Doosan G20 SIIIA Operation & Maintenance Manual
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Doosan G20 SIIIA Operation & Maintenance Manual

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G20, 30, 40 SIIIA
OPERATION & MAINTENANCE MANUAL
Original Instruction
This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46674960_en_C_02/18
G20 SIIIA
SERIAL No : G02030001 ->
G30 SIIIA
SERIAL No : G03030001 ->
G40 SIIIA
SERIAL No : G04030001 ->

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  • Page 1 This manual contains important safety information and must be made available to personnel who operate and maintain this machine. G20 SIIIA SERIAL No : G02030001 -> G30 SIIIA SERIAL No : G03030001 -> G40 SIIIA SERIAL No : G04030001 ->...

  • Page 3: Table Of Contents

    CONTENTS FOREWORD ............................5 GENERAL DATA ............................ 11 SAFETY ..............................13 OPERATING INSTRUCTIONS ......................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.
  • Page 4 G20, 30, 40 SIIIA Operation & Maintenance Manual...

  • Page 5: Foreword

    FOREWORD CONTENTS FOREWORD ............................6 DECLARATION OF CONFORMITY ......................7 G20, 30, 40 SIIIA Operation & Maintenance Manual...
  • Page 6 English or work situation that may arise. version. IF IN DOUBT CONSULT SUPERVISION. © COPYRIGHT 2018 DOOSAN COMPANY This machine has been designed and supplied for use only following specified conditions applications: •...

  • Page 7: Declaration Of Conformity

    Jan Moravec Engineering Director Issued at Dobris, Czech Republic Date The technical documentation for the machinery is available from: Doosan Bobcat EMEA s.r.o. (DBEM), U Kodetky 1810, 263 12 Dobris, Czech Republic G20, 30, 40 SIIIA Operation & Maintenance Manual...
  • Page 8 97/23/CE y, en conformidad con los términos de esta Directiva, ha sido excluido del ámbito de aplicación de ésta. 27) Gerente de ingeniería, 28) Emitido en Dobris, República Checa, 29) Fecha, 30) La documentación técnica de la máquina está disponible en: Doosan Bobcat EMEA s.r.o, U Kodetky 1810, 263 31) 2006/95/CE Directiva del equipo de baja tensión...
  • Page 9 Apparecchiature a Pressione 97/23/CE e, in conformità con le disposizioni di questa Direttiva, è stato escluso dallo scopo di questa Direttiva. altre direttive CE applicabili., 27) Responsabile Tecnico, 28) Emesso a Dobris, Repubblica Ceca, 29) Data, 30) La documentazione tecnica della macchina è disponibile presso: Doosan Bobcat EMEA s.r.o, U Kodetky 1810, 263 12...
  • Page 10 G20, 30, 40 SIIIA Operation & Maintenance Manual...

  • Page 11: General Data

    GENERAL DATA CONTENTS GENERAL DATA............................ 12 GENERAL INFO ............................ 12 ELECTRICAL DATA ..........................12 G20, 30, 40 SIIIA Operation & Maintenance Manual...

  • Page 12: General Data

    GENERAL 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...

  • Page 13: Safety

    SAFETY 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...

  • Page 14: Safety Decals

    SAFETY DECALS GRAPHIC FORM AND 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 Diesel fuel Crush Warning manual before operation or No open flame.
  • Page 15 WARNING - Flammable liquid. G20, 30, 40 SIIIA Operation & Maintenance Manual...

  • Page 16: Safety Instructions

    SAFETY INSTRUCTIONS DANGER CAUTION This machine is not designed for operating life- Exercise extreme caution when using booster sustaining equipment. It is equipped with a safety battery. To jump battery, connect ends of one booster shutdown system that will cause the machine to stop cable to the positive (+) terminal of each battery.

  • Page 17: Earthing

    WARNING WARNING Failure to properly earth the Generator Set can result Electrical Shock - in severe injury or death. Do not operate electrical equipment while standing in IF USED AS ALTERNATE POWER SUPPLY water, on wet earth or with wet hands or shoes. Connect only after the main service entrance switch Use extreme caution when working on electrical has been DISCONNECTED and LOCKED OPEN.

  • Page 18: Hazardous Substance Precaution

    HAZARDOUS SUBSTANCE PRECAUTION Make sure that all protective covers are in place and that the canopy / doors are closed during operation. The specification of this machine is such that the CAUTION machine is not suitable for use in flammable gas risk areas.

  • Page 19: Battery

    The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: • anti-freeze • engine lubricant • preservative grease • rust preventative • diesel fuel • battery electrolyte AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.
  • Page 20 G20, 30, 40 SIIIA Operation & Maintenance Manual...

