Ghaddar Machinery Co. Training Manual Online

TRAINING MANUAL

ENGINE & NON-ENGINE COURSES

Contacts: Mohammed Shaat – Trainer
Oussama Ghaddar – Trainer
Contact Information
Ghaddar Machinery Co. Headquarters
Ghazieh, Sidon, Lebanon
Phone: +961 7 220 000 Fax: +961 7 223 322
P.O. Box: 110 Sidon
Email: [email protected]

www.ghaddar.com
Outline Engine Training Courses
Introduction 6
Training Center Overview 6
Course Description 7
Kubota Series 8
John Deere Series 10
Cummin Series 12
Installations & Applications 16
Non-Engine Training Courses

Engine-Related Training Courses 19
Alternator Training Courses 20
Genset Control Training Courses 21
Hybrid / Solar Training Courses 22
Sales Training Courses 23
Training logistics 24
General Conditions for enrolment 24
Registration Form 25
ENGINE TRAINING COURSES
3
Introduction
Ghaddar Machinery Co. is a multi-territorial Appointed
Distributor for Kubota and John Deere engines and Leroy
Somer alternators and Authorized Cummins G-Drive engines
GOEM. The company focuses on the distribution of Engines
and their applications, in addition to spare parts and Service.
Ghaddar Machinery Co. builds on a 40 years’ experience in distribution, marketing and technical
support of engines in the sectors of Electrical Power and Industrial applications.
Training Center Overview
Ghaddar Machinery Co. Trainers are all Certified and they enjoy a strong experience in training and
technical capability that proved successful to many trainees and their companies by adding a lot to
their experience in troubleshooting and repairing these engines.
Ghaddar Machinery Co. training Center offers the ultimate environment for effective training. It makes
available for the trainees a wide range of training equipment and constantly updated course material
specially prepared to suit their specific training needs.
4
Course Description
Title Duration Pre-requisite
KUBOTA 05 & 03 Series 1 day
KUBOTA V3 Series 1 day
JOHN DEERE PowerTech M 1 day
JOHN DEERE PowerTech E 1 day Electronically Controlled Engines
Cummins QSX15 (CM570) 2 days Electronically Controlled Engines
Cummins QSK23 (CM500) 2 days Electronically Controlled Engines
Cummins QST30 (Genset) 2 days Electronically Controlled Engines
Cummins KTA19/38/50 2 days
Installation & Application Kubota & 1 day

John Deere Powered Genset
Installation & Application 1day
Cummins Powered Genset
1- Welcome Note & Acquaintance

Program 2- Agenda & Domestics
3- Course objective
4- Brief Description for the Company
5- Various generator ranges
6- Theoretical sessions
7- Practical implementation
8- Evaluation of acquired knowledge
9- Evaluation of the training Course
5
KUBOTA 05 & 03 Series
Course Overview
An instructor-Led training course, with engine dismantling
and assembly. It is designed to give an insight into the
features and mechanical aspects of Kubota mechanical
engines (05 & 03 series) that are used for power generation.
The course is aimed at those within a technical role of
engines. Fresh mechanical engineers and technicians
can attend the course.
Pre-requisite
Persons with a sound diesel engine background, wishing to attain knowledge of KUBOTA
engines models 05 & 03, Mechanical range.
Course Objectives
• The course aim is to provide an excellent understanding of Kubota
mechanical engines (05 & 03 series).
At the end of the course the delegates will be able to:

• Understand Kubota Mechanical range
• Understand engine model and serial number
• FABs: Features, Advantages and Benefits.
• Use information in Kubota Manuals
• Dismantle and re-assemble the engine
• Fuel pump settings
• Understand engine service requirements
• Technical presentation
• Use of Kubota manual
• Engine service bulletins
Target Engines Course Duration Course Location
Mechanical range of Our Training facility in Lebanon

1 Day
05 & 03 Series
6
KUBOTA V3 Series
Course Overview
features and mechanical aspects of Kubota mechanical
engines (V3 series) that are used for power generation.
Pre-requisite
Persons with a sound diesel engine background, wishing to attain knowledge of KUBOTA
engines V3 series, Mechanical range.
Course Objectives
• The course aim is to provide an excellent understanding of Kubota
mechanical engines (V3 series).

