Doosan G60XW/XF Operation & Maintenance Manual
Doosan G60XW/XF Operation & Maintenance Manual

Doosan G60XW/XF Operation & Maintenance Manual

50 and 60 hz
Table of Contents

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50 Hz: G60 - G80 - G115 - G150 - G200XW/XF
60 Hz: G65 - G100 - G135 - G170 - G225XW/XF
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_A_12/15

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Summary of Contents for Doosan G60XW/XF

  • Page 1 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF OPERATION & MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine.
  • Page 3: Table Of Contents

    Generator Serial Number Engine Serial Number NOTES: YOUR DIPP DEALER: ADDRESS: PHONE: Doosan Benelux SA Drève Richelle 167 B-1410 Waterloo BELGIUM 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 4 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 5: Foreword

    Operation within the ambient temperature range • © COPYRIGHT 2015 specified in the GENERAL INFORMATION section of DOOSAN COMPANY this manual. 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 6 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 7: General Data (Configuration 1)

    GENERAL DATA CONTENTS GENERAL DATA (CONFIGURATION 1)......................... ELECTRICAL DATA (CONFIGURATION 1) ......................GENERAL DATA (CONFIGURATION 2)......................... ELECTRICAL DATA (CONFIGURATION 2) ......................50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 8 GENERAL DATA (CONFIGURATION 1) UNIT MODEL 50HZ G60XW/XF G80XW/XF G115XW/XF G150XW/XF G200XW/XF Engine Speed - RPM 1500 1500 1500 1500 1500 UNIT MODEL 60HZ G65XW/XF G100XW/XF G135XW/XF G170XW/XF G225XW/XF Engine Speed - RPM 1800 1800 1800 1800 1800 Engine Fuel...
  • Page 9 GENERAL DATA (CONFIGURATION 2) UNIT MODEL 50HZ G60XW/XF G80XW/XF G115XW/XF G150XW/XF G200XW/XF Engine Speed - RPM 1500 1500 1500 1500 1500 UNIT MODEL 60HZ G65XW/XF G100XW/XF G135XW/XF G170XW/XF G225XW/XF Engine Speed - RPM 1800 1800 1800 1800 1800 Engine Fuel...
  • Page 10 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 11: Safety

    SAFETY CONTENTS SAFETY DECALS ..............................GRAPHIC FORM AND MEANING OF ISO SYMBOLS .................. SAFETY INSTRUCTIONS ............................ EARTHING ..............................IF USED AS ALTERNATE POWER SUPPLY ....................HAZARDOUS SUBSTANCE PRECAUTION ....................GENERAL INFORMATION ..........................Electricity Materials Battery Radiator Transport 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION &...
  • Page 12: Safety Decals

    SAFETY DECALS GRAPHIC FORM AND MEANING OF ISO SYMBOLS PROHIBITION / MANDATORY INFORMATION / INSTRUCTIONS WARNING WARNING: Electrical shock risk WARNING - Pressurised component WARNING - Hot surface. or system. WARNING - Pressure control. WARNING - Corrosion risk. WARNING - Air/gas flow or Air discharge.
  • Page 13 WARNING - Maintain correct tyre WARNING - Before connecting the tow WARNING - For operating pressure. bar or commencing to tow consult the temperature below 0°C (32°F), consult Operation & Maintenance manual. the Operation & Maintenance manual. WARNING - Do not undertake any WARNING - Consult the Operation &...
  • Page 14 Lifting point. On (power). Off (power). Read the Operation & Maintenance When parking use prop stand, Compressor oil filling manual before operation or handbrake and wheel chocks. maintenance of this machine is undertaken. Diesel fuel Parking brake. Rough Service Designation. No open flame.
  • Page 15: 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 shutdown system that will cause the machine to stop booster cable to the positive (+) terminal of each operating whenever a shutdown condition is present.
  • Page 16: 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 17: Hazardous Substance Precaution

    HAZARDOUS SUBSTANCE PRECAUTION GENERAL INFORMATION Ensure that the operator reads and understands the decals and consults the manuals before maintenance or CAUTION operation. Ensure that the Operation & Maintenance manual, and Use extreme care to avoid contacting hot surfaces the manual holder, are not removed permanently from (engine exhaust manifold and piping).
  • Page 18 Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: • anti-freeze • engine lubricant •...
  • Page 19: Operating Instructions

    OPERATING INSTRUCTIONS CONTENTS OPERATING INSTRUCTIONS ..........................COMMISSIONING ............................CONNECTING THE LOAD..........................PRIOR TO STARTING ............................ STARTING............................... STOPPING ..............................CONTROLLER ..............................QUICKSTART GUIDE ............................. STARTING THE ENGINE..........................STOPPING THE ENGINE ..........................STOP / RESET MODE ............................MANUAL MODE ..............................STARTING SEQUENCE..........................ENGINE RUNNING ............................
  • Page 20: 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 21: Starting

