Doosan G400-SIIIA Operation & Maintenance Manual
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Doosan G400-SIIIA Operation & Maintenance Manual

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G400/500-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.
46687871_en_B_03/16
G400-SIIIA
SERIAL No : G40030001 ->
G500-SIIIA
SERIAL No : G50030001 ->

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  • Page 1 G400/500-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. G400-SIIIA SERIAL No : G40030001 -> G500-SIIIA SERIAL No : G50030001 -> 46687871_en_B_03/16...
  • Page 3 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: Doosan Benelux SA Drève Richelle 167 B-1410 Waterloo BELGIUM G400, 500-SIIIA OM Manual...
  • Page 4 G400, 500-SIIIA OM Manual...
  • Page 5 FOREWORD CONTENTS FOREWORD ............................6 DECLARATION OF CONFORMITY ......................7 G400, 500-SIIIA OM Manual...
  • Page 6 English or work situation that may arise. version. IF IN DOUBT CONSULT SUPERVISION. © COPYRIGHT 2015 DOOSAN COMPANY This machine has been designed and supplied for use only following specified conditions applications: •...
  • Page 7 DECLARATION OF CONFORMITY SAMPLE G400, 500-SIIIA OM Manual...
  • Page 8 G400, 500-SIIIA OM Manual...
  • Page 9 G400, 500-SIIIA OM Manual...
  • Page 10 G400, 500-SIIIA OM Manual...
  • Page 11 GENERAL DATA CONTENTS GENERAL DATA............................ 12 GENERAL INFO ............................ 12 ELECTRICAL DATA ..........................12 G400, 500-SIIIA OM Manual...
  • Page 12 GENERAL DATA UNIT MODEL G400 G500 Engine Speed - RPM 1500 / 1800 1500 / 1800 Engine Fuel Diesel Diesel Manufacturer Scania Scania Model DC13 071 A 00 DC16 071 A 00 Number of cylinders / Displacement (litres) 6/12.7 8/16.4 FLUID CAPACITIES Engine Crankcase Lubricant (litres) Fuel Tank (litres)

  • Page 13: Table Of Contents

    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: Hot Liquid Coolant Drain Engine Oil Drain Flammable Liquid G400, 500-SIIIA OM 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 G400, 500-SIIIA OM Manual...
  • Page 21 OPERATING INSTRUCTIONS CONTENTS OPERATING INSTRUCTIONS ....................22 COMMISSIONING ........................... CONNECTING THE LOAD ......................PRIOR TO STARTING ........................STARTING ............................STOPPING ............................BASIC DIGITAL CONTROLS OPERATION ..................Overview IDENTIFYING KEYPAD BUTTONS AND INDICATORS ..............Operation Buttons Display Buttons Status L.E.D.S VIEWING REAL-TIME DATA - ACCESSING THE SCREENS ............CHECKING SOFTWARE VERSION / LAMP TEST ................

  • Page 22: Operating Instructions

    OPERATING INSTRUCTIONS Never operate unit without first observing all safety PRIOR TO STARTING warnings and carefully reading the operation & Before starting the engine, carry out the following checks: maintenance manual shipped from the factory with this machine. 1. Engine oil level: Add as required. COMMISSIONING Upon receipt of the unit, and prior to putting it into CAUTION...

  • Page 23: Starting

    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 24: Identifying Keypad Buttons And Indicators

    Figure 1 IDENTIFYING KEYPAD BUTTONS AND INDICATORS Operation Buttons Use this button to scroll the generator operation mode from AUT-MAN-OFF. Press this button START 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 25: Display Buttons

    Display Buttons Figure 2 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 26 Figure 5 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. Rem Start/Stop Figure 8 Low Coolant...

  • Page 27: Checking Software Version / Lamp Test

    Figure 10 Figure 12 Run Hours Alarm List Not in Auto NumStarts Wrn Coolant Level E-Stop Shutdown KW hours KVAr hours Next Srv Time 250 h This screen displays operational information of the This screen displays the alarm / shutdown list of the generator set in terms of run hours, number of starts, generator set.

  • Page 28: Parameter Adjustments Via Keypad

    PARAMETER ADJUSTMENTS VIA KEYPAD PT Ratio The generator set potential transformers ratio. PTs are Press the “PAGE” button until you reach the parameter not needed on 480 Volt systems and below. adjustment menu. Nominal Voltage 1 Use the “INCREASE” and / or “DECREASE” buttons to scroll through the parameter menus.