• Understand Kubota Mechanical range
• Use information in Kubota Manuals
• Fuel pump settings
• Use of Kubota manual
• E-Gov installation

1 Day
V3 Series
7
JOHN DEERE PowerTech M
Course Overview
features and mechanical aspects of John Deere
mechanical engines that are used for power generation.
Pre-requisite
Persons with a sound diesel engine background, wishing to attain knowledge of John
Deere PowerTech M, Mechanical range.
Course Objectives
• The course aim is to provide an excellent understanding of John
Deere PowerTech M, Mechanical range.

• Understand Powertech M range: 2.9L, 4.5L & 6.8L
• Use information in John Deere Manuals
• Use of CTM manual
• Understand PowerAssist mobile application

1 Day
2.9L, 4.5L & 6.8L
8
JOHN DEERE PowerTech E
Course Overview
andassembly. It is designed to give an insight into the
features and Electronic aspects of John Deere
mechanical engines that are used for power generation.
Pre-requisite
Persons with a sound diesel engine background, besides to using laptop software, electrical
wiring schematic and using multi-meter tool.
Course Objectives
• The course aim is to provide an excellent understanding of John
Deere PowerTech E, Electronic range.

• Understand Powertech E range: 6068 & 6090
• Use information in John Deere Manual
• Understand engine ECU wiring: Engine Side
• Understand engine ECU wiring: OEM Side
• Use multi-meter for trouble-shooting
• Understand DTC to diagnose faults
• ECU connections with Genset Controllers
• Understand PowerAssist mobile application
• Usage of Service advisor software in engine service
Electronic range of Our Training facility in Lebanon

1 Day
6.8L & 9.0L
9
Cummins QSX15 (CM570)
Course Overview
features and Electronic aspects of Cummins QSX15 that
is equipped with HPITP injectors and controlled by CM570
ECU, that is applied in power generation.
Pre-requisite
“Cummins electronic engines and Insite software” course is needed to attend QSX15
(CM570) training course.
Course Objectives
• The course aim is to provide an excellent understanding of Cummins
G-Drive engine, QSX15 (CM570).

• Understand Cummins range
• Understand engine circuits: Cooling, induction, fuel and lubrication
• Engine FABs: Features, Advantages and Benefits.
• Use information in Cummins related Manual
• Understand Quickserve mobile application
• Usage of INSITE software tool in engine service
Cummins G-Drive Our Training facility in Lebanon

2 Days
QSX15 (CM570)
10
Cummins QSK23 (CM500)
Course Overview
This course will allow participants to recognize the QSK23
engines, their components flow paths and operation
procedures. Use of the correct rebuild procedures with
reference to the QSK23 Manuals. Outline the QSK23
operation and maintenance schedules. A Thorough
understanding of the HPI Fuel system. Use of the INSITE
software tool.
Pre-requisite
“Cummins electronic engines and Insite software” course is needed to attend QSK23
(CM500) training course.
Course Objectives
• The course aim is to provide an excellent understanding of Cummins
G-Drive engine, QST30 (Genset)

• Usage of INSITE software in engine service

2 Days
QST30 Genset
11
Cummins QST30 (Genset)
Course Overview
This course will ensure participants have a good working
knowledge of the structure and operation of the QST30
engine and its components. Emphasis will be placed on the
fuel system and the the electronic management system.
Once qualified the participants will be able to confidently
troubleshoot the mechanical and electronic QST30
systems using the INSITE diagnostic tool.
Pre-requisite
“Cummins electronic engines and Insite software” course is needed to attend
QST30 training course.
Course Objectives
The course aim is to provide an excellent understanding of Cummins
G-Drive engine, QST30 (Genset)

• Usage of INSITE software in engine service

2 Days
QST30 Genset
12
Cummins KTA19/38/50
Course Overview
This course will ensure participants are able to recognise
the K19/38/50 engine, its components, system flow paths,
operation procedures, correct rebuild practices with
reference to the shop manual and attention to the correct
troubleshooting, repair and maintenance procedures.
Pre-requisite
External customers, experienced technicians and technicians with little experience in diesel
engines, technicians with experience on other engines and new to Cummins
Course Objectives
• The participants at the end of the training will be able to confidently
identify all aspects of the K19/38/50 engine, including engine systems,
engine rebuild procedures according to QSOL and the PT fuel system.
At the end of the course the delegates will be able to understand:

• Cummins G_drive range of engines
• Engine Systems, Features and components
• Engine Teardown including, cylinder head and top set, piston and liner
and timing case and gear train R & R.
• PT fuel system, injector cam timing and fuel