    STARTING STOPPING 1. Turn off all external electrical power loads. CAUTION 2. Turn Main Breaker “OFF”. 3. Allow 5 minute cool down. Use the EMERGENCY STOP button ONLY in the event of an emergency. 4. Push controller “STOP” Button. NEVER use it for normal shut-down. 5.
  • Page 22: Controller

    CONTROLLER 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 Press the Manual Mode button .
  • Page 23: Stopping The Engine

    STOPPING THE ENGINE Select Stop/Reset mode. The generator is stopped NOTE: For further details, see the section entitled ‘OPERATING INSTRUCTIONS’ elsewhere in this manual. 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 24: Stop / Reset Mode

    STOP / RESET MODE NOTE: If a digital input configured to panel lock is active, changing module modes is not 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.
  • Page 25: Manual Mode

    MANUAL MODE NOTE: If a digital input configured to panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Manual Mode is activated by pressing the Manual Mode button.
  • Page 26: Engine Running

    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. A loading request can come from a number of sources. •...
  • Page 27: Test Mode

    TEST MODE NOTE: If a digital input configured to panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Test Mode is activated by pressing the Test Mode button.
  • Page 28: Engine Running

    ENGINE RUNNING Once the engine is running and all starting timers have expired, the animated Engine Running icon is displayed. In Test Mode , the load is automatically transferred to the generator. NOTE: The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine.
  • Page 29: Automatic Mode

    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.
  • Page 30: Engine Running

    ENGINE RUNNING Once the engine is running and all starting timers have expired, the animated Engine Running icon is displayed. The generator is placed on load if configured to do so. NOTE: The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine.
  • Page 31: Engine General Introduction

    ENGINE GENERAL INTRODUCTION CONTENTS GENERAL INFORMATION .............................32 DANGER, WARNING, CAUTION AND NOTE ......................33 GENERAL INFORMATION..........................33 GENERAL INSTRUCTIONS..........................33 PRECAUTIONS IN STARTING THE ENGINE ....................34 CAUTIONS FOR INSPECTION AND REPAIR ....................34 GENERAL REPAIR..............................35 OTHER SAFETY INSTRUCTIONS AND ENVIRONMENTAL POLLUTION............35 USE OF GENUINE PARTS.............................36 ENGINE MAINTENANCE ............................36 PREVENTION OF DAMAGE AND ABRASION....................36 PREVENTION OF POLLUTION ........................37...
  • Page 32: General Information

    In the event that a part must 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.
  • Page 33: Danger, Warning, Caution And Note

    Note) is used to provide additional descriptions causes of pollution. and information required for maintenance technicians to successfully operate Doosan engines. The recommended repair methods and 'Danger,' 'Warning,' and 'Caution' can enhance the degree of WARNING completion of engine maintenance and prevent bodily injury which may occur to workers.
  • Page 34: Precautions In Starting The Engine

    2. If it is inevitable to perform inspection or repair on the operating engine, do not get close to the rotating DANGER parts. Do not touch the exhaust manifold or heat screen WARNING when engine is running, or immediately after it has stopped.
  • Page 35: General Repair

    7. Replace parts such as cotter pins, gaskets, O-rings, seal rings, oil seals, and washers with new ones WARNING during repairs. Reuse of parts may be the cause of engine faults and engine may not operate properly. Battery fluid is corrosive and dangerous because of 8.
  • Page 36: Use Of Genuine Parts

    Always use coolant mixed with antifreeze. If coolant faults to engine for which Doosan shall not be held liable. without antifreeze is used, the coolant may freeze causing the coolant passage in the cylinder block to Consider the following while managing engines: freeze and damage the engine.
  • Page 37: Prevention Of Pollution

    PREVENTION OF POLLUTION Consider the following to manage engine without causing environmental pollution. 1. Drain oil and coolant using collection containers. 2. Discard oil and coolant according to the regulations of the relevant authorities. 3. Be careful not to let drained oil and cooling water flow into the ground or the sewer.
  • Page 38 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 39: Engine Operation And Maintenance

    OPERATION AND MAINTENANCE CONTENTS STARTING AND STOPPING OF THE ENGINE ....................40 PREPARING FOR START..........................40 STARTING THE ENGINE ..........................40 RUNNING IN..............................40 DURING OPERATION............................40 STOPPING THE ENGINE ..........................41 BREAK-IN PERIOD OF THE ENGINE .......................41 GENERAL INFORMATION..........................41 BREAK-IN PERIOD OF A NEW ENGINE......................41 CHECK POINTS ...............................41 COLD START OPERATION..........................41 INSPECTION AFTER STARTING THE ENGINE .....................41...
  • Page 40 Use fuel, oil, and coolant recommended by Doosan. Otherwise, critical 1. Oil pressure. damage to the engine may occur.
  • Page 41 BREAK-IN PERIOD OF THE ENGINE GENERAL INFORMATION CAUTION Doosan engines are subjected to a final approval test to ensure the provision of high quality engines before being shipped. However, engines are not operated for a long The oil pressure may increase with high rpm and period of time in this test.
  • Page 42 As parts related to exhaust and weather or areas with cold climate. When replacing turbocharger are used at high temperature, be careful not engine oil, use of Doosan genuine engine oil is to mix the bolts and nuts with other parts when recommended.
  • Page 43: Engine Performance And Specifications