  • Page 21: Operating Instructions

    Alternator Protection Date / Time 3-WAY FUEL VALVE ..........................OIL SUMP PUMP........................... SOCKET SET - CE ................................................GOVERNOR LEVER - G20 SIIIA ......... SPEED CONTROL OF ELECTRONICALLY CONTROLLED ENGINES - G30, G40SIIIA DECOMMISSIONING ......................... LONG TERM STORAGE RECOMMENDATIONS (6 months or more) ........................70 SHORT TERM STORAGE ......................

  • Page 22: Operating Instructions

    OPERATING INSTRUCTIONS Never operate unit without first observing all safety Always use the 5 connections, 3 phases, neutral and warnings and carefully reading the operation & earth. maintenance manual shipped from the factory with this Make sure your installation is in compliance with local machine.

  • Page 23: Starting

    WARNING DANGER Do not remove the cap from a HOT engine radiator. POWER is present upon cranking the engine. The sudden release of pressure from a heated cooling system can cause severe injury or death. CAUTION CAUTION Allow starter to cool for one minute between start attempts.

  • Page 24: Dse 4510 Mkii Controller

    DSE 4510 MKII CONTROLLER DESCRIPTION OF CONTROLS Note: The following descriptions detail 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, Auto Mode, and Manual/Start Mode functions.
  • Page 25 CONTROL PUSH-BUTTONS ICON DESCRIPTION STOP / RESET MODE This button places the module into its Stop/Reset Mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and the module is put into Stop mode, the module will automatically instruct the generator to unload ('Close Generator' and 'Delayed Load Output 1, 2, 3 &...
  • Page 26 MODULE DISPLAY 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 G20, 30, 40 SIIIA Operation &...
  • Page 27 INSTRUMENTATION ICONS When viewing instrumentation pages, an icon is displayed in the lnst. Icon section to indicate what section is currently being displayed. ICON DETAILS Generator voltage and frequency instrumentation screen Generator current instrumentation screen Load power instrumentation screen Engine speed instrumentation screen Hours run instrumentation screen Battery voltage instrumentation screen Oil pressure instrumentation screen...
  • Page 28 ACTIVE CONFIGURATION An icon is displayed in the Active Config section to indicate the active configuration within the currently selected within the controller. ICON DETAILS Appears when the main configuration is selected Appears when the alternative configuration is selected FRONT PANEL EDITOR (FPE) / AUTO RUN ICON 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.
  • Page 29 MODE ICON An icon is displayed in the Mode Icon section to indicate the mode the controller is currently in. ICON DETAILS Appears when the engine is at rest and the unit is in stop mode Appears when the engine is at rest and the unit is 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.
  • Page 30 ALARM ICONS (PROTECTIONS) An icon is displayed in the Alarm Icon section to indicate the alarm that is current active on the controller. 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 module displays the Alarm Icon and the Stop/Reset Mode button LED begins to flash.
  • Page 31 WARNING ALARM ICONS Warnings are non-critical alarm conditions and do not affect the operation of the generator system. They serve to draw the operator's attention to an undesirable condition. By default, warning alarms are self-resetting when the fault condition is removed. However, enabling 'all warnings are latched' will cause warning alarms to latch until reset manually.
  • Page 32 WARNING ALARM ICONS (CONT’D) ICON FAULT DESCRIPTION The generator output voltage has fallen below the pre-set Generator Under Voltage pre-alarm setting after the Safety On timer has expired. The generator output voltage has risen above the pre-set Generator Over Voltage pre-alarm setting.
  • Page 33 ELECTRICAL TRIP ALARM ICONS Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module de-energises all the 'Delayed Load Output' and the 'Close Gen Output' outputs to remove the load from the generator.
  • Page 34 SHUTDOWN ALARM ICONS Shutdown alarms are latching and immediately stop the Generator. On initiation of the shutdown condition the module de-energises all the 'Delayed Load Output' and the 'Close Gen Output' outputs to remove the load from the generator. Once this has occurred, the module shuts the generator set down immediately to prevent further damage. The alarm must be accepted and cleared, and the fault removed to reset the module.
  • Page 35 SHUTDOWN ALARM ICONS (CONT’D) ICON FAULT DESCRIPTION The generator output voltage has fallen below the pre-set Generator Under Voltage alarm setting after the Safety On timer has expired. The generator output voltage has risen above the pre-set Generator Over Voltage alarm setting.
  • Page 36 VIEWING THE INSTRUMENT PAGES NAVIGATION MENU To enter the navigation menu, press both the Up and Down buttons simultaneously. Figure 5 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.
  • Page 37 NAVIGATION MENU ICONS ICON DESCRIPTION Generator instrumentation. Current and load instrumentation. Engine instrumentation Module information Engine DTCs (Diagnostic Trouble Codes) if active Event log G20, 30, 40 SIIIA Operation & Maintenance Manual...