  • Page 29: Engine Parameters

    Controller ADDR Max Stability Time If generator nominal voltage is not stable within the time The setting of the controller address. after starter is OFF and idle time elapes, then the genset RS232 Mode will shutdown. Stability means that voltage and frequency are within warning setting limits.

  • Page 30: Engine Protection

    ECU Freq Select Fuel Level Del This function is not used. Factory Setting = DEFAULT. Delay for low fuel level. ECU Speed Adjust Batt Overvolt This function is not used. Factory Default Setting = O. Warning threshold for high battery voltage. ENGINE PROTECTION Batt Undervolt Warning threshold for low battery voltage.

  • Page 31: Date / Time

    Volt unbal Threshold for generator voltage unbalance alarm. 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 32: Options

    OPTIONS 3-WAY FUEL VALVE Figure 16: 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 33: Oil Sump Pump

    OPTIONS [CONT’D] OIL SUMP PUMP Figure 19: Hand pump This machine may be equipped with an oil sump pump Figure 17: Oil pan drain Oil pan drain valve Description The oil sump pump allows for easier removing of engine oil. Removing oil Run the engine until it is at operating temperature.

  • Page 34: Socket Set - Ce

    OPTIONS [CONT’D] SOCKET SET - CE SUPER-START PACKAGE (COLD START FOR -23°C) Figure 20: Sockets This machine may be equipped with cold start kit. DESCRIPTION: The cold start option serves to improve start conditions during winter operation at ambient temperature from -10°C to -23°C.
  • Page 35 OPTIONS [CONT’D] Figure 22: 240VAC External Power Terminal Block The heater must not be operated: • In filling stations and tank farms. • In places where explosive vapors or dust may build up (e.g. near fuel, coal, wood dust or cereal stores). •...

  • Page 36: Decommissioning

    DECOMMISSIONING LONG TERM STORAGE RECOMMENDATIONS (6 MONTHS OR MORE) When the machine is to be permanently decommissioned • Engine cooling system - Treat with rust inhibitor and or dismantled, it is important to ensure that all hazard drain. Check with engine dealer further...
  • Page 37 MAINTENANCE CONTENTS MAINTENANCE INFORMATION ......................GENERAL ............................SCHEDULED MAINTENANCE ................................................INTRODUCTION ENVIRONMENT AND SAFETY ......................ENVIRONMENTAL RESPONSIBILITY .................... SAFETY............................DIFFERENT TYPES OF ADVISORY ....................WARNINGS AND ADVISORIES ......................SMOKING............................SAFETY PRECAUTIONS FOR RUNNING THE ENGINE ............... SAFETY PRECAUTIONS FOR HANDLING MATERIALS ............... SAFETY PRECAUTIONS FOR MAINTENANCE AND REPAIR ............
  • Page 38 COOLING SYSTEM ..........................COOLANT............................CHECKING COOLANT LEVEL......................CHECKING ANTIFREEZE AND CORROSION INHIBITOR............. ANTIFREEZE AND CORROSION INHIBITOR................. CHANGING COOLANT ........................CLEANING THE COOLING SYSTEM ....................AIR CLEANER............................READING THE VACUUM INDICATOR..................... RENEWING THE FILTER ELEMENT ....................RENEWING THE SAFETY CARTRIDGE......................67 FUEL SYSTEM............................CHECKING FUEL LEVEL.........................

  • Page 39: Maintenance Information

    G400SIIIA/G500SIIIA MAINTENANCE Hoses INFORMATION Each month it is recommended that the intake hoses from the air cleaner and all flexible hoses used for water and fuel be inspected for the following: WARNING 1. All rubber hose joints and the screw type hose clamps must be tight and the hoses showing no signs of wear, Any unauthorised modification or failure to maintain abrasion or deterioration.

  • Page 40: Introduction

    INTRODUCTION This Operator's manual describes the operation and maintenance of Scania industrial engines. engines direct-injection, liquid-cooled, four-stroke, turbocharged diesel engines. The engines are available with different output and engine speed settings. Engine power for the engine ordered is indicated on a plate located on the engine control unit.

  • Page 41: Environment And Safety

    ENVIRONMENT AND SAFETY ENVIRONMENTAL RESPONSIBILITY Caution Advisories preceded by Caution warn of faults and Scania develops and produces engines that are as incorrect operation that could lead to equipment being environmentally-friendly as possible. Scania has made damaged. Example: major investments in the reduction of harmful exhaust emissions order fulfil...