    PERFORMANCE AND SPECIFICATIONS CONTENTS ENGINE SPECIFICATIONS AND PERFORMANCE ................ENGINE SPECIFICATION..........................44 ENGINE OUTPUT ............................46 ENGINE SPECIFICATIONS ..........................47 ENGINE POWER..............................48 EXTERIOR VIEW DRAWING OF THE ENGINE (D1146/PU086)............. FRONT/REAR (D1146/PU086).........................49 LEFT/RIGHT (D1146/PU086) ...........................49 EXTERIOR VIEW DRAWING OF THE ENGINE (D1146T/PU086T) ..........FRONT/REAR (D1146T/PU086T) ........................50 LEFT/RIGHT (D1146T/PU086T) ........................50 EXTERIOR VIEW DRAWING OF THE ENGINE (P086TI) ...............
  • Page 44: Engine Specifications And Performance

    ENGINE SPECIFICATIONS AND PERFORMANCE ENGINE SPECIFICATION D1146/ D1146T/ P086T P086TI Items P086TI Remarks PU086 PU086T (Power Up) (Power Up) 4stroke, 4stroke, in-line, in-line, water-cooled 4stroke, in-line, water-cooled type, turbo Engine type water-cooled type, charged inter cooled type, turbo naturally charged aspirated Combustion chamber type Direct injection type...
  • Page 45 ENGINE SPECIFICATION (CONT’D) D1146/ D1146T/ P086T P086TI Items P086TI Remarks PU086 PU086T (Power Up) (Power Up) Open at 16° BTDC Intake valve Close at 36° ABDC Open at 46° BBDC Exhaust valve Close at 14° ATDC Lubrication method Full forced pressure feed type Oil pump type Gear type driven by camshaft Oil filter type...
  • Page 46: Engine Output

    ENGINE OUTPUT (Production tolerance: ±5%) Condition Generating-Set Engines Remarks Continuous Prime Stand by 50Hz 105PS 116PS (1,500 rpm) (77kW) (85kW) D1146 Standard 60Hz 130PS 143PS (1,800 rpm) (96kW) (105kW) 50Hz 145PS 160PS (1,500 rpm) (107kW) (118kW) D1146T Standard 60Hz 170PS 187PS (1,800 rpm) (125kW)
  • Page 47: Engine Specifications

    ENGINE SPECIFICATIONS Item Engine model DP066TA Engine model DP066LA 4-stroke, in-line, water-cooled, 4-stroke, in-line, water-cooled, Engine type turbocharged turbocharged and air-cooled Combustion chamber type Direct injection Cylinder liner type Dry liner Timing gear system Gear driven type No. of piston rings 2 compression rings and 1 oil ring Number of cylinders - bore x stroke (mm) 6 - Ø102 ×...
  • Page 48: Engine Power

    ENGINE POWER (Tolerance: ±5%) Engine model Performance Injection Power Torque Remarks Code Model timing (kW / rpm) (kg·m / rpm) (Suffix) (BTDC°) 135 / 1,800 (stand-by) 00G03 122 / 1,800 (prime) DP066TA 115 / 1,500 (stand-by) 00G04 105 / 1,500 (prime) (BTDC) 120 / 1,800 (stand-by) 00G05...
  • Page 49: Exterior View Drawing Of The Engine (D1146/Pu086)

    EXTERIOR VIEW DRAWING OF THE ENGINE (D1146/PU086) FRONT/REAR (D1146/PU086) 1. Cylinder head cover 5. Mounting bracket 2. Cooling water pipe 6. Oil level gauge 3. Fuel injection pipe 7. Flywheel 4. Water pump 8. Flywheel housing LEFT/RIGHT (D1146/PU086) 1. Cooling fan 10.
  • Page 50: Exterior View Drawing Of The Engine (D1146T/Pu086T)

    EXTERIOR VIEW DRAWING OF THE ENGINE (D1146T/PU086T) FRONT/REAR (D1146T/PU086T) 1. Exhaust elbow 5. Water pump 2. Turbocharger 6. Mounting bracket 3. Cylinder head cover 7. Flywheel 4. Air pipe 8. Flywheel housing LEFT/RIGHT (D1146T/PU086T)) 1. Cooling fan 9. Oil filter 2.
  • Page 51: Exterior View Drawing Of The Engine (P086Ti)

