Doosan G400-SIIIA Manual

This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
46687871_en_B_03/16
G400/500-SIIIA
OPERATION & MAINTENANCE MANUAL
Original Instruction
G400-SIIIA SERIAL No : G40030001 ->
G500-SIIIA SERIAL No : G50030001 ->

3 G400, 500-SIIIA OM Manual
CONTENTS
FOREWORD............................................................................................................................................ 5
GENERAL DATA .................................................................................................................................... 11
SAFETY ................................................................................................................................................. 13
OPERATING INSTRUCTIONS .............................................................................................................. 21
MAINTENANCE .....................................................................................................................................37
ALTERNATOR INSTALLATION & MAINTENANCE ...............................................................................77
REFERENCE INFORMATION
Write the correct information for YOUR DIPP generator in the spaces below. Always use these numbers when
referring to your DIPP generator.
Doosan Benelux SA
Drève Richelle 167
B-1410 Waterloo
BELGIUM
Generator Serial Number
Engine Serial Number
NOTES:
YOUR DIPP DEALER:
ADDRESS:
PHONE:

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5 G400, 500-SIIIA OM Manual
FOREWORD
CONTENTS
FOREWORD ........................................................................................................................................... 6
DECLARATION OF CONFORMITY ........................................................................................................ 7

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FOREWORD
The contents of this manual are considered to be
proprietary and confidential to and should not be
reproduced without the prior written permission of the
company.
Nothing contained in this document is intended to extend
any promise, warranty or representation, expressed or
implied, regarding the products described herein. Any
such warranties or other terms and conditions of sale of
products shall be in accordance with the standard terms
and conditions of sale for such products, which are
available upon request.
This manual contains instructions and technical data to
cover all routine operation and scheduled maintenance
tasks by operation & maintenance staff. Major overhauls
are outside the scope of this manual and should be
referred to an authorised service department.
The design specification of this machine has been
certified as complying with EC directives. As a result:
a) Any machine modifications are strictly prohibited, and
will invalidate EC certification.
The use of repair parts / lubricants / fluids other than
those included within the approved parts list may create
hazardous conditions over which the company has no
control. Therefore the company cannot be held
responsible for equipment in which non-approved repair
parts are installed.
The company reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.
The intended uses of this machine are outlined below
and examples of unapproved usage are also given,
however the company cannot anticipate every application
or work situation that may arise.
IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for use
only in the following specified conditions and
applications:
•Operation within the ambient temperature range
specified in the GENERAL INFORMATION section of
this manual.
The use of the machine in any of the situation types
listed in table 1:
a) Is not approved,
b) May impair the safety of users and other persons,
and
c) May prejudice any claims made against the
company.
The company accepts no responsibility for errors in
translation of this manual from the original English
version.
© COPYRIGHT 2015
DOOSAN COMPANY
TABLE 1
Use of the machine outside the ambient temperature
range specified in the GENERAL INFORMATION
SECTION of this manual.
This machine is not intended and must not be used
in potentially explosive atmospheres, including
situations where flammable gases or vapours may
be present.
Use of the machine fitted with non approved
components / lubricants / fluids.
Use of the machine with safety or control
components missing or disabled.
Use of the machine for storage or transportation of
materials inside or on the enclosure except when
contained within the toolbox.
GENERATOR
Use of the generator to supply load(s) greater than
those specified.
Use of unsafe or unserviceable electrical equipment
connected to the generator.
Use of electrical equipment: (a) Having incorrect
voltage and / or frequency ratings. (b) Containing
computer equipment and / or similar electronics.

7 G400, 500-SIIIA OM Manual
DECLARATION OF CONFORMITY
SAMPLE

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9 G400, 500-SIIIA OM Manual

10 G400, 500-SIIIA OM Manual

11 G400, 500-SIIIA OM Manual
GENERAL DATA
CONTENTS
GENERAL DATA.................................................................................................................................... 12
GENERAL INFO .................................................................................................................................... 12
ELECTRICAL DATA ............................................................................................................................... 12

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GENERAL DATA
GENERAL INFO
G400/500 SIIIA INFORMATION ON AIRBORNE NOISE
• The A-weighted emission sound pressure level
TBD
• The A-weighted emission sound power level
TBD
The operating conditions of the machinery are in compliance with ISO 3744:1995 and EN ISO 8528-10:1998.
ELECTRICAL 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) 38 48
Fuel Tank (litres) 1080
(1750 OPTIONAL)
1080
(1750 OPTIONAL)
Radiator & Engine Coolant (litres) 48.5 52
Electrical System 24VDC 24VDC
UNIT MEASUREMENTS / WEIGHTS
Overall length (mm) 4760 4760
Overall width (mm) 1740 1740
Overall height (mm) (12 hours fuel tank) 2340 2340
Overall height (mm) (24 hours fuel tank) 2540 2540
Weight (with fuel) (kg) (12 hours fuel tank) 5984 6400
Weight (without fuel) (kg) (12 hours fuel tank) 5091 5595
Weight (with fuel) (kg) (24 hours fuel tank) 6648 7084
Weight (without fuel) (kg) (24 hours fuel tank) 5274 5780
COG (°) 1.8 1.8
UNIT MODEL G400 G500
Nominal Apparent Power (kVA Prime) 400 500
Nominal Active Power (kW Prime) 320 400
Nominal Voltage 400 400
Nominal Current (PF=1) 462 578
Nominal Current (PF=0,8) 578 725