  • Page 42: Warnings And Advisories

    WARNINGS AND ADVISORIES Hazardous gases SMOKING WARNING WARNING Only start the engine in a well ventilated area. The exhaust gases contain carbon monoxide Smoking is prohibited nitrogen oxides, which are toxic. • in the vicinity of flammable or explosive material, If it is run in an enclosed space, there should be an e.g.

  • Page 43: Safety Precautions For Handling Materials

    SAFETY PRECAUTIONS FOR HANDLING SAFETY PRECAUTIONS FOR MAINTENANCE AND MATERIALS REPAIR Fuel and lubricating oil Switch off the engine Always switch off the engine before carrying out maintenance repair work, unless otherwise WARNING indicated. Make it impossible to start the engine: Remove any All fuels and lubricants as well as many chemicals starter key, or cut the power using the main power switch are flammable.

  • Page 44: Cooling System

    Batteries Lubrication system WARNING WARNING The batteries contain and form oxyhydrogen gas, Hot oil can cause burns and skin irritation. Wear particularly during charging. Oxyhydrogen gas is protective gloves and goggles when changing hot flammable and highly explosive. oil. There must be no smoking, naked flames or sparks Make sure that there is no pressure in the lubrication near the batteries or the battery compartment.

  • Page 45: Certification

    THE ENGINE DATA PLATE Before starting Ensure that all guards are in place before starting the The engine data plate indicates, in the form of a code, the engine. Ensure that no tools or other objects have been engine type, its size and applications. It also indicates the left on the engine.

  • Page 46: Component Identification

    G400 SIIIA COMPONENT IDENTIFICATION Figure 25 The illustrations show a normal version of a DC13 engine. The engine ordered may have different equipment. 1. Turbocharger 9. Engine data plate 2. Oil cooler 10. Fuel filter 3. Oil filler 11. Fuel pump with hand pump 4.
  • Page 47 G500 SIIIA COMPONENT IDENTIFICATION Figure 26 The illustrations show a normal version of a DC16 engine. The engine ordered may have different equipment. 1. Turbocharger 7. Oil filler 2. Starter motor 8. Engine control unit 3. Oil dipstick 9. Centrifugal oil cleaner 4.

  • Page 48: Starting And Running

    G400/500SIIIA STARTING AND RUNNING CAUTION Note: When the engine is started for the first time, carry out the maintenance items listed under First start in the maintenance schedule. See The starter motor must only be cranked twice for 30 the Maintenance section. seconds at a time.

  • Page 49: Running

    RUNNING Check instruments and warning lamps at regular intervals. Engine speed range 50 Hz 1500 rpm Engine operating speed range. Controlled by the engine management system. 60 Hz 1800 rpm Limp home mode G400SIIIA Coolant temperature If there is a fault in the normal throttle opening or if CAN Normal coolant temperature during operation is 80-90°C/ communication is interrupted, the following emergency 176-194°F.

  • Page 50: Engine Shutdown

    Oil pressure ENGINE SHUTDOWN 1. Run the engine without a load for a few minutes if it Information about the normal oil pressure and lowest has been run continuously with a heavy load. permitted oil pressure is contained in the section headed Technical Data.

  • Page 51: Maintenance

    G400/500SIIIA MAINTENANCE • M maintenance: More extensive maintenance. • L maintenance: Includes nearly all maintenance The maintenance programme covers a number of points items. that are divided into the following sections: • XL maintenance: Includes all maintenance items. • Lubrication system During a period, the sequence is S-M-S-L-S-MS-L-S-M-S-XL.

  • Page 52: Maintenance Intervals

    G400/500SIIIA MAINTENANCE INTERVALS Daily First time at Interval (hours) At least first start 1,000 2,000 6,000 annual every 5 years Lubrication system Checking oil level Changing the oil Cleaning the centrifugal oil cleaner Renewing the oil filter Cooling system Checking coolant level Checking coolant antifreeze or corrosion protection Cleaning the cooling system and...

  • Page 53: Lubrication System

    LUBRICATION SYSTEM OIL ANALYSIS Oil companies can offer analysis of the engine oil. OIL GRADE The following conditions must remain fulfilled when the Recommended oil Part Number oil is changed. Protec Engine Fluid E7 54480918 • Viscosity at 100°C (212°F): max. ±20% of original value of the fresh oil.