    EXTERIOR VIEW DRAWING OF THE ENGINE (P086TI) FRONT/REAR (P086TI) EA9O1005_1 1. Cylinder head 2. Cooling water pipe 3. Flywheel 4. Mounting bracket 5. Water pump 6. Flywheel housing 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 52: Left/Right (P086Ti)

    LEFT/RIGHT (P086TI) EA9O1005_2 1. Cooling fan 11. Oil drain valve 2. Thermostat 12. Starter 3. Oil filler cap 13. Intake manifold 4. Air pipe 14. Fuel injection pump 5. Turbocharger 15. Oil filter 6. Exhaust elbow 16. Oil level gauge 7.
  • Page 53: Exterior View Drawing Of The Engine (P086T Power Up)

    EXTERIOR VIEW DRAWING OF THE ENGINE (P086T POWER UP) FRONT/REAR (P086T POWER UP) EK00345A 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 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION &...
  • Page 54: Left/Right (P086T Power Up)

    LEFT/RIGHT (P086T POWER UP) EK00346A 1. Cooling pan 11. Oil drain valve 2. Alternator 12. Intake manifold 3. Thermostat 13. Fuel filter 4. Turbocharger 14. Fuel injection pump 5. Exhaust manifold 15. Oil level gauge 6. Starter 16. Oil filter 7.
  • Page 55: Top (P086T Power Up)

    TOP (P086T POWER UP) EK00347A 1. Oil cap 2. Breather 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 56: Exterior View Drawing Of The Engine (P086Ti Power Up)

    EXTERIOR VIEW DRAWING OF THE ENGINE (P086TI POWER UP) FRONT/REAR (P086TI POWER UP) EK00348A 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 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION &...
  • Page 57: Left/Right (P086Ti Power Up)

    LEFT/RIGHT (P086TI POWER UP) EK00349A 1. Cooling pan 11. Oil drain valve 2. Alternator 12. Intake manifold 3. Thermostat 13. Fuel filter 4. Turbocharger 14. Fuel injection pump 5. Exhaust manifold 15. Oil level gauge 6. Starter 16. Oil filter 7.
  • Page 58: Top (P086Ti Power Up)

    TOP (P086TI POWER UP) EK00350A 1. Oil cap 2. Breather 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 59: Engine Identification Number

    ENGINE IDENTIFICATION NUMBER • Type 5 ENGINE CODE AND MANUFACTURING NUMBER The engine model and serial number are located on the engine as illustrated. These numbers are required when Sales Model name (4-7 digits) requesting warranty and ordering parts. Production Year (1 digit) Serial Number (5 digits) After new representative specification (3 digits) •...
  • Page 60: Engine Assembly Diagram

    ENGINE ASSEMBLY DIAGRAM EXTERNAL VIEW OF ENGINE 1) DP066LA EI9OM005-1 1. Oil filter 14. Coolant pump 2. Fuel filter 15. Alternator 3. Oil Cooler 16. Engine mounting bracket 4. Intake manifold 17. Engine lift hook 5. Fuel injection pump 18. Dipstick 6.
  • Page 61 2) DP066TA EI9OM005-2 1. Oil filter 15. Alternator 2. Fuel filter 16. Engine mounting bracket 3. Oil Cooler 17. Engine lift hook 4. Intake manifold 18. Dipstick 5. Fuel injection pump 19. Exhaust manifold 6. Fuel injection nozzle 20. Push rod chamber 7.
  • Page 62: Technical Information

    TECHNICAL INFORMATION NUMBER STAMP ON ENGINE • The engine code and manufacturing number are marked on the specified location as shown in the figure. This number is required for a warranty claim and part order. EI9OM006-1 • Engine number stamp Engine code Serial number Year of manufacture...
  • Page 63: Engine Regular Inspection

    REGULAR INSPECTION CONTENTS GENERAL INFORMATION............................65 GENERAL INFORMATION..........................65 ROUTINE INSPECTION...........................65 REGULAR INSPECTION TABLE .........................66 GENERAL CONDITIONS ..........................66 USE OF GENUINE PARTS ..........................67 COOLING SYSTEM...............................67 GENERAL INFORMATION..........................67 COOLANT STANDARDS ..........................67 CAPACITY OF COOLANT..........................67 CHECKING THE COOLANT ..........................67 MEASUREMENT OF COOLANT CONCENTRATION ..................68 DISCHARGING THE COOLANT ........................69 CHARGING THE COOLANT ..........................69 CLEANING THE COOLING CIRCUIT ......................70...
  • Page 64 CONTENTS (CONT’D) INTAKE/EXHAUST SYSTEM ..........................81 GENERAL INFORMATION ..........................81 AIR FILTER ..............................81 DISASSEMBLY OF AIR FILTER ........................81 CLEANING OF THE AIR FILTER ELEMENT....................82 CHANGING THE AIR FILTER ELEMENT......................83 TURBOCHARGER ............................83 ROUTINE CHECK AND SERVING THE TURBOCHARGER ................83 DISASSEMBLY AND CLEANING A TURBOCHARGER .................83 CYLINDER BLOCK/HEAD .............................84 VALVE CLEARANCE ............................84 HOW TO ADJUST THE VALVE CLEARANCE ....................84...
  • Page 65: General Information

