naked flames within the vicinity of the machine Fuel oil or batteries may generate gas causing fire If inspecting the engine while it is running do not wear accessories such as necklaces rings watches or gloves Such access...

Page 72: ...ter Adjust the V belt tension o Every 2 000hrs Clean the radiator o Lubrication system Check for leakage o Check the oil level gauge o Change the lubricating oil a Replace the oil filter cartridge a Fuel system Check the fuel line for leakage o Clean the fuel strainer of fuel feed pump o Remove sediment from fuel tank o Drain the water in separator o Replace the fuel filter element Check fuel Inje...

Page 73: ...eration the antifreeze portion is decreased Therefore the antifreeze level must be increased to the proper level after replenishing the coolant concentration of antifreeze during winter CAPACITY OF COOLANT CHECKING THE COOLANT DANGER If the radiator cap is opened to exchange or replenish coolant while the engine is overheated hot water will spurt out and may cause serious burns If it is absolutely...

Page 74: ...are and confirm the parts with identical colors on the test sheet and the standard color table 1 Compare the changed pink color part A of the test sheet with the GLYOOL FREEZEPOINT End pad of the standard color table on top of the container and confirm the concentration The concentration indication has to be within the color scope of 33 50 2 It should be maintained at the optimum range in the gree...

Page 75: ...ed If the radiator cap is opened while the engine is overheated hot water will spurt out and may cause serious burns Open the radiator cap after ensuring that the engine has been cooled sufficiently Mark and separately manage the containers for storing coolant from beverage containers to avoid confusion If coolant is ingested see a doctor immediately 3 Pour in the coolant in slowly CAUTION Be care...

Page 76: ...uantity of antifreeze or corrosion inhibitor or by use of coolant without such ingredients If the coolant pump leaks or the coolant is severely contaminated within the first 6 months of operation e g the coolant color becomes discolored brown grey or black depending on the degree of contamination clean the cooling system in the following way before removing the cooling pump 1 Drain the coolant 2 T...

Page 77: ...tly depends on the intake air conditions Dirty air may contaminate and clog the cooling pins This results in reduced engine power or engine failure Always check the intake system for air leaks damage or contamination of the air filter CAUTION To keep the optimum performance of the air cooler clean it regularly Air air intercooler with downstream radiator Combined radiator Cooling air Hot charge ai...

Page 78: ...low the engine oil to flow back into the oil pan The engine oil level should indicate between the upper limit and the lower limit of the oil level gauge Engine oil should be periodically replaced based on the regular inspection table The oil filter and the cartridge should be replaced as the engine oil is replaced ENGINE OIL STANDARDS Use the specified engine oil suitable for the environment and c...

Page 79: ...substances to get into the engine causing damage to the engine 3 Insert the oil level gauge and then remove it to check the engine oil level viscosity and contamination Replenish or replace the engine oil if required 1 Check the oil level everyday using the oil level gauge 2 Check if the oil level is between the upper limit A and the lower limit B of the oil level gauge 3 If engine oil level is be...

Page 80: ...ts WARNING Discard exchanged oil according to the regulations set forth by the relevant authorities Disposing of discharged oil into the ground sewers drains rivers or the sea will cause serious environmental pollution Violation of regulations regarding discard of engine oil without observing the handling regulations will be punished REPLACEMENT OF ENGINE FILTER Check the oil pressure and leakage ...

Page 81: ...ntent is max 0 05wt Fuels with a sulphur content of 0 05wt are not permitted as they result in increased corrosion and greatly reduce the service life of engines The oil change intervals must be halved if the sulphur content is 0 02wt Fuel Ingredients Unit Standard Product Specific Gravity kg litres 0 83 Flash Point C 40 47 8 Viscosity 40 C cSt 1 955 2 459 Sulfur content wt 0 05 0 038 Cloud point ...

Page 82: ...vely because it may damage the screw Check the fuel filter regularly and drain the water in the fuel filter If water enters the fuel system it will cause serious failure and may damage the fuel filter or reduce performance Water in the fuel system may stop the engine Use approved fuel only Use of non approved fuel may result in increased water in the fuel filter REPLACING FUEL FILTER 1 Clean the a...

Page 83: ...t should only be repaired by authorised personnel The adjustment and test of the fuel injection pump must be conducted using an appropriate tester CAUTION If any parts that contain a seal ring copper seal ring rubber coating seal ring etc are disassembled then replace the seal ring with a new one Failure to do so may cause leakage in the fuel filter connections preventing normal functioning AIR BL...

