Doosan G10WMI-2D-T2 Instruction manual

Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 22637300 (8-2-2010) Rev H
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.
OPERATION, MAINTENANCE
GENERATOR MODELS
MANUAL
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)
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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3
TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
DRAWBAR NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HAZARDOUS SUBSTANCE PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Unit Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Consumables Service Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Consumable Service Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Expendable Service Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BEFORE TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SETTING UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
STARTING (AUTOSTART MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
STOPPING (AUTOSTART MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOTE STARTING AND STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIAGNOSTICS/AUTO SHUTDOWN (AUTOSTART MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE CONTROLS and INSTRUMENTS (AUTOSTART MODELS) . . . . . . . . . . . . . . . . . . . . . . 35
CUSTOMER - DIAGNOSTIC GAUGE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STARTING (KEY START MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STOPPING (KEYSTART MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSTICS and AUTO SHUTDOWN (KEYSTART MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . 40
ENGINE CONTROLS and INSTRUMENTS (Keystart Models) . . . . . . . . . . . . . . . . . . . . . . . . . 41
GENERATOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MONITOR SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CIRCUIT BREAKERS - Flip to Reset (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
RECEPTACLES (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PROTECTION/REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
VOLTAGE SELECTION/ADJUSTMENTS G25 thru G185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SWITCH POSITION - 120/208V 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SWITCH POSITION - 277/480V 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SWITCH POSITION - 120/240 1Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
VOLTAGE SELECTION/ADJUSTMENTS G240 thru G570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
120/208V 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
277/480V 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
BASIC DIGITAL CONTROLS OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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TABLE OF CONTENTS
Operation & Maintenance Manual
TITLE PAGE
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ADJUSTMENT INSTRUCTIONS and TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ACCESSING COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
VOLTAGE REGULATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OVERCURRENT RELAY ADJUSTMENT (Set Dial on the OCR Relay) . . . . . . . . . . . . . . . . . . . . . 72
POWER BYPASS SWITCH FOR ENGINE ECU SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PACKAGE PREVENTIVE MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ALTERNATOR INSTALLATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 75
SAFETY MEASURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION - COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SERVICING-MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
TECHNICAL CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

22637300 5
Drawbar Notice

Operation & Maintenance Manual Drawbar Notice
622637300
Drawbar Notice
This machine may have been shipped from the factory with the drawbar positioned upright. To
convert from shipping position to towing position, the following tools are required:
Tool Required:
Ratchet, 24mm socket and an 18mm socket to fit ratchet
Torque wrench set to 166 ft-lbs (226 Nm) and 67 ft-lbs. (91 Nm)
24mm socket and an 18mm socket to fit torque wrench
Hardware included: (1) 16mm nut, (2) Washers, (2) Safety Chains
1. Remove hardware box from generator.
2. Open box and remove the bag containing hardware, safety chains and assembly
instructions.
3. Using the jack, raise the front of the unit so that the end of the drawbar is
approximately 1 inch above the ground.
4. While holding the drawbar, carefully remove the temporary retaining bolt that holds
the drawbar to the top of the enclosure (See Fig. 1).
5. Carefully lower drawbar to the Level Position.
6. Install the bolt (that was removed in Step 4) with the washers and nut from the
included hardware to secure the end of the drawbar underneath the unit and torque to
166 ft-lbs (226 Nm). Also torque the drawbar pivot bolt to 166 ft-lbs. (226 Nm). See
Figure 2).
7. Install safety chains by first removing the longest bolt used to attach the hitch then
insert the last link of one chain onto the bolt. Slide one spacer back on the bolt and put
the assembly back into the hitch. Slide the other spacer onto the bolt, then the last link
of the other safety chain washer. Tighten the nut to 67 ft-lbs (91 Nm).

22637300 7
Safety Symbols

Operation & Maintenance Manual Safety Symbols
822637300
Symbols below point out potential safety hazards and provide important information about this
machine. Read and understand. Heed warnings and follow instructions. If you do not
understand, inform your supervisor.
Prohibition/ Mandatory Information/Instructions WARNING
WARNING - Read the
operator’s manual before
operating this machine.
WARNING - Do not open
radiator until radiator is
cool and pressure is
relieved.
WARNING - Read the
operator’s manual before
towing machine.