    GENERAL INFORMATION CAUTION GENERAL INFORMATION After purchasing an engine over time, each of the Incorrect inspection methods may cause engine engine’s parts will age and the initial engine performance faults. cannot be maintained. Cleaning an engine with liquids such as water or wax Regular inspection and replacement of components may cause breakdown of electrical parts.
  • Page 66: Regular Inspection Table

    REGULAR INSPECTION TABLE GENERAL CONDITIONS Regular inspection and replacement according to the recommended regular inspection table allows you to maintain the engine with optimum conditions and best performance for a long period and prevent unexpected accidents in advance. ( o : Inspection and Adjustment • : Replacement) Inspection interval (Hours) Check Points Daily...
  • Page 67: Use Of Genuine Parts

    Using unauthorized or remanufactured parts may cause critical P086TI 14/11 damage and faults to engine for which Doosan shall not P086TI Power Up be held liable. COOLING SYSTEM PU086 PU086T GENERAL INFORMATION The coolant should be replaced according to the cycle CHECKING THE COOLANT specified in the inspection interval table.
  • Page 68: Measurement Of Coolant Concentration

    MEASUREMENT OF COOLANT CONCENTRATION 5. Compare and confirm the parts with identical colors on the test sheet and the standard color table. • Special Tools Figure Product Number/Name % GLYCOL / FREEZEPOINT (°C)(End Pad) 60.99901-0038 test sheet SCA Units per litre COOLANT TEST SHEET TEST The coolant concentration can be measured as follows:...
  • Page 69: Discharging The Coolant

    Do not mix antifreezes from different manufacturers. Do not mix the coolant with different concentrations. Do not add antirust which is not recommended by Doosan. As insufficient coolant concentration may cause corrosion or freezing, alternatively, an excessive concentration may degrade the cooling performance.
  • Page 70: Cleaning The Cooling Circuit

    WARNING Discard exchanged coolant according regulations set forth by the relevant authorities. Disposing of exchanged coolant into the ground, sewers, drains, rivers, or the sea will cause serious environmental pollution. Violation of regulations regarding discard of coolant without observing the handling regulations, will be punished.
  • Page 71: Inter Cooler

    INTER COOLER The air cooler adopts an air cooling fan, which has sufficient cooling capacity. The life and performance of an air cooler greatly depends on the intake air conditions. Dirty air may contaminate and clog the cooling pins. This results in reduced engine power or engine failure.
  • Page 72: Lubrication System

    PU086T SAE 15W40 API CD OR CE ABOVE NOTE: Use of Doosan genuine engine oil is recommended. 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 73: Engine Oil Capacity

    ENGINE OIL CAPACITY 3. Insert the oil level gauge, and then remove it to check the engine oil level, viscosity, and contamination. Replenish the engine oil based on the following Replenish or replace the engine oil if required. recommended oil amount. Engine oil capacity (litres) Engine Model and Product...
  • Page 74: Replacement Of Engine Oil

    6. Run the engine at idle speed for several minutes so the oil can circulate through the lubrication system. When replacing the oil filter cartridge, be sure to use the genuine Doosan part. 7. Stop the engine and wait for approximately 10 FUEL SYSTEM minutes.
  • Page 75: Fuel Standards

    The quality of fuel is very important to satisfy the engine performance, extension of engine life and the allowable exhaust gas level. Doosan engines are designed to use diesel fuel available in the local market. If the optimum engine performance is required, select the proper fuel by referring to the fuel selection table below.
  • Page 76: Water Draining From Fuel Filter

    WATER DRAINING FROM FUEL FILTER REPLACING FUEL FILTER An oil filter has two functions: oil filtering and water separation. 1. The water separation function of the fuel filter drains water and sediment from the water separator. 2. Stop the engine, and loosen the drain plug for water separation manually.
  • Page 77: Preventing Fuel Contamination

    8. Tighten it by 3/4 to 1 turn with a fuel filter wrench. 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.
  • Page 78: Fuel Injection Nozzle

    6. Washer CAUTION 7. Cap nut 8. Nozzle If any parts that contain a seal ring (copper seal ring, rubber coating seal ring, etc.) are disassembled, then CHECK FUEL INJECTION NOZZLE PRESSURE replace the seal ring with a new one. Failure to do so may cause leakage in the fuel filter connections 1.
  • Page 79: Removal Of Nozzle