Page 84: ...on chamber in the piston crown The injector consists of the nozzle and the nozzle holder 1 Nozzle holder 2 Union nut 3 Shim 4 Coil spring 5 Guide bush 6 Washer 7 Cap nut 8 Nozzle CHECK FUEL INJECTION NOZZLE PRESSURE 1 Install a nozzle to the nozzle tester 2 Check injection pressure by cranking to meet the correct pressure 3 Check the nozzle spray status If it is defective replace the nozzle CAUTIO...

Page 85: ... before use The cutter can also be clamped in a lathe Polish needle seat with wooden cleaning tool by chucking the needle in a lathe at the pintle end Clean the spray holes of nozzles by chucking a cleaning needle of suitable diameter in the collet If the carbon deposits in the spray holes cannot be removed by rotating and pressing have the needle project only slightly from the collet and drive ou...

Page 86: ...on pump until the fuel drops from 1 plunger at the rate of one drop every 6 8 sec Tighten the driving gear fixing bolt of the fuel pump 6 After adjusting the injection timing disassemble the U shape pipe and readjust the delivery valve and the valve spring 7 Turn the coupling until the notch mark of the indicator plate attached to the fuel injection pump is aligned with the notch mark of the coupl...

Page 87: ...cing an air filter Be careful not to let dust inside when assembling the air filter AIR FILTER Air cleaner is mounted on the engine to purify the air for combustion The intervals at which the air cleaner requires servicing depend on the specific operating conditions encountered Clogged air filters may cause black smoke and reduce power A check should be made from time to time to see that the faste...

Page 88: ... the element in the warm cleaning solvent for 10 minutes and then shake it back and forth for approximately 5 minutes c Rinse the element with clean water drain the water and then dry it at room temperature Fully dry the element before reassembling CAUTION Never use steam spray gasoline alkali or hot cleansing solution to clean the element 3 In an emergency temporarily clean the element by using t...

Page 89: ...intenance state of the engine Regularly perform inspection and maintenance as specified in order to maintain turbocharger performance 1 Intake system The air filter should be carefully managed For a wet type air filter the intake resistance should be as small as possible 2 Exhaust system When exhaust gas leaks from the exhaust pipe or turbocharger joint supercharging efficiency is lowered Ensure t...

Page 90: ...even if the fuel injection system is normal HOW TO ADJUST THE VALVE CLEARANCE 1 Loosen the lock nuts of rocker arm adjusting screws 2 Push the feeler gauge of specified value between a rocker arm and a valve stem to measure the clearance of the valve and rocker arm contacting part 3 Adjust the clearance with adjusting screw respectively and then tighten with the lock nut 4 Adjust valve clearance w...

Page 91: ...Center Then adjust the valves corresponding to mark o in the below table NOTE 6 cylinder is located at the side near the cooling fan NOTE 1 cylinder is positioned at the valve overlap when 6 cylinder is positioned at the compression TDC Top Dead Center I Intake E Exhaust 3 Only adjust the valve clearance when the engine is cold CAUTION Crankshaft revolution is done by hand without using a starting...

Page 92: ...d water if insufficient Check the specific gravity of electrolyte If it is below the specified value 1 12 1 28 replenish it STARTER When servicing the engine immerse the starter motor s pinion gear and ring gear in the fuel wash them completely and apply grease again When cleaning the surrounding of engine ensure that no water enters the starter CAUTION Starter should be protected from humidity at...

Page 93: ...dge of contact surface 2 is flush with the V belt c Slowly depress pad 3 until the spring can be heard to disengage This will cause the indicator 1 to move upwards NOTE If pressure is maintained after the spring has disengaged a false reading will be obtained d Read the tension value at the point that the top surface of indicator arm 1 intersects with the scale e Before taking readings ensure that...

Page 94: ... XF G225XW XF 60Hz 5 Tension adjustment and V belt replacement a Loosen fixing bolts and nuts b Adjust the alternator until V belts have correct tensions c Tighten fixing bolts and nuts d To change the V belts loosen fixing bolts and nuts Then push the alternator toward water pump pulley by hand EA9O2007 ...

Page 95: ...nd actuator condition checking It also has a black box function that manages engine operation records when faults are detected for users to have more convenience in operating this precise digital speed controller Product Features Rigid and stable case structure and easily recognizable front design Readily understandable GUI graphic user interface with graphic LCD displays Easy and simple setup wit...

Page 96: ... MCU 16 bit DSC dsPIC33FJ256 2 Display Graphic LCD 128 64 LED 6 EA 3 Keypad 8 Button Keys 4 Output 3 Contact Points a and b 5 Input RMS 3V Min 6 Memory 128Mb 7 Communication RS232 57600bps CAN J1939 250kbps 8 Rated Power DC 24V 12V to 30V 9 Current Consumption 120mA 10 Operating Temperature 20 to 70 C 11 Storing Temperature 30 to 80 C 12 Operating Humidity 0 to 95 ...