  • Page 54: Changing The Oil

    CHANGING THE OIL G400SIIIA Note: Renew the oil filter and clean the centrifugal Figure 29 oil cleaner when changing oil. 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.

  • Page 55: Renewing Oil Filter

    G500SIIIA G400SIIIA RENEWING THE OIL FILTER Figure 32 CAUTION Clean the centrifugal oil cleaner when renewing the oil filter. Otherwise, the oil filter will be blocked and resistance in the filter will increase. If this happens, an overflow valve in the filter retainer opens and lets the oil pass without being filtered.
  • Page 56 Figure 36 Figure 37 1 Oil filter 2 Pressure filter G500SIIIA RENEWING THE OIL FILTER Figure 38 CAUTION Clean the centrifugal oil cleaner when renewing the oil filter. Otherwise, the oil filter will be blocked and resistance in the filter will increase. If this happens, an overflow valve in the filter retainer opens and lets the oil pass without being filtered.

  • Page 57: Cleaning The Centrifugal Oil Cleaner

    G400/500SIIIA CLEANING THE CENTRIFUGAL OIL Figure 40 CLEANER When cleaning the centrifugal oil cleaner there will be some dirt deposits in the rotor cover. If this is the case, this indicates that the rotor is working. If it is clean and not working, the cause must be established immediately.
  • Page 58 7. Remove the paper insert and scrape away any Figure 45 remaining dirt deposits inside the rotor cover. If the deposits are thicker than 28 mm, the centrifugal oil cleaner must be cleaned more often. Figure 43 8. Wash the parts. 9.
  • Page 59 Tightening torque CAUTION Up to engine serial number 6 841 927: 27 Nm. From engine serial number 6 841 928: 45 Nm. To reduce the risk of oil leakage it is important to tighten the cover to the correct tightening torque. Tool 588 651 or 2 259 530 together with a ratchet head is suitable for use during maintenance.
  • Page 60 G400/500SIIIA COOLING SYSTEM The chart depicts coolant properties at different percents of antifreeze and corrosion inhibitor concentration by volume. COOLANT Figure 50 WARNING 50 % Ethylene glycol can be fatal if ingested and can cause skin irritation and eye damage. The coolant recommended by Scania is a mixture of water with antifreeze and corrosion inhibitor (ethylene glycol).
  • Page 61 Antifreeze and corrosion inhibitor concentration 2. The measured concentration of ethylene glycol is table (metric) 35% by volume (freezing point -21 °C). According to the table there are 14 litres of ethylene glycol in the 35% by volume of Scania antifreeze provides sufficient cooling system.
  • Page 62 Antifreeze and corrosion inhibitor concentration 2. The measured concentration of ethylene glycol is table (imperial) 35% by volume (freezing point -6°F). According to the table there are 3.7 US gallons of ethylene glycol in the 35% by volume of Scania antifreeze provides sufficient cooling system.

  • Page 63: Checking Antifreeze And Corrosion Inhibitor

    G400/500SIIIA CHECKING COOLANT LEVEL CHECKING ANTIFREEZE AND CORROSION INHIBITOR The following instructions apply to Scania expansion Note: Use only pure fresh water that is free from tanks. For other types of expansion tanks, follow the particles, sludge and other impurities. manufacturer's instructions.

  • Page 64: Antifreeze And Corrosion Inhibitor

    ANTIFREEZE AND CORROSION INHIBITOR Only the product Scania coolant, or other products that are tested to provide proper antifreeze and protection against corrosion for Scania, may be used in Scania engines. Products that do not satisfy the requirements for use in a Scania engine can result in faults in and damage to the cooling system.

  • Page 65: Changing Coolant

    CHANGING COOLANT 5. Disconnect the hose. 6. Set the heating control to maximum heating and start the engine. Idling speed must not exceed 600 rpm. Environment Leave the engine idling for 15 minutes. Avoid spillage and use a suitable container. Used coolant 7.

  • Page 66: Cleaning The Cooling System

    CLEANING THE COOLING SYSTEM 8. Refit the thermostats. Note: Clean the cooling system more often than 9. Fill the cooling system with new coolant following the specified in the maintenance programme if specification under Coolants earlier in the document. necessary. Environment CAUTION Avoid spillage and use a suitable container.