    • Clean annular groove with scraper over full Opening circumference. Wash out dislodged carbon deposits pressure Engine Model Remarks and dirt. (kg/cm • Scrape needle seat with cleaning cutter. Dip cutter in D1146 at 200 rpm test oil before use. The cutter can also be clamped in D1146T at 200 rpm a lathe.
  • Page 80 5. Ensure the indication point at the flywheel housing 7. Turn the coupling until the notch mark of the indicator inspection hole coincides with the specified injection plate attached to the fuel injection pump is aligned angle. If the injection timing is not correct, adjust as with the notch mark of the coupling.
  • Page 81: Priming Pump Strainer Cleaning

    PRIMING PUMP STRAINER CLEANING AIR FILTER 1. Clean the priming pump strainer filter frequently. • Air cleaner is mounted on the engine to purify the air for combustion. 2. The strainer filter is incorporated in the priming pump inlet side. •...
  • Page 82: Cleaning Of The Air Filter Element

    CLEANING OF THE AIR FILTER ELEMENT a) Before washing the element, clean the element by using compressed air as described above. Clean the air filter element by using the most suitable method for the work environment among the three b) Soak the element in the warm cleaning solvent for methods stated below.
  • Page 83: Changing The Air Filter Element

    CHANGING THE AIR FILTER ELEMENT ROUTINE CHECK AND SERVING THE TURBOCHARGER 1. Remove the hex nut, remove the dirty element. The turbocharger performance is affected by the maintenance state of the engine. Regularly perform inspection and maintenance as specified in order to maintain turbocharger performance.
  • Page 84: Cylinder Block/Head

    CYLINDER BLOCK/HEAD VALVE CLEARANCE Adjust the valve clearance. • When disassembling the engine or cylinder head. • When there is excessive noise in the valve connection. • When the engine runs abnormally even if the fuel injection system is normal. HOW TO ADJUST THE VALVE CLEARANCE 1.
  • Page 85: Adjusting The Valve Clearance

    ADJUSTING THE VALVE CLEARANCE Guide for valve clearance adjustment Flywheel Intake Valve Exhaust Valve Cylinder No. Cooling Fan EA9O5005 1. Rotate the crankshaft so that #1. cylinder may be Intake Valve Exhaust Valve Engine Model positioned at the compression TDC (Top Dead (mm) (mm) Center).
  • Page 86: Cylinder Compression Pressure

    CYLINDER COMPRESSION PRESSURE ELECTRICAL SYSTEM 1. Start and warm up the engine. BATTERY 2. Stop the engine and disassemble the fuel injection • Check the battery for cracks and ensure there is no nozzle holder assembly. electrolyte leakage. Replace the battery if defective. 3.
  • Page 87: Others/Driving System

    OTHERS/DRIVING SYSTEM V-BELT The tension of the V-belts should be checked daily. 1. Change the V-belts if necessary. a) If wear or differing tensions are found in a multiple V-belt drive, always replace the complete set of V-belts. 2. Checking condition. DV2213049A a) Check V-belts for cracks, oil, overheating and wear.
  • Page 88 5. Tension adjustment and V-belt replacement. EA9O2007 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.
  • Page 89: Alternator Installation & Maintenance

    ALTERNATOR INSTALLATION AND MAINTENANCE CONTENTS GENERAL SAFETY WARNING......................DESCRIPTION............................DEGREE OF PROTECTION - CHARACTERISTICS................ FREQUENCY ............................ ACCESSORIES..........................TRANSPORT AND STORAGE ......................INSTALLATION AND COMMISSIONING ....................CHECK BEFORE INSTALLATION....................INSULATION TEST ........................... BALANCING ............................ASSEMBLY OF ADAPTORS AND DISCS FOR MJB 160 ..............ALIGNMENT............................
  • Page 90: General Safety Warning

    GENERAL SAFETY WARNING The generators which are the subject of these “instructions” are components designed for use in industrial areas (machines/plants) and therefore cannot be treated as retail goods. Electric rotating machines have dangerous parts: when operating they have live rotating This documentation consequently contains information components.
  • Page 91: Description

    TRANSPORT AND STORAGE WARNING The generator is shipped ready for installation. It should be carefully inspected on arrival in order to verify if damage has occurred during transport; if any, they Here enclosed with this “instructions manual” there should be referred directly to the haulier (writing one note self-adhesive leaflets which reporting...
  • Page 92: Installation And Commissioning

    INSTALLATION AND COMMISSIONING CHECK BEFORE INSTALLATION touch power terminals during WARNING immediately after the insulation resistance check because the winding is in voltage. Before installing the generator - Make sure that name plate data corresponds to the power supply and operating conditions and that the installation complies with...
  • Page 93: Balancing

    correction coefficient applied different temperatures: Twinding (° C) 0.69 1.42 2.82 correction Example: Rmis = 50 M Ohms at the winding temperature of 30° C; ·(R = 2 ·50 = 100 M Ohms isol 20°C 30°C BALANCING Unless otherwise indicated the rotor is balanced dynamically with a half-key fitted on the shaft extension, in compliance with IEC 34-14.
  • Page 94: Electrical Connection

