Table of Contents
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OPERATION, MAINTENANCE
G10WMI-2D-T2 (B63)
G25WMI-2A-T2 (B54)
G40WMI-2A-T2 (B50)
G60WJD-2A-T2 (B55)
G70WJD-2A-T3 (D63)
G80
G90WJD-2A-T3 (C24)
G125
G145WJD-2A-T3 (C27)
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 22637300 (8-2-2010) Rev H
MANUAL
GENERATOR MODELS
G185WJD-2A-T3 (C28)
G240WJD-2B-T3 (C31)
G240WCU-2C-T3 (D97)
G290WCU-3B-T3 (C38)
G290WCU-3C-T3 (D77)
G450WCU-2B-T2 (C34)
G450WCU-2C-T2 (D96)
G570WCU-2B-T2 (C37)
G570WCU-2C-T2 (D78)
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Table of Contents
Related Manuals for Doosan G125
Summarization of Contents
Drawbar Notice
Drawbar Notice Procedures
Step-by-step instructions for converting the drawbar from shipping to towing position.
Safety Symbols
Understanding Safety Symbols
Explanation of various safety symbols used in the manual and on the machine.
Safety Information
Hazardous Substance Precautions
Precautions for handling hazardous substances used or produced by the machine.
General Data
Unit Specifications Overview
Overview of unit specifications including engine, fluid capacities, running gear, and weights.
Consumables Service Parts
Part numbers for consumable service items like air filters, oil filters, and fuel filters.
Expendable Service Parts
Part numbers for expendable service items and maintenance kits.
Operating Instructions
Before Towing Procedures
Steps and precautions to take before towing the generator unit.
Towing Guidelines
Instructions and warnings for safely towing the generator unit.
Setting Up and Leveling
Procedure for positioning and leveling the generator unit for operation.
Pre-Start Checks
Essential checks and inspections before starting the generator engine.
Starting Autostart Models
Procedure for starting generator units equipped with autostart functionality.
Stopping Autostart Models
Procedure for safely stopping generator units with autostart.
Autostart Diagnostics and Shutdowns
Explanation of diagnostic codes and automatic shutdown conditions for autostart models.
Autostart Engine Controls and Instruments
Description of controls and instruments used for operating autostart generator models.
Diagnostic Gauge Operation
Guide to operating the diagnostic gauge and interpreting its readouts.
Starting Key Start Models
Procedure for starting generator units using a key start ignition system.
Stopping Key Start Models
Procedure for safely stopping generator units with key start ignition.
Key Start Diagnostics and Shutdowns
Explanation of diagnostic codes and automatic shutdown conditions for key start models.
Key Start Engine Controls and Instruments
Description of controls and instruments for operating key start generator models.
Voltage Selection and Adjustments (G25-G185)
Procedure for selecting and adjusting output voltages for G25 to G185 models.
120/208V 3 Phase Switch Position
Steps for setting the voltage selector to 120/208V 3-phase output.
277/480V 3 Phase Switch Position
Steps for setting the voltage selector to 277/480V 3-phase output.
120/240 1 Phase Switch Position
Steps for setting the voltage selector to 120/240 1-phase output.
Voltage Selection and Adjustments (G240-G570)
Procedure for selecting and adjusting output voltages for G240 to G570 models.
120/208V 3 Phase Configuration
Details on configuring the 120/208V 3-phase output settings.
277/480V 3 Phase Configuration
Details on configuring the 277/480V 3-phase output settings.
Basic Digital Controls Operation
Operation Buttons Identification
Identification and function of the main operation buttons on the digital controller.
Display Buttons and Status LEDs
Explanation of display buttons and status indicators on the digital controller.
Viewing Real-Time Data
Guide to accessing and viewing real-time operational data on the controller.
Software Version and Lamp Test
Procedure to check software version and test control panel LEDs.
Adjusting LCD Contrast
Procedure for adjusting the contrast of the digital controller's LCD display.
Parameter Adjustments via Keypad
Instructions for navigating and adjusting parameters using the controller keypad.
Setpoint Descriptions
Definitions and explanations of various setpoints for basic generator settings.