Page 97: ... devices Connecting to Actuators The actuator is also called governor and controls the amount of the fuel spray to the engine cylinder The controller is connected to the actuator attached on the engine by connecting two wires of the controller terminal to A and B of the actuator regardless of their polarities Wiring should be 18AWG 105 or better and the outside should be wrapped by plastic tubes f...

Page 98: ...ng to the PID control values Step 5 The controller checks the operation condition and displays LED outputs and fault messages according to the detected information Configuration and Operation The controller can be configured and operated by input keys according to the menus on the LCD display by selecting proper ones and assigning values in the selected menu to input control information to the sys...

Page 99: ...e controller will start control based on information from pick up sensor and other input devices and designated parameter values At this moment where breakdowns of the surrounding devices or system errors occur the LCD display will show such errors and processing messages Step 1 DC 24V power supply to the terminals E and F When DC 24V power is supplied to the terminals E and F the controller will ...

Page 100: ...ontrol 5 Date Time setup It offers function for users to move to the screen for designating year month day and hour 6 Alarm list It offers function for users to move to the alarm display for the alarm list 7 Actuator Test It offers menu to test the impedance XL of the actuator and any problems in operating load current It displays current and voltage according to the duty values 8 Default setup It...

Page 101: ...ror messages and alarms 4 CRANKING RPM Users can designate values to activate the actuator when the engine starts to operate 5 GEAR NUMBER Users can input the number of flywheel teeth in the engine to the controller so that the controller can calculate the accurate RPM depending on the values of the pick up sensor from the engine 6 STARTING FUEL Users can designate the amount of fuels used when th...

Page 102: ...of the controller and then you can see DRIVE UNIT MENU Use direction buttons to select Alarm List menu and then press Enter button Step 2 Use Up Down Left and Right buttons in ALARM LIST menu to confirm the fault messages Default Setup Menu When you cannot identify the type of the control engine by the controller this menu offers the most common parameter setting values Step 1 Press Menu button of...

Page 103: ...hen the controller displays Low Battery Fault message you need to charge the battery or replace it with the one having normal voltage before starting the controller Step 2 Configure parameter values required for selection of the engine type and control of the engine There are3 ways to configure parameters required for the controller 1 Using default setup 2 Designating the engine type in Engine Typ...

Page 104: ...e battery line 2 Replace the battery E03 Pick up Error Problems in sensor signals when the engine starts Engine RPM lower than 600 1 Alarm message pop up on LCD 2 Error LED on 3 Actuator control signal off 1 Check the RPM sensor and connecting circuits 2 Replace the RPM sensor E04 Pick up Error Problems in sensor signals during the engine operation Engine RPM 600 or higher 1 Alarm message pop up o...

Page 105: ... our A S center for service request Step 3 Check whether the power LED turns on or not after supplying power to DC 24V input terminals E F of the battery If the LED does not turn on cut the power off and contact our A S center for service request Step 4 Check whether the power LED turns on and Doosan logo appears on the LCD display after supplying power to DC 24V input terminals E F of the battery...

Page 106: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 106 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 107: ...08 RECEIPT 109 Standards and safety measures 109 Inspection 109 Identification 109 Storage 109 Application 109 Contraindications to use 109 INSTALLATION 111 Assembly 111 Checks prior to first use 112 Terminal connection diagram TAL 44 TAL 46 113 Commissioning 114 SERVICING MAINTENANCE 115 Safety measures 115 Bearings 116 Mechanical defects 116 Electrical faults 117 Dismantling reassembly 119 Table...

Page 108: ...and and take notice of the different 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 operati...

Page 109: ... machine see drawing Make sure that the 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 112 To pr...

Page 110: ...T4 U2 T2 V1 T5 V2 red or white black or white T3 W1 T6 W2 STATOR 6 wires T1 to T6 identification yellow green blue Varistor Star connection Delta connection R2 R1 Q2 Q1 F2 F1 N W V A1 A2 2K 2 5K 1W optional ST1 ST2 R1 R2 External voltage trimmer remove ST1 OPTIONAL T1 Y 3PH T1 T2 T2 T3 T3 N R791T Black Black Black Blue Green yellow V AC S UF SL UF OE Consult R150 manual FUSE R150 ref 5384 50 60 Hz...

Page 111: ...to stand under the load CAUTION After 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 coup...

Page 112: ...mmend the use of space heaters as well 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 st...