    For single bearing generators it is further necessary to Terminals arrangement permits star series and star verify all dimensions of the flywheel and flywheel parallel connection: it is anyway necessary, when housing. Furthermore it is necessary to check the changing the connection from star series to star parallel, dimensions of the coupling and of the flange on the to check and modify the connection to the voltage generator.
  • Page 95: Single Phase Loads

    Grounding Connection zig–zag Inside the terminal box there is a terminal for grounding, and a second terminal is on a foot of the generator. Grounding has to be carried out using a copper wire of suitable size, in compliance with applicable standards.
  • Page 96: Stator Winding Insulation Check Through Polarization Index

    BEFORE INITIAL START-UP, MAKE THE STATOR WINDING INSULATION CHECK THROUGH FOLLOWING CHECKS: POLARIZATION INDEX Mechanical checks - Verify that: Qualitative insulation resistance versus time curves: • Fixing bolts are securely fixed. • The alignment and coupling is correct. Insulation probably good •...
  • Page 97: Removal Of Moisture From Windings

    The ratio between those insulation resistances is called Bring the oven to 110 – 150° C maximum. The drying of polarisation index (PI): windings for generators MJB 160 – 200 – 225 may take 2 - 4 hours depending on the starting condition insulation resistance.
  • Page 98: Maintenance

    MAINTENANCE As a general rule, the machine should be subjected to a first inspection after approx. 100 operating hours (in any case not more than 1 year) and subsequent inspections when performing maintenance on prime mover. When performing inspection check that: For safety purposes it is necessary that any testing •...
  • Page 99: Maintenance Of Bearings

    MAINTENANCE OF BEARINGS • Using proper lifting apparatus, remove the rotor (3) from the main stator, through the D.E. side, taking The lifetime of bearings is determined by multiple factors special care to avoid any damage to the windings. and specifically by: FOR SINGLE BEARING GENERATORS: •...
  • Page 100 The following table indicates the tightening torques valid for locking screws and nuts: Tightening torques in Nm Application Thread diameter (cl.8.8) (cl.12.9) Fixing of electrical connections. Fixing of screws in low strength material components (aluminium). Fixing of components (shields, bearing caps, etc). Fixing of feet or flange.
  • Page 101: Voltage Regulators

    VOLTAGE REGULATORS Use of potentiometers P1/VOLT- Potentiometer for adjusting the output voltage VOLTAGE REGULATOR “MARK V” (M16FA655A) of the generator; it allows a wide range of voltage setting (i.e. between 350 and 470 V; or between 170 and 260 V The generators are equipped with an automatic voltage depending on winding connections)).
  • Page 102: Voltage Regulator "Mark I" (M40Fa640A/A)

    Connection of AVR The AVR is connected to the terminals of the generator and to exciter using FAST-ON terminals. Fuse - On the AVR there is a protecting fuse. Should it be necessary to replace it, high speed fuses should be used;...
  • Page 103 FREQ - Potentiometer for changing the low speed If the procedure is properly carried out, the excitation protection. Usually it is set in order to reduce the voltage threshold is set to a value 15-20% higher than excitation when the speed is 10 % below the rated value the excitation voltage at the maximum desired load, at 50 Hz.
  • Page 104: Instructions For Manual Control Of Generators

    SLOPE - Potentiometer for changing the slow speed This source could consist of a bank of batteries or of a protection characteristic slope. This potentiometer can voltage transformer and a rectifier unit connected at the increase or decrease the under speed ramp slope, and alternator output.
  • Page 105: Trouble Shooting And Repairs

    TROUBLE SHOOTING AND REPAIRS ELECTRICAL ANOMALY TROUBLE POSSIBLE CAUSE REMEDY (always to be done with the machine switched off - SAFETY HAZARD) a) Loose connections. a) Check and repair. b) Rotating diodes or surge suppressor b) Check the diodes and change in case broken.
  • Page 106: Mechanical Anomaly

    MECHANICAL ANOMALY TROUBLE POSSIBLE CAUSE REMEDY (always to be done with the machine switched off - SAFETY HAZARD) a) Ventilate in order to reduce the ambient a) High ambient temperature. temperature. b) Create sufficient free space around to b) Hot air reflow. the machine.
  • Page 107: Spare Parts - Nomenclature

    SPARE PARTS – NOMENCLATURE Pos. Part name Type / Code MJB 160 MJB 200 MJB 225 6310 2RS C3 / 6313 2RS C3 / 6215 2RS C3 / D side (D:E) bearing 346245050 346245065 346242075 6311 2RS C3 / N side (N.D.E.) bearing 6309 2RS C3 / 346245045 346240055 Voltage regulator...
  • Page 108: Wiring Diagram For 12 Terminals Generators With Avr Mark V Without Auxiliary Winding