Safety Symbols Operation & Maintenance Manual
22637300 9
WARNING - Diesel fuel is
flammable. No open
flames or sparks.
WARNING - Battery
contains acid. Gases are
flammable. No open
flames or sparks.
WARNING - Do not
perform maintenance until
all electrical power has
been disconnected.
WARNING - Rotating fan. 65 MPH maximum towing speed.

Operation & Maintenance Manual Safety Symbols
10 22637300
Safety Symbols
Look for these signs on machines manufactured in North America, which point out
potential hazards to the safety of you and others. Read and understand thoroughly.
Heed warnings and follow instructions. If you do not understand, inform your
supervisor.
Safety Decals area available free of charge.
Safety decals are identified by the decal heading:
DANGER, WARNING or CAUTION
Decal part numbers are on the bottom of each decal and are listed
in the parts manual. Help promote product safety! Assure that
decals are present on the machines. Replace decals that are not
legible.

Safety Symbols Operation & Maintenance Manual
22637300 11

12 22637300
Always use genuine replacement parts!

22637300 13
Safety

Operation & Maintenance Manual Safety
14 22637300
Safety
DANGER
!
This machine is not designed for operating life-sustaining equipment. It
is equipped with a safety shutdown system that will cause the machine to
stop operating whenever a shutdown condition is present.
DANGER
!
Never operate the engine of this machine inside a building without
adequate ventilation. Avoid breathing exhaust fumes when working on
on near the machine.
WARNING
!
A battery contains sulfuric acid and can give off gases which are
corrosive and potentially explosive. Avoid contact with skin, eyes, and
clothing. In case of contact, flush area immediately with water.
WARNING
!
Improper operation of this equipment can cause severe injury or death.
Read Operator’s Manual supplied with this machine before operation or
service.
Modification or alteration of this machine CAN result in severe injury or
death. Do not alter or modify this machine without the express written
consent of the manufacturer.

Safety Operation & Maintenance Manual
22637300 15
CAUTION
!
Exercise extreme caution when using booster battery. To jump battery,
connect ends of one booster cable to the positive (+) terminal of each
battery. Connect one end of other cable to the negative (-) terminal of the
bosster battery and other end to a ground connection away from dead
battery (to avoid a spark occurring near any explosive gases that may be
present). After starting unit, always disconnect cables in reverse order.
WARNING
!
Never inspect or service unit without first disconnecting battery cable(s)
to prevent accidental starting.
Wear eye protection while cleaning unit with compressed air, to prevent
debris from injuring eyes.
WARNING
!
HOT PRESSURIZED FLUID - Remove cap slowly to relieve PRESSURE
from HOT radiator. Protect skin and eyes. HOT water or steam and
chemical additives can cause serious personal injury.

Operation & Maintenance Manual Safety
16 22637300
WARNING
!
Flammable Fuels - Do not fill tank when engine is running.
Do not smoke or use an open flame in the vicinity of the generator set or
fuel tank.
Do not permit smoking, open flame, or sparks to occur near the battery,
fuel, cleaning solvents or other flammable substances and explosive
gases.
Do not operate Genset if fuel has been spilled inside or near the unit.
WARNING
!
Electrical Shock -
Do not operate electrical equipment while standing in water, on wet
ground or with wet hands or shoes.
Use extreme caution when working on electrical components. Battery
voltage (12V/24V DC) is present unless the battery cables have been
disconnected. Higher voltage (potentially 480V) is possibly present at all
times.
WARNING
!
Always treat electrical circuits as if they were energized.
Disable Start Control before attempting any repair service, disconnect all
leads to electrical power requirements and disconnect battery to prevent
start up.
GROUNDING
Depending upon your application, it may be MANDATORY to ground this unit to earth or to
NOT ground this unit to earth. Comply with local electrical codes and Operation Manual.