  • Page 67: Air Cleaner

    G400/500SIIIA AIR CLEANER 4. Assemble the air cleaner. 5. Reset the vacuum indicator by pressing the button. READING THE VACUUM INDICATOR If the indicator's red plunger is fully visible, renew the air Figure 53 cleaner filter element following the instructions. RENEWING THE FILTER ELEMENT Note: Renew the filter element earlier than the...

  • Page 68: Fuel System

    FUEL SYSTEM CAUTION Sulphur content in fuel and its effect on oil change interval Fit the filter elements in the filter covers before • A sulphur content of 0-2,000 ppm in the fuel gives an placing them in the fuel filter housings or the filter oil change interval of up to 500 hours.

  • Page 69: Renewing The Water Separating Fuel Filter

    6. Press a new filter element into the snap fastener in G400/500SIIIA RENEWING THE WATER SEPARATING FUEL FILTER the cover. 1. Close the shut-off cock in the fuel pipe and position a 7. Fit the filter element and cover in the filter housing. container under the filter.
  • Page 70 G400SIIIA BLEEDING THE FUEL SY STEM G500SIIIA BLEEDING THE FUEL SYSTEM Figure 58 Figure 59 1. Attach a clear plastic hose to the bleed nipple on the fuel filter housing (1). Place the end of the plastic hose 1. Attach a clear plastic hose to the bleed nipple on the in a container that holds at least 3 litres (0.8 US fuel filter housing (1).

  • Page 71: Miscellaneous

    MISCELLANEOUS Figure 62 CHECKING THE DRIVE BELT CAUTION Refit the drive belt with the same direction of rotation as it had before removal. Check the drive belt thoroughly, particularly at the idler rollers. Figure 60 (G400SIIIA) The drive belt must be renewed if it has cracks. Figure 61 (G500SIIIA) Check the drive belt for cracks.

  • Page 72: Checking For Leaks

    Check drive belt wear. Figure 63 The drive belt is starting to become worn, but can be refitted. Figure 64 The belt is worn down to the cord. The drive belt must be renewed. CHECKING FOR LEAKS • Start the engine. •...

  • Page 73: Checking And Adjusting The Valve Clearance

    G400SIIIA CHECKING AND ADJUSTING THE VALVE Figure 67 CLEARANCE Note: Checking and adjusting valve clearances should also be done one more time after the first 500 hours of operation. Then the normal interval will follow (every 2,000 hours). Note: Valve adjustment should be carried out on a Special tool 99 109 is used when turning from above.
  • Page 74 Reading in the lower window: Figure 70 Rotate the flywhel in the normal direction of rotation using turning tool 99 309. Read the mark on the flywheel visible in the lower window of the flywheel housing. Reading in the upper window: Fit turning tool 99 109 in the holes of the upper window.
  • Page 75 Figure 73 G400SIIIA Checking and adjusting the unit injector Tightening torques Lock nut for unit injectors 39 Nm (29 lbf/ft) WARNING When the unit injector is being checked and the measurement is outside the setting dimension by ±0.5 mm, it is necessary to be very careful when handling this unit injector 1.
  • Page 76 G500SIIIA CHECKING AND ADJUSTING THE VALVE Option 1 CLEARANCE Figure 76 Note: Checking and adjusting valve clearances should also be done one more time after the first 500 hours of operation. Then the normal interval will follow (every 2,000 hours). Special tool 99 309 is used when turning from below.
  • Page 77 From below Valve transition Injector Adjust intake valve on Adjust exhaust valve cylinder oncylinder TDC down 4 and 5 7 and 8 4 and 5 TDC up 2 and 6 1 and 5 2 and 6 TDC down 3 and 7 2 and 4 3 and 7 TDC up...
  • Page 78 Figure 81 Figure 82 O Intake valve X Exhaust valve Option 2 Adjusting the valves 1. Rotate the flywheel in the direction of engine rotation until TDC DOWN can be seen in the lower inspection hole and there is a valve transition on cylinder 6. Adjust the valves marked in bold in diagram A.

  • Page 79: Diesel

    DIESEL CAUTION COMPOSITION OF THE FUEL The composition of the fuel is extremely important for the Mixing kerosene or other paraffins with the fuel is operation and service life of the engine and injection prohibited. The injectors may be damaged. system.

  • Page 80: Preparing The Engine For Storage

    G400/500SIIIA PREPARING THE ENGINE • If it gets in your eyes: Flush with a gentle jet of FOR STORAGE water for at least 15 minutes and contact a doctor. If the engine is not being used for an extended period its •...