  • Page 38 GENERAL NAVIGATION It is possible to scroll through the display to view different pages of information by repeatedly operating the Up or Down navigation buttons. Figure 7 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 reverts back to the Home Page.
  • Page 39 HOME This is the page that is displayed when no other page has been selected and is automatically displayed after a period of inactivity (Page Delay Timer) of the module fascia buttons. It also contains the voltage reading of the generator and mains that is measured from the module's voltage inputs.
  • Page 40 ENGINE These pages contain instrumentation gathered about the engine 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 •...
  • Page 41 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 G20, 30, 40 SIIIA Operation & Maintenance Manual...
  • Page 42 ENGINE OTC (ECU ALARMS) If the DSE module is connected to an ECU: This page contains active Diagnostic Trouble Codes (DTC) only if the engine ECU generating a fault code. These alarm conditions are detected by the engine ECU and displayed by the DSE controller.
  • Page 43 ICON FAULT DTC DESCRIPTION The engine ECU has detected a fault not recognised by the Check Engine Fault DSE module, contact engine manufacturer for support. The engine ECU has detected that the engine oil pressure Low Oil Pressure has fallen below its configured low oil pressure alarm level. The engine ECU has detected that the engine speed has Under Speed fallen below its configured under speed alarm level.
  • Page 44 OPERATION Note: The following descriptions detail 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. QUICKSTART GUIDE This section provides a quick start guide to the module's operation. STARTING THE ENGINE Figure 14 Press the Manual /...
  • Page 45 STOP/RESET MODE Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock. Stop/Reset Mode is activated by pressing the Stop/Reset Mode button. The Stop/Reset icon is displayed to indicate Stop/Reset Mode operations.
  • Page 46 AUTOMATIC MODE Note: If a digital input configured to external panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Auto Mode is activated by pressing the Auto Mode button. The Auto Mode icon is displayed to indicate Auto Mode operations if no alarms are present.
  • Page 47 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 timer is initiated.
  • Page 48 ENGINE RUNNING Once the engine is running and all starting timers have expired. the animated Engine Running icon is displayed. In manual mode, the load is not transferred to the generator unless a 'loading request' is made. • Activation of an auxiliary input that has been configured to Remote Start On Load or Auxiliary Mains Fail. •...
  • Page 49 MAINTENANCE ALARM Depending upon module configuration one or more levels of engine maintenance alarm may occur based upon a configured schedule. Example 1 Figure 18 Screen capture from DSE Configuration Suite Software showing the configuration of the Maintenance Alarm for Oil, Air and Fuel.
  • Page 50 Example 2 Figure 19 Screen capture from DSE Configuration Suite Software showing the configuration of a digital input for Maintenance Reset Alarm Air. Example 3 Figure 20 Screen capture from DSE Configuration Suite Software showing the Maintenance Alarm Reset 'button' in the DSE Configuration Suite SCADA I MAINTENANCE section.
  • Page 51 STOP MODE • Scheduled runs do not occur when the module is in Stop/Reset Mode. MANUAL/START MODE • Scheduled runs do not occur when the module is in Manual/Start Mode waiting for a manual start. • Activation of a Scheduled Run 'On load' when the module is operating OFF LOAD in Manual/ Start Mode will force the set to run ON LOAD.
  • Page 52 FRONT PANEL CONFIGURATION This configuration mode allows the operator to fully configure 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)
  • Page 53 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR • Press the 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. •...
  • Page 54 FAULT FINDING STARTING SYMPTOM POSSIBLE REMEDY Check the battery and wiring to the unit. Unit is inoperative Check the DC supply. Read/Write configuration does not operate Check the DC fuse. Check DC supply voltage is not above 35 Volts or below 9 Volts. Unit shuts down Check the operating temperature is not above 70°C.
  • Page 55 LOADING SYMPTOM POSSIBLE REMEDY Engine runs but generator will Check Warm up timer has timed out. not take load Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device. Note that the set will not take load in manual mode unless there is an active load signal.
  • Page 56 COMMUNICATIONS SYMPTOM POSSIBLE REMEDY CAN DATA FAIL Indicates failure of the CAN data link to the engine ECU. Check all wiring and termination resistors (If required). INSTRUMENTS SYMPTOM POSSIBLE REMEDY Inaccurate generator Check that the CT primary, CT secondary and VT ratio settings are correct for measurements on controller the application.
  • Page 57 DIAGNOSTICS / AUTO SHUTDOWN (ANALOG CONTROLLER) Figure 23 The operating controls and instruments are arranged on 10. Engine Communication - Indicates the controller the control panel as shown. A description of each panel has communication with the engine ECU. device is as follows: 11.
  • Page 58 GENERATOR CONTROL PANEL (ANALOG CONTROLLER) Figure 24 Meters Protection / Regulation 1. AC VOLTS - Indicates the generator output voltage. 10. 3 Phase Direct Hookup Connections - L1, L2, L3, N (neutral), PE (Protective Earth). (Not shown.) 2. AC AMPERES - Indicates the generator load in amperes corresponding to AMPERAGE OUTPUT 11.