Engine Parameters Configuration
Details on configuring engine parameters like start speed, preheat time, and crank limits.
Engine Protection Systems
Overview of engine protection features including shutdown delays and alarm settings.
Alternator Protection Features
Description of alternator protection mechanisms like overload and short circuit detection.
Maintenance Procedures
General Maintenance Information
Overview of periodic servicing and preventive maintenance for maximum output and performance.
Scheduled Maintenance
Information on the maintenance schedule based on normal operating conditions.
Wiring Routing Clamps Checks
Daily checks for loose wire routing clamps, wear, and vibration abrasion.
Electrical Terminals Checks
Daily checks for evidence of arcing around electrical terminals.
Grounding Circuit Checks
Daily checks of the grounding circuit for compliance with electrical codes.
Hose Inspections
Monthly inspection of intake, water, and fuel hoses for wear and damage.
Wiring Insulation Checks
Daily checks for loose or frayed wiring insulation and sleeving.
Fuel/Water Separator Maintenance
Daily checks and periodic replacement of the fuel/water separator element.
Air Vent Cleaning
Daily cleaning of air vents to remove obstructions or debris.
Air Cleaner Servicing
Procedure for servicing air cleaners to ensure maximum protection against dust.
Fastener Torque Specifications
Torque values for various fasteners, including metric and inch charts.
Tire Inspection and Maintenance
Weekly checks of tire condition and air pressure.
Engine Radiator Checks
Procedure for checking the engine coolant level and inspecting the radiator.
Diagnostic Lamp Testing
Monthly testing of diagnostic lamps to ensure proper function.
Emergency Stop Switch Operation Check
Monthly check of the emergency stop switch functionality.
Engine Protection Shutdown System Testing
Testing the engine protection shutdown system for proper operation.
High Containment Fluid Alarm System Check
Periodic checks of the high containment fluid alarm system.
Adjustment and Testing Procedures
Accessing Compartments
Instructions for safely accessing generator compartments for maintenance.
Voltage Regulator Adjustment
Detailed steps for adjusting the voltage regulator for proper output.
Overcurrent Relay Adjustment
Procedure for adjusting the overcurrent relay settings based on KVa.
Power Bypass Switch for ECU Service
Information on using the power bypass switch for engine ECU diagnostics.
Preventive Maintenance Schedule
Schedule outlining daily, weekly, monthly, and hourly maintenance tasks.
Alternator Installation and Maintenance
Leroy Somer Alternator Model Information
Details about Leroy Somer alternator models and their compliance with standards.
Alternator Safety Measures
Essential safety precautions for handling and servicing the alternator.
Alternator Identification Plate
Information on identifying the alternator model using its nameplate.
Voltage Regulation - AREP System
Explanation of the AREP excitation system and R438/R448 AVR voltage regulation.
R 438 or R448 Regulator Specifications
Technical specifications and protection features of the R438/R448 regulators.
LAM Characteristics and Operation
Explanation of the Load Adjustment Module (LAM) function and its effects.
Installation and Commissioning
Procedures for installing and commissioning the generator set.
Assembly and Handling
Guidelines for assembling and safely handling the generator set.
Coupling Alternator to Prime Mover
Steps for correctly coupling the alternator to the prime mover.
Inspection Prior to First Use
Essential electrical checks to perform before the initial operation of the alternator.
R438 Adjustments (AREP System)
Detailed adjustment procedures for the R438 AVR in AREP systems.
Servicing and Maintenance
Procedures for servicing and maintaining the alternator and generator components.
Safety Measures for Servicing
Crucial safety precautions to follow during servicing and troubleshooting operations.
Mechanical Defects and Troubleshooting
Common mechanical defects, their causes, and recommended actions.
Electrical Faults and Causes
Troubleshooting common electrical faults in the alternator and their causes.
Winding Insulation Check
Procedure for checking winding insulation using a high voltage test.
Diode Bridge Check
Procedure for checking the functionality of the alternator's diode bridge.
Alternator Electrical Characteristics Table
Table of electrical characteristics for alternators, including resistances and excitation currents.
Alternator Exploded Views
Diagrams showing exploded views of alternator components with part numbers.
Revision History
Record of revisions made to the manual over time.
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