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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
Transport

14 G400, 500-SIIIA OM Manual
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
manual before operation or
maintenance of this machine is
undertaken.
Diesel fuel
No open flame.
Crush Warning
No Water Coolant Fill Earthing Point

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Warning: Hot Liquid Coolant Drain Engine Oil Drain
Flammable Liquid

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SAFETY INSTRUCTIONS
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.
Never operate the machine inside a building without
adequate ventilation. Avoid breathing exhaust fumes
when working on or 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 the Operation &
Maintenance 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.
WARNING
This machine is equipped with an Auto Start System,
which can cause the machine to start at any time.
Follow all safety recommendations outlined in this
manual to avoid injury to personnel. DISCONNECT
BATTERY BEFORE SERVICING.
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 booster battery and other end to a
earth 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 PRESSURISED 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.
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.

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WARNING
Electrical Shock -
Do not operate electrical equipment while standing in
water, on wet earth 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
energised.
Disable Start Control before attempting any repair
service, disconnect all leads to electrical power
requirements and disconnect battery to prevent start
up.
EARTHING
Comply with applicable electrical codes.
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 earth when
required by IEC 364-4-41.
The Generator Set is internally earthed neutral to the
frame of the Generator Set. This internal earth
connection is essential for proper Generator Set
performance and personal protection.
External earthing consists of connecting the
generator neutral to a solid earth, and is the
responsibility of the operator, when earthing is
required by IEC 364-4-41 Protection Against Electric
Shock, and other local codes as applicable.
Several methods are employed to externally earth
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 10 mm
2
, shall be used for the external
earth conductor, when earthing is required.
A qualified, licensed electrical contractor,
knowledgeable in local codes, should be consulted.
WARNING
Failure to properly earth 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.
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 earthing rod). Connect the
welding earth 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.

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HAZARDOUS SUBSTANCE PRECAUTION
CAUTION
Use extreme care to avoid contacting hot surfaces
(engine exhaust manifold and piping).
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.
GENERAL INFORMATION
Ensure that the operator reads and understands the
decals and consults the manuals before maintenance or
operation.
Ensure that the Operation & Maintenance manual, and
the manual holder, are not removed permanently from
the machine.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
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
machine is not suitable for use in flammable gas risk
areas. If such an application is required then all local
regulations, codes of practice and site rules must be
observed. To ensure that the machine can operate in a
safe and reliable manner, additional equipment such as
gas detection, exhaust spark arresters, and intake (shut-
off) valves may be required, dependant on local
regulations or the degree of risk involved.
A weekly visual check must be made on all fasteners /
fixing screws securing mechanical parts. In particular,
safety-related parts such as coupling hitch, drawbar
components, road-wheels, and lifting bail should be
checked for total security.
All components which are loose, damaged or
unserviceable, must be rectified without delay.
Electricity
The human body has a low tolerance for electricity and is
a very good conductor. Exposure to electrical shock can
results in an interruption of normal heart activity, thermal
burns, severe muscle contractions and even death.
Never operate the generator without all protections in
place. Controller and busbar doors must be closed at any
time during operation.
If life testing is necessary, it should only be performed by
properly trained people.
While testing on life electrical equipment, rubber sole
shoes and adequate rubber gloves must be worn, and all
local regulations must be respected.
Materials
The following substances may be produced during the
operation of this machine:
• engine exhaust fumes
AVOID INHALATION.
Ensure that adequate ventilation of the cooling system
and exhaust gases is maintained at all times.
WARNINGS
Warnings call attention to instructions which must be
followed precisely to avoid injury or death.
CAUTIONS
Cautions call attention to instructions which must be
followed precisely to avoid damaging the product,
process or its surroundings.
NOTES
Notes are used for supplementary information.

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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.
Should engine lubricants or fuel come into contact with
the eyes, then irrigate with water for at least 5 minutes.
Should engine lubricants or fuel come into contact with
the skin, then wash off immediately.
Consult a doctor if large amounts of engine lubricants or
fuel are ingested.
Consult a doctor if engine lubricants or fuel are inhaled.
Never give fluids or induce vomiting if the patient is
unconscious or having convulsions.
Safety data sheets for engine lubricants and fuel should
be obtained from the lubricant supplier.
Battery
Batteries contain corrosive liquid and produce explosive
gas. Do not expose to naked lights. Always wear
personal protective clothing when handling. When
starting the machine from a slave battery ensure that the
correct polarity is observed and that connections are
secure.
DO NOT ATTEMPT TO SLAVE START A FROZEN
BATTERY SINCE THIS MAY CAUSE IT TO EXPLODE.
Radiator
Hot engine coolant and steam can cause injury. Ensure
that the radiator filler cap is removed with due care and
attention.
Transport
When loading or transporting machines ensure that the
specified lifting and tie down points are used.

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