    WIRING DIAGRAM FOR 12 TERMINALS GENERATORS WITH AVR MARK V WITHOUT AUXILIARY WINDING. STAR PARALLEL CONNECT. SERIES CONNECTION 220 V 50 Hz 400 V 50 Hz 240 V 60 Hz 480 V 60 Hz Single phase load Single phase load U1 (T1) * FOR 60 Hz OPERATION, THE STATOR...
  • Page 109: Alternator Components

    ALTERNATORS COMPONENTS CONTENTS MJB 160 COMPACT ..........................MJB 200 .............................. MJB 225 ............................... MJB 250 ............................... SELF-ADHESIVE WARNING LABELS ....................50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 110: Mjb 160 Compact

    MJB 160 COMPACT STANDARD CONFIGURATION Delivered generators may differ in details from that illustrated. COMMON COMPONENTS COMPONENTS FOR SINGLE BEARING COMPACT CONSTRUCTION Item Description Item Description Housing with stator Complete rotor SAE adaptor N.D.E. endshield D.E. protective screen Disc Fuse N.D.E.
  • Page 111: Mjb 200

    MJB 200 STANDARD CONFIGURATION Delivered generators may differ in details from that illustrated. COMMON COMPONENTS COMPONENTS FOR SINGLE BEARING COMPACT CONSTRUCTION Item Description 2 + 14 Housing with stator Item Description Complete rotor SAE adaptor N.D.E. endshield D.E. protective screen Fuse Terminal box Complete flexplate coupling (71 + 87)
  • Page 112: Mjb 225

    MJB 225 STANDARD CONFIGURATION Delivered generators may differ in details from that illustrated. COMMON COMPONENTS COMPONENTS FOR SINGLE BEARING COMPACT CONSTRUCTION Item Description Item Description 2 + 14 Housing with stator SAE adaptor Complete rotor N.D.E. endshield D.E. protective screen Fuse Complete flexplate coupling (71 + 87) Terminal box...
  • Page 113: Mjb 250

    MJB 250 STANDARD CONFIGURATION Delivered generators may differ in details from that illustrated. COMMON COMPONENTS COMPONENTS FOR SINGLE BEARING COMPACT CONSTRUCTION Item Description Item Description 2 + 14 Housing with stator Complete rotor SAE adaptor N.D.E. endshield D.E. protective screen Fuse Complete flexplate coupling (71 + 87) AVR connection cable kit...
  • Page 114: Self-Adhesive Warning Labels

    SELF-ADHESIVE WARNING LABELS LABEL N°1 REFER TO INSTRUCTION MANUAL BEFORE REMOVING COVERS. LABEL N°2 LABEL N°3 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 115 It is the responsibility of the set assembler to ensure that the self-adhesive warning labels provided are fitted to the generator, as follows. FRAME SIZE 160 - 200 Label No.2 On both sides Label No.1 Label No.3 On both sides FRAME SIZE 250 - 315 - 400 Label No.1 Label No.2...
  • Page 116 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 117: Main Breaker Operation

    MAIN BREAKER OPERATION CONTENTS OPERATING INSTRUCTIONS ......................BREAKER ADJUSTING INSTRUCTIONS (S150 TO S250 SERIES) ..........TIME / CURRENT CHARACTERISTIC CURVES (S150 TO S250 SERIES)........BREAKER ADJUSTING INSTRUCTIONS (S400 AND S600 SERIES)..........TIME / CURRENT CHARACTERISTIC CURVES (S400 AND S600 SERIES) ......50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION &...
  • Page 118: Operating Instructions

    OPERATING INSTRUCTIONS TRIPPED Handle Trip Button (ON) (OFF) RESET Operation Operation effort S160 - S250 110N S400 115N 125N 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 119: Breaker Adjusting Instructions (S150 To S250 Series)

    BREAKER ADJUSTING INSTRUCTIONS ELECTRONIC TYPE: S150 TO S250 SERIES TIME / CURRENT CHARACTERISTIC CURVES Under bar is default setting. Electronic Type 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 120: Breaker Adjusting Instructions (S400 And S600 Series)

    BREAKER ADJUSTING INSTRUCTIONS ELECTRONIC TYPE: S400 AND S600 SERIES TIME / CURRENT CHARACTERISTIC CURVES Under bar is default setting. Electronic Type 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 121 WIRING DIAGRAMS 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 122 50 Hz: G60 - G80 - G115 - G150 - G200XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G65 - G100 - G135 - G170 - G225XW/XF...
  • Page 123: Warranty Conditions

    / owner that each STATUTORY OR OTHERWISE (EXCEPT THAT OF new Doosan Global Export Generator will be free from TITLE) INCLUDING ALL IMPLIED WARRANTIES AND defects in material and workmanship for twelve (12)

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