  • Page 59: Options

    BASIC DIGITAL CONTROLS OPERATION Overview Doosan's Digital Controller is a comprehensive generator set controller that is used as the primary interface between the operator and the generator set. It provides a high degree of engine and generator protection. Multiple real-time parameters can also be viewed.

  • Page 60: Viewing Real-Time Data - Accessing The Screens

    OPTIONS [CONT’D] Display Buttons Figure 26 OFF AUT MAN Use this button to scroll the display between measurement screen, adjustment screen and the default Ready screen. Use it also to back out of the screens. 1800 Timer Use this button to select an adjustment parameter confirm proper...
  • Page 61 OPTIONS [CONT’D] Figure 29 This screen is ONLY shown on Engines utilising J1939 engine communications. Indication of faults / shutdowns from the engine control unit is shown here. The ECU I000000 Yellow Lamp indicates an engine warning and the ECU Red Lamp indicates an engine shutdown.

  • Page 62: Checking Software Version / Lamp Test

    OPTIONS [CONT’D] This screen displays the load parameters of the Figure 36 generator set in terms of active power, power factor, reactive power, and apparent power. These values are Alarm List indicated in total and per phase. Not in Auto Figure 34 Wrn Coolant Level Run Hours...

  • Page 63: Setpoints Descriptions

    OPTIONS [CONT’D] Press “ENTER” to select the desired parameter menu. Mode [OFF, MAN, AUT] This is the equivalent of controller "Mode" buttons. Use the “INCREASE” and / or “DECREASE” buttons to scroll to the parameter to be adjusted. Fault Reset Go to Manual Press “ENTER”...
  • Page 64 OPTIONS [CONT’D] PreHeat Time Cooling Time Runtime of the unloaded generator set to cool the engine The time delay for preheating after the unit gets the start before stop. command. The unit begins to start after preheating. Select No Preheat with a setting = O. Factory default setting = 10 After Cool Time seconds.

  • Page 65: Engine Protection

    OPTIONS [CONT’D] ENGINE PROTECTION Batt Undervolt Warning threshold for low battery voltage. Eng prot del [s] Battvolt del During the start of the generator set, some engine protections have to be blocked (e.g. Oil Pressure). The Delay for low battery voltage alarm. protections are unblocked after the protection del time.
  • Page 66 OPTIONS [CONT’D] Volt unbal del Delay for generator voltage unbalance alarm. Gen >f SD Shutdown level for generator over frequency. Gen>f Wrn Warning level for generator over frequency. Gen <f Wrn Warning level for generator under frequency. Gen <f SD Shutdown level for generator under frequency.

  • Page 67: 3-Way Fuel Valve

    OPTIONS [CONT’D] 3-WAY FUEL VALVE Figure 40: Valve lever position This machine may be equipped with a 3-way fuel valve. Description The 3-way fuel valve combined with an external fuel connection module will provide maximum autonomy. Installation and usage Connecting directly to 3-way fuel valve block. Stop the engine.

  • Page 68: Oil Sump Pump

    OPTIONS [CONT’D] Figure 42: Oil pan drain Figure 44: Hand pump Hand pump Oil pan drain valve Recycle or dispose of used oil in an environmentally safe manner. OIL SUMP PUMP Close the engine oil pan drain valve. This machine may be equipped with an oil sump pump Description WARNING The oil sump pump allows for easier removing of engine...

  • Page 69: Socket Set - Ce

    SOCKET SET - CE GOVERNOR LEVER - G20SIIIA 4TNV-BGGE Figure 45: Socket Set CE - G20/G30 SIIIA Sockets Figure 47: Sockets 1P 16A Socket 3P 32A Socket 3P 64A Figure 46: Socket Set CE - G40 SIIIA Sockets CAUTION Never attempt to adjust the low or high idle speed limit screw.

  • Page 70: Speed Control Of Electronically Controlled Engines - G30, G40Siiia

    SPEED CONTROL OF ELECTRONICALLY DECOMMISSIONING CONTROLLED ENGINES - G30, G40SIIIA 4TNV98-Z 4TNV98T-Z When the machine is to be permanently decommissioned or dismantled, it is important to ensure that all hazard The electronically controlled engines have no governor risks are either eliminated or notified to the recipient of lever.

  • Page 71: Maintenance

    EXTERNAL VIEWS - G30 SIIIA 4TNV98-ZGGE, G40 SIIIA 4TNV98T-ZGGE ......77 GENERAL INFORMATION ...................... 78 EPA CERTIFIED ENGINE DATA and SPECIFICATIONS - G20 SIIIA 4TNV88-BGGE....EPA CERTIFIED ENGINE DATA and SPECIFICATIONS - G30 SIIIA 4TNV98-ZGGE....EPA CERTIFIED ENGINE DATA and SPECIFICATIONS - G40 SIIIA 4TNV98T-ZGGE....

  • Page 72: Foreword

    FOREWORD In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help you do this. Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble-free and economical engine operation.
  • Page 73 WARNINGS AND ADVISORIES SMOKING Hazardous gases WARNING WARNING Smoking is prohibited Only start the engine in a well ventilated area. The exhaust gases contain carbon monoxide and • in the vicinity of flammable or explosive material, nitrogen oxides, which are toxic. e.g.
  • Page 74 SAFETY PRECAUTIONS FOR HANDLING MATERIALS Environment Fuel and lubricating oil Always hand in leftover and used chemicals to an authorised waste disposal contractor. WARNING SAFETY PRECAUTIONS FOR MAINTENANCE AND REPAIR All fuels and lubricants as well as many chemicals Switch off the engine are flammable.
  • Page 75 Electrical system Cooling system The engine must be switched off and the power disconnected using the master switch or battery master WARNING switch before working on the electrical system. External power supplies to extra equipment on the engine must also be disconnected. Never open the coolant filler cap when the engine is hot.

  • Page 76: External Views - G20Siiia 4Tnv88-Bgge

    EXTERNAL VIEWS - G20SIIIA 4TNV88-BGGE 1. Lifting eye (Flywheel end) 15. Intake manifold 2. Turbocharger 16. Fuel filter 3. Lifting eye (Engine cooling fan end) 17. Fuel inlet 4. Engine coolant pump 18. Fuel return to fuel tank 5. Engine cooling fan 19.

  • Page 77: External Views - G30Siiia 4Tnv98-Zgge, G40Siiia 4Tnv98T-Zgge

    EXTERNAL VIEWS - G30SIIIA 4TNV98-ZGGE, G40SIIIA 4TNV98T-ZGGE 1. Lifting eye (Flywheel end) 15. Intake manifold 2. Turbocharger 16. Fuel filter 3. Lifting eye (Engine cooling fan end) 17. Fuel inlet 4. Engine coolant pump 18. Fuel return to fuel tank 5.

  • Page 78: General Information

    GENERAL INFORMATION EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS - G20 SIIIA 4TNV88-BGGE Engine Model 4TNV88-B Version Type Vertical, 4-cycle water cooled diesel engine Combustion system Direct injection Aspiration Natural aspiration No. of cylinders Bore x stroke ø88 x 90 mm...

  • Page 79: Epa Certified Engine Data And Specifications - G30 Siiia 4Tnv98-Zgge

    EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS - G30 SIIIA 4TNV98-ZGGE Engine Model 4TNV98-Z Version Type Vertical, 4-cycle water cooled diesel engine Combustion system Direct injection Aspiration Natural aspiration No. of cylinders Bore x stroke ø98 x 110 mm Displacement 3,319 litres 1500 1800 Continuous...

  • Page 80: Epa Certified Engine Data And Specifications - G40 Siiia 4Tnv98T-Zgge

    EPA CERTIFIED ENGINE DATA AND SPECIFICATIONS - G40 SIIIA 4TNV98T-ZGGE Engine Model 4TNV98T-Z Version Type Vertical, 4-cycle water cooled diesel engine Combustion system Direct injection Aspiration Turbocharged No. of cylinders Bore x stroke ø98 x 110 mm Displacement 3,319 litres 1500 1800 Continuous...

  • Page 81: Engine Identification

    Doosan Genuine Parts Confirmation of Engine Number Genuine Doosan parts are identical with those used in the engine production, and accordingly, they are It is advisable to quote the engine serial number together warranted.

  • Page 82: Emission Control Label

    EMISSION CONTROL LABEL ENGINE LABEL (FOR 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. G20, 30, 40 SIIIA Operation &...

  • Page 83: Fuel, Lubricants, And Coolant

    Engine failure or with the diesel fuel. malfunction resulting from use of such improper fuel will not be warranted by Doosan. Water and sediment in the fuel should not exceed 0.05% by volume. To help avoid fuel system or engine damage, please read...
  • Page 84 Handling of the Fuel. Biocides Any fuel containing dust particles or water might cause In warm or humid weather, fungus and/or bacteria may engine failure. form in diesel fuel if there is water in the fuel. If fungus or bacteria has caused fuel system problems, you should Therefore, the following must be observed.

  • Page 85: Lubricant

    LUBRICANT NOTE: Using a mixture of different brands or quality of oils will adversely affect the original oil The quality of engine oil can affect engine performance, quality; therefore, never mix different brand or startability and engine life. different type oils. Use of unsuitable engine oil will result in piston ring, not use API,...

  • Page 86: Coolant

    COOLANT CAUTION • Be sure to add Long Life Coolant Antifreeze (LLC) to soft water. In cold season, the LLC is especially important. Without LLC, cooling performance will decrease due to scale and rust in the cooling water line. Without LLC, cooling water will freeze and expand to break the cooling line.

  • Page 87: Engine Operation

    ENGINE OPERATION Engine Exhaust Gas Caution (Carbon Monoxide) WARNING • Do not breathe exhaust gas because it contains carbon monoxide, which by itself has no color or odor. Carbon monoxide is a dangerous gas. It can cause unconsciousness and can be lethal. •...
  • Page 88 Fan Belt Check Check the fan belt for tension and abnormalities. When the belt is depressed 7 - 10 mm with the thumb (about 100 N [10 kg] pressure) midway between the fan pulley and alternator pulley, the belt tension is correct. If the belt tension is too high, it will result in alternator failure.

  • Page 89: Checks And Operation After Start-Up

    CHECKS AND OPERATION AFTER START-UP OPERATION AND CARE OF A NEW ENGINE. Check after the Engine Start-up Your engine is carefully tested and adjusted in the factory, however, further run-in is necessary. Avoid any Check the following items in the engine warming-up harsh engine operation within the initial 100 operating operation.

  • Page 90: Cold Start Device

    If no steam or engine coolant can be seen or heard, open the canopy or door. If the engine coolant is boiling, wait COLD START DEVICE until it stops before proceeding. The engine coolant level should be between the “MAX COLD” and “MIN” marks on the reserve tank.

  • Page 91: Periodical Inspection And Maintenance

    (a) Replacing the engine oil and engine oil filter intervals with Doosan Protect engine fluid and filters. (1st time) NOTE: The use of genuine Doosan oil and filters will Excercise caution when handling hot engine oil as it may qualify for extended warranty coverage. Refer cause serious burns.
  • Page 92 Fuel System Air Bleeding The entry of air into the fuel system will cause difficult engine starting or engine malfunction. When carrying out service procedures such as emptying the fuel tank, draining the filter/separator, and changing the fuel filter element be sure to bleed air from the fuel system.

  • Page 93: Inspection Every 1000 Hours Operation

    -reduces the cooling effect. Even when antifreeze agent (LLC) is mixed, the cooling water gets contaminated due to deteriorated ingredients. Replace the cooling water at Be sure to use genuine Doosan part (super fine mesh least Once a year. filter). Otherwise, it results in engine damage, uneven engine performance and shorter engine life.

  • Page 94: Inspection Every 1500 Hours Operation

    INSPECTION EVERY 1500 HOURS OPERATION (e) Clean EGR Cooler (a) Inspect, Clean and Test Fuel Injectors The EGR cooler is apt to be contaminated with rust and scale that deteriorate the cooling performance. Carbon As the adjustment requires specialized knowledge and accumulation in the exhaust gas passage of the cooler skill, consult your Portable Power dealer.

  • Page 95: Inspection Every 2000 Hours Operation

    INSPECTION EVERY 2000 HOURS OPERATION (a) Flushing the cooling system and checking the Diagnosis Tool (Yanmar genuine) cooling system parts As this maintenance requires specialized knowledge and skill, consult your Portable Power dealer. Rust and water scale will accumulate in the cooling system through many hours of operation.

  • Page 96: Engine Troubleshooting

    ENGINE TROUBLESHOOTING This item contains a simple troubleshooting. When a failure takes place on your engine, diagnose the cause referring this troubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest company engine service outlet.
  • Page 97 Engine overheat. Cooling system defect Insufficient coolant volume. Fan belt slippage. Thermostat malfunction. Radiator filler cap malfunction. Cooling system interior fouled. Radiator clogged. Improper servicing Engine over-loaded. Air cleaner element clogged. Insufficient airflow/restriction. Restricted coolant flow (high concentration of antifreeze, etc.) Low oil pressure Lack of oil...
  • Page 98 Excessive oil consumption Incorrect oil Wrong selection of type and viscosity. Too much oil quantity. Engine burning oil Faulty piston rings/damaged cylinder bores. Faulty valve stem seal. Oil leakage Damaged seal / Damaged turbocharger seal Loose joints/gaskets. Improper installation of filter and piping. Excessive fuel consumption Fuel leakage Damaged seals.

  • Page 99: Alternator Installation & Maintenance

    ALTERNATOR INSTALLATION AND MAINTENANCE CONTENTS FOREWORD ............................SAFETY MEASURES ........................WARNING SYMBOLS ........................RECEIPT ............................Standards and safety measures ....................Inspection ............................. Identification ..........................Storage ............................Application ............................ Contraindications to use ....................... TECHNICAL CHARACTERISTICS - G20, G30 SIIIA TAL040F, TAL042C ........Electrical characteristics .......................

  • Page 100: Foreword

    FOREWORD A set of self-adhesive decals depicting the various warning symbols is included with this maintenance manual. They should be positioned as shown in the This section concerns the alternator which you have just drawing below once the machine has been fully installed. purchased.

  • Page 101: Receipt

    RECEIPT STANDARDS AND SAFETY MEASURES Our alternators comply with most international standards. See the EC Declaration of Incorporation. INSPECTION On receipt of your alternator, check that it has not suffered any damage in transit. If there are obvious signs of knocks, contact the transporter (you may be able to claim on their insurance) and after a visual check, turn the machine by hand to detect any malfunction.
  • Page 102 RATINGS Date : Voltage Phase Weight : r.p.m. Conn. Th.class. Altitude : P.F. : A.V.R. Excit. Contin. full load Excit. values B.R. at no load 40 C. D.E. bearing Std by N.D.E. bearing P.R. 27 C. Made in ......166631 Moteurs Leroy-Somer - Boulevard Marcellin Leroy, IEC 60034 - 1 &...

  • Page 103: Technical Characteristics - G20, G30 Siiia Tal040F, Tal042C

    TECHNICAL CHARACTERISTICS - G20, G30 SIIIA TAL040F, TAL042C ELECTRICAL CHARACTERISTICS MECHANICAL CHARACTERISTICS This machine is an alternator without sliprings and • Steel frame revolving field brushes, wound as "2/3 pitch"; 6-wire, with class H insulation and a field excitation system available •...

  • Page 104: Technical Characteristics - G40 Siiia Lsa42.3

    TECHNICAL CHARACTERISTICS - G40 SIIIA LSA42.3 ELECTRICAL CHARACTERISTICS MD 35: The PARTNER LSA 42.3 alternator is a generator without single bearing with standard feet and SAE flanges/ sliprings and revolving field brushes, wound as “2/3 coupling discs. pitch”; 12-wire, with class H insulation and a field excitation system available in either “SHUNT”...

  • Page 105: Installation

    INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards. ASSEMBLY WARNING mechanical handling operations must CAUTION undertaken using suitable equipment and the machine must be horizontal. Check how much the machine weighs before choosing the lifting tool.

  • Page 106: Checks Prior To First Use

    CHECKS PRIOR TO FIRST USE • the winding connection corresponds to the site operating voltage (See TERMINAL Electrical checks CONNECTION DIAGRAMS, which appear on the following pages). WARNING Under no circumstances should an alternator, new or otherwise, be operated if the insulation is less than 1 meg ohm for the stator and 100,000 ohms for the other windings.

  • Page 107: Terminal Connection Diagram G20, G30 Siiia Tal040F, Tal042C

    TERMINAL CONNECTION DIAGRAM - G20, G30 SIIIA TAL040F, TAL042C To modify the connection, change the position of the stator cables on the terminals. The winding code is specified on the nameplate. 6 wires connection Connection L1 (U) W - L3 R120 V - L2 3 PH...