Page 113: ...SHUNT three phase 6 wire SHUNT three phase 6 wire T1 T4 T6 T3 T5 T2 L2 V L3 W L1 U T1 T4 T6 T3 T5 T2 F Delta 3PH D Star 3PH R150 T5 T4 T6 T3 T2 T1 W 3 L3 N DE NDE V 2 L2 U 1 L1 T5 T4 T6 T3 T2 T1 W 3 L3 DE NDE V 2 L2 U 1 L1 Connection codes Factory connection Connection codes Voltage Detection Factory connection Star T1 T4 T3 T6 T5 T2 L1 U L3 W L2 V D L1 U L3 W T1 T4 T3 T6 T5 L L T2 L2 V F Delta Wi...

Page 114: ...nside the terminal box is connected 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 ma...

Page 115: ... connections in the installation Electrical 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 ...

Page 116: ...alternator housing more than 40 C above 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 an...

Page 117: ...peed do not touch the AVR voltage pot 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 h...

Page 118: ... series with a rheostat of approximately 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 in...

Page 119: ...and 125 CAUTION The screws for fixing 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 termin...

Page 120: ...lange two bearing alternator and insert a tube of the corresponding diameter on the shaft end or a 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 t...

Page 121: ...xc A 400V 50 Hz i exc excitation current of the exciter field For 60 Hz machines the i exc values are approximately 5 to 10 lower Table of weights values given for information only Type Stator L N Rotor Exciter Field Exciter Armature G80 TAL44 C 0 050 2 35 11 65 0 790 G100 G115 TAL44 E 0 034 2 89 12 94 0 920 G135 G150 TAL44 J 0 029 3 15 12 94 0 920 G170 TAL46 A 0 023 0 51 10 01 0 1001 G200 TAL46 B...

Page 122: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 122 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 123: ...F G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 123 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ALTERNATORS COMPONENTS CONTENTS TAL44 SINGLE BEARING SHUNT 124 TAL46 SINGLE BEARING SHUNT 125 ...

Page 124: ... M6 10 107 1 Diode support ring M5 6 29 1 Earth continuity bolts M6 10 124 Terminal block M6 6 30 1 Drive end DE shield 144 1 Terminal box 31 8 Fixing bolts M12 69 198 1 Voltage regulator AVR M5 3 6 32 1 S A E adaptor ring 199 1 Interference suppression module RFI kit M5 6 33 2 Protective guard M6 6 320 1 Coupling sleeve 36 1 Non drive end NDE shield 322 2 Coupling discs 37 4 Tie rod M14 90 323 8 ...

Page 125: ...1 Terminal block M12 20 30 1 Drive end DE shield 134 1 Panel fixing M6 10 31 6 Fixing bolts 198 1 Voltage regulator AVR 33 1 Protective guard M6 6 199 1 Interference suppression module RFI kit 36 1 Non drive end NDE shield M12 75 279 6 8 Connection bar 37 8 Tie rod 320 1 Coupling sleeve 41 1 Terminal box front panel M6 8 322 3 Coupling discs 47 1 NDE terminal box seal M6 8 323 6 Fixing bolts M16 1...

Page 126: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 126 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz ...

Page 127: ...XF 60Hz MAIN BREAKER OPERATION CONTENTS OPERATING INSTRUCTIONS 128 BREAKER ADJUSTING INSTRUCTIONS S150 TO S250 SERIES 129 TIME CURRENT CHARACTERISTIC CURVES S150 TO S250 SERIES 129 BREAKER ADJUSTING INSTRUCTIONS S400 AND S600 SERIES 130 TIME CURRENT CHARACTERISTIC CURVES S400 AND S600 SERIES 130 WIRING DIAGRAMS 131 ...

Page 128: ... G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 128 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz OPERATING INSTRUCTIONS Handle I ON O OFF Trip Button TRIPPED RESET Operation Operation effort S160 S250 22N 110N 28N S400 68N 115N 125N ...

Page 129: ...W XF 50HZ OPERATION MAINTENANCE MANUAL 129 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz BREAKER ADJUSTING INSTRUCTIONS ELECTRONIC TYPE S150 TO S250 SERIES TIME CURRENT CHARACTERISTIC CURVES Under bar is default setting Electronic Type ...

Page 130: ...W XF 50HZ OPERATION MAINTENANCE MANUAL 130 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz BREAKER ADJUSTING INSTRUCTIONS ELECTRONIC TYPE S400 AND S600 SERIES TIME CURRENT CHARACTERISTIC CURVES Under bar is default setting Electronic Type ...

Page 131: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 131 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz WIRING DIAGRAM MARELLI ...

Page 132: ...G80XW XF G115XW XF G150XW XF G200XW XF 50HZ OPERATION MAINTENANCE MANUAL 132 G100XW XF G135 XW XF G170XW XF G225XW XF 60Hz WIRING DIAGRAM LS TAL ...

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Page 134: ...Doosan Bobcat EMEA s r o U Kodetky 1810 263 12 Dobříš Czech Republic www doosanportablepower eu ...