  • Page 81: Batteries

    11. Drain the coolant if the engine is not to be stored with 6. Connect and bleed the fuel system. For more coolant in the system. Plug and tape all coolant information refer to Maintenance. connections if the engine is to be stored without a cooling system.

  • Page 82: Technical Data

    G400SIIIA TECHNICAL DATA GENERAL DATA Number of cylinders and configuration 6, straight Working principle 4-stroke engine Cylinder diameter (mm/in) 130/5.12 Piston stroke (mm/in) 160/6.30 Displacement (dm3/in3) 12.7/775.0 Firing sequence 1 - 5 - 3 - 6 - 2 - 4 Compression ratio 17.3:1 Engine direction of rotation viewed from rear...

  • Page 83: Intake System

    INTAKE SYSTEM Permissible pressure drop in the intake system with cleaned filter (mbar) Permissible pressure drop in the intake system with blocked (dirty) filter (mbar) ELECTRICAL SYSTEM Type 1-pin, 24 V, DC Starter motor, standard equipment 1-pin, 24 V, 5.5 kW Alternator, standard equipment 1-pin, 28 V, 100 A G400, 500-SIIIA OM Manual...
  • Page 84 G500SIIIA TECHNICAL DATA GENERAL DATA Number of cylinders and configuration Working principle 4-stroke engine Cylinder diameter (mm/in) 130/5.118 Piston stroke (mm/in) 154/6.06 Displacement (dm3/in3) 16.4/1,001 Firing sequence 1 - 5 - 4 - 2 - 6 - 3 - 7 - 8 Compression ratio 16.7:1 Engine direction of rotation viewed from rear...
  • Page 85 INTAKE SYSTEM Permissible pressure drop in the intake system with cleaned filter (mbar) Permissible pressure drop in the intake system with blocked (dirty) filter (mbar) ELECTRICAL SYSTEM Type 1-pin, 24 V, DC Starter motor, standard equipment 1-pin, 24 V, 7.0 kW Alternator, standard equipment 1-pin, 28 V, 100 A G400, 500-SIIIA OM Manual...
  • Page 86 G400, 500-SIIIA OM Manual...
  • Page 87 G400/500SIIIA ALTERNATOR INSTALLATION AND MAINTENANCE CONTENTS FOREWORD ............................SAFETY MEASURES ........................WARNING SYMBOLS ........................RECEIPT .............................. STANDARDS AND SAFETY MEASURES ..................INSPECTION ........................... IDENTIFICATION ..........................Nameplate STORAGE ............................APPLICATION ..........................CONTRAINDICATIONS TO USE ....................TECHNICAL CHARACTERISTICS ....................... ELECTRICAL CHARACTERISTICS ....................MECHANICAL CHARACTERISTICS ....................
  • Page 88 ELECTRICAL FAULTS ........................Checking the winding Checking the diode bridge Checking the windings and rotating diodes using separate excitation DISMANTLING, REASSEMBLY ..................... Tools required Screw tightening torque Access to diodes Access to connections and the regulation system Replacing the NDE bearing Dismantling the rotor assembly Reassembling the machine Dismantling and reassembly of the filters...

  • Page 89: 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 90: Receipt

    RECEIPT STORAGE Prior to commissioning, machines should be stored: STANDARDS AND SAFETY MEASURES • Away from humidity (< 90%); after a long period of Our alternators comply with most international standards. storage, check the machine insulation (See “Electrical See the EC Declaration of Incorporation on the last page. checks”...

  • Page 91: Technical Characteristics

    TECHNICAL CHARACTERISTICS MECHANICAL CHARACTERISTICS • Steel frame ELECTRICAL CHARACTERISTICS • Cast iron end shields This LSA 46.2 alternator is a machine without slip rings or revolving armature brushes, wound as “2/3 pitch”, 12 • Protected ball bearings, greased for life wire, with class H insulation and an AREP field excitation system...

  • Page 92: Installation

    INSTALLATION CAUTION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards. When coupling the alternator to the prime mover, do not use the fan to turn the alternator or rotor. The ASSEMBLY holes of the coupling discs should be aligned with the flywheel holes by cranking the engine.