Safety Operation & Maintenance Manual
22637300 17
WARNING
!
The Generator Set can produce high voltages, which can cause severe
injury or death to personnel and damage to equipment. The Generator Set
should have proper internal and external ground when required by the
National Electric Code.
The Generator Set is internally grounded neutral to the frame of the
Generator Set. This internal ground connection is essential for proper
Generator Set performance and personal protection.
External grounding consists of connecting the generator neutral to a
solid earth ground, and is the responsibility of the operator, when
grounding is required by National Electrical Code, Article 250, and other
local codes as applicable. Several methods are employed to externally
ground portable generator sets, depending on the intended use and code
requirements. In all cases, a continuous length of splice-free copper
cable, no smaller than AWG#8, shall be used for the external ground
conductor, when grounding is required.
A qualified, licensed electrical contractor, knowledgeable in local codes,
should be consulted.
The Generator Set has two main applications:
(1) If the Generator Set is supplying electrical power to portable equipment, the vehicle frame
shall NOT be grounded to earth per National Electrical Code, Article 250-34(b). All other
provisions of the Article shall be complied with.
(2) If the Generator Set is connected to a temporary or fixed distribution system (such as a
building), grounding of the vehicle frame is required at the service entrance to the building, per
National Electrical Code, Article 250-20 (b).
If the Generator Set is supplying power to more than one temporary or fixed wiring system, a
separate ground cable must be connected from the generator neutral to each distribution
systems ground as detailed above.
WARNING
!
Failure to properly ground the Generator Set can result in severe injury
or death.
IF USED AS ALTERNATE POWER SUPPLY
Connect only after the main service entrance switch has been DISCONNECTED and
LOCKED OPEN. In addition, circuit overload protection must be provided in accordance with
National Electrical Codes and local regulations.

Operation & Maintenance Manual Safety
18 22637300
WARNING
!
TOWING -
Do not tow this unit in excess of 65 mph (104 km/hr).
Do not tow this unit with a vehicle whose towing capacity is less than the
gross vehicle weight.
Steps for determining correct load limit -
1. Locate the statement “The weight of cargo should never exceed
xxx kg or xxx lbs” on your vehicle’s placard.
2. This figure equals the available amount of cargo and luggage load
capacity.
3. Determine the combined weight of luggage and cargo being loaded
on the vehicle. That weight may not safely exceed the available cargo
and luggage load capacity.
Always make sure the wheels, tires and towbar connectors are in safe
operating condition and tow bar is properly connected before towing.
Chock the wheels of the unit when it is not connected to the tow vehicle.
Do not store or transport material or equipment in or on the unit.
WARNING
!
Drawbar/Hitch Hookup -
Safety chains must be crossed under drawbar and attached to towing
vehicle to prevent drawbar from dropping to ground in event of coupling
failure.

Safety Operation & Maintenance Manual
22637300 19
WARNING
!
If the drawbar is removed from this machine, use new OEM fasteners,
thread locking compound and torque per the tables included in this
manual, when re-installing the drawbar.
WARNING
!
Voltage Selection - Do not turn Voltage Selector Switch while engine is
running. Voltage selection, adjustment and electrical connections shall
be performed only by qualified personnel.
CAUTION
!
Welding -
Prior to any welding, disconnect alternator relays, diagnostic circuit
board, voltage regulator circuit board, meters, circuit breakers and
battery cables. Open all circuit breakers, and remove any external
connections (except grounding rod). Connect the welding ground as
close as possible to the area being welded.
WARNING
!
Electrical Loading -
Never make electrical connections with the unit running.
Before placing the unit in operation, verify the electrical rating of the
Generator Set and do not exceed generator set ratings.

Operation & Maintenance Manual Safety
20 22637300
CAUTION
!
Use extreme care to avoid contacting hot surfaces (engine exhaust
manifold and piping).
HAZARDOUS SUBSTANCE PRECAUTION
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.
Avoid ingestion, skin contact and breathing fumes for the following substances: Antifreeze,
Engine Lubricating Oil, Preservative Grease, Rust Preventative, Diesel Fuel and Battery
Electrolyte.
The following substances may be produced during the operation of this machine and may be
hazardous to health:
• Avoid build-up of engine exhaust fumes in confined spaces.
• Avoid breathing exhaust fumes.
• Avoid breathing brake lining dust during maintenance.
• Always operate in a well ventilated area.