  • Page 108: Terminal Connection Diagrams G40 Siiia Lsa42.3

    TERMINAL CONNECTION DIAGRAMS - G40 SIIIA LSA42.3 To modify the connection, change the position of the stator cables on the terminals. The winding code is specified on the nameplate. Any intervention on the alternator terminals during connection or checks should be performed with the machine stopped.
  • Page 109 12 wires connection Connection code Factory connection L.L voltage 50 Hz 60 Hz Winding L1(V) L3(W) 110 - 120 1 phase 120 - 130 3 phases 110 - 120 L2(V) R 220 voltage sensing: L2(V) L3(W) 0 => (T8) / 110 V => (T11) L1(U) R 438 voltage sensing: 0 =>...

  • Page 110: Commissioning

    Connection checks COMMISSIONING WARNING WARNING The machine can only be started up and used if the Electrical installations must comply with the current installation is in accordance with the regulations and legislation in force in the country of use. instructions defined in this manual. Check that: The machine is tested and set up at the factory.

  • Page 111: Servicing - Maintenance

    SERVICING - MAINTENANCE SAFETY MEASURES WARNING Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the These operations must be performed at a cleaning machine in its original state. station, equipped with a vacuum system that collects and flushes out the products used.

  • Page 112: Mechanical Defects

    BEARINGS The bearings are permanently greased Approximate life of the grease (depending on use) = 20,000 hours or 3 years. MECHANICAL DEFECTS FAULT ACTION Bearing Excessive temperature rise - If the bearing has turned blue or if the grease has turned black, change in one or both bearings the bearing (bearing temperature more...

  • Page 113: Electrical Faults

    ELECTRICAL FAULTS FAULT ACTION EFFECT CHECK / CAUSE No voltage at Connect a new battery of 4 The alternator builds up and its - Lack of residual magnetism no load on to 12 volts to terminals E- voltage is still correct when the start-up and E+, respecting the battery is removed...
  • Page 114 Checking the winding Assembly A You can check the winding insulation by performing a Exciter field ASSEMBLY A high voltage test. In this case, you must disconnect all Rh. 50Ω - 300W AVR wires. Diode 1A CAUTION 12V battery Damage caused to the AVR in such conditions is not Assembly B: Connect a “Variac”...

  • Page 115: Dismantling, Reassembly

    DISMANTLING, REASSEMBLY Access to connections and the regulation system CAUTION The terminals and AVR are accessed directly by removing the terminal box lid (41). During the warranty period, this operation should AVR is accessed directly by removing the terminal box only be carried out in an LEROY-SOMER approved workshop or in our factory, otherwise the warranty may be invalidated.
  • Page 116 Replacing the NDE bearing on single-bearing • After extracting the rotor, be careful not to damage the machines fan and place the revolving field on special V-blocks. NOTE: If intervention is required on the main field Dismantling (rewinding, replacement of components), the •...
  • Page 117 TABLE OF CHARACTERISTICS Table of weights G20, G30 SIIIA TAL040F, TAL042C (values given for information only) Table of average values: Type Total weight (kg) Rotor (kg) Alternator - 4 pole - 50 Hz - Winding no. 6. TAL040F TAL042C The voltage and current values are given for no-load operation and operation at rated load with separate field excitation.
  • Page 118 EXPLODED VIEW, PARTS LIST AND TIGHTENING TORQUE TAL040F single-bearing SHUNT SCREW TORQUE SCREW TORQUE REF. QTY DESCRIPTION REF. QTY DESCRIPTION Ø N.m. Ø N.m. Stator assembly NDE bearing Rotor assembly Preloading wavy washer Wound exciter field Earth terminal Field fixing screw DE flange Exciter armature Air outlet grille...
  • Page 119 EXPLODED VIEW, PARTS LIST AND TIGHTENING TORQUE TAL042C single-bearing SHUNT SCREW TORQUE SCREW TORQUE REF. QTY DESCRIPTION REF. QTY DESCRIPTION Ø N.m. Ø N.m. Stator assembly NDE bearing Rotor assembly Preloading wavy washer Wound exciter field Earth terminal Field fixing screw DE flange Exciter armature Air outlet grille...

  • Page 120: Exploded View, Parts List And Tightening Torque

    EXPLODED VIEW, PARTS LIST AND TIGHTENING TORQUE LSA 42.3 single-bearing SCREW TORQUE REF. QTY DESCRIPTION Ø Plastic cover Terminal box lid Terminal box screw 3.6 ±0.4 Plug Access flap 3.6 ±0.4 NDE bearing Preloading wavy washer Wound exciter field Field fixing screw Exciter armature Terminal plate support Terminal plate...
  • Page 122 Doosan Bobcat EMEA s.r.o U Kodetky 1810 263 12 Dobříš Czech Republic www.doosanportablepower.eu...

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