  • Page 93: Mechanical Checks

    WARNING Ensure that the alternator has the degree of protection matching the defined environmental conditions. Mechanical checks Before starting the machine for the first time, check that: • all fixing bolts and screws are tight. • the length of screw and tightening torque are correct •...
  • Page 94 Connection codes Voltage L.L Factory connection 12 wire L1(U) 50 Hz 60 Hz Winding 190 - 208 190 - 240 3-phase L3(W) L2(V) 190 - 208 L1(U) R 250 voltage sensing: 0 => (T8) / 110 V => (T11) L2(V) L3(W) R 450 voltage sensing: 0 =>...

  • Page 95: Connection Checks

    Option connection diagram Remote voltage potentiometer R 791 T interference suppression kit (standard for CE marking) Connections Black Black Black Voltage adjustment via remote potentiometer Blue White Current transformer connection (optional) Coupling D & A Coupling D - PH 1 - PH 1 In - Secondary 1A (coupl.

  • Page 96: Setting Up

    SETTING UP CAUTION Do not use: trichlorethylene, perchlorethylene, trichloroethane or any alkaline products. The various adjustments during tests must be made by a qualified engineer. Ensure that the drive speed specified on the nameplate is reached before WARNING commencing adjustment. After operational testing, replace all access panels or covers.

  • Page 97: Bearings

    BEARINGS The bearings are permanently greased Approximate life of the grease (depending on use) = 20,000 hours or 3 years. As an option, the bearings are regreasable Regreasing interval: 3500 hrs of operation DE bearing: Amount of grease: 41 gr NDE bearing: Amount of grease: 30 gr Standard grease LITHIUM - standard - NLGI 3...

  • Page 98: Electrical Faults

    ELECTRICAL FAULTS FAULT ACTION EFFECT CHECK / CAUSE The alternator builds up and its voltage is still correct when the - Lack of residual magnetism battery is removed - Check the connection of the The alternator builds up but its voltage reference to the AVR Connect a new battery of 4 voltage does not reach the rated...

  • Page 99: Checking The Winding

    Checking the winding Assembly A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode You can check the winding insulation by performing a on both exciter field wires (5+) and (6-). high voltage test.

  • Page 100: Dismantling, Reassembly

    DISMANTLING, REASSEMBLY • Change the crescents, respecting the polarity. Access to connections and the regulation system CAUTION Access directly by removing the top of the cover (48) or the AVR access door (466). During the warranty period, this operation should Replacing the NDE bearing only be carried out in an LEROY-SOMER approved workshop or in our factory, otherwise the warranty...

  • Page 101: Dismantling The Rotor Assembly

    • Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). CAUTION 78 36 Threaded rod When dismantling the rotor involves changing parts or rewinding, the rotor must be rebalanced. Dowel Rotor NDE shield •...

  • Page 102: Reassembling The Machine

    Reassembling the machine • Check that the machine assembly is correctly mounted and that all screws are tightened. • Mount the rotor (4) in the stator (1) (see drawing above) taking care not to knock the windings. Dismantling and reassembly of the filters If using a single-bearing or double-bearing machine with •...

  • Page 103: Table Of Characteristics

    TABLE OF CHARACTERISTICS Field excitation current i exc (A) Symbols: “i exc”: excitation current of the exciter field Table of average values Type No load At rated load Alternator - 4 poles - 50 Hz - Standard winding No. 6. (400V for the excitation values) S4 (G400SIIIA) The voltage and current values are given for no-load...
  • Page 104 SPARE PARTS ACCESSORIES First maintenance parts Space heater for use when stopped Emergency repair kits are available as an option. The space heater must run as soon as the alternator stops. It is installed at the rear of the machine. Its They contain the following items: standard power is 250W with 220V or 250W with 110V on request.

  • Page 105: Exploded View, Parts List And Tightening Torque

    EXPLODED VIEW, PARTS LIST AND TIGHTENING TORQUE Ref. Description Screw Torque Ref. Description Screw Torque Ø Ø Stator assembly Inner bearing retainer Rotor assembly Preloading (wavy) Lifting ring washer Drive end shield Protection varistor 6 or 4 Fixing screws (+ PCB) Protective grille “O”...
  • Page 106 Electric Power Generation Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006/42/CE dated 17 May 2006. MOTEURS LEROY-SOMER MLS HOLICE STLO.SRO MOTEURS LEROY-SOMER DIVISION LEROY-SOMER Boulevard Marcellin Leroy SLADKOVSKEHO 43 1, rue de la Burelle...

This manual is also suitable for:

G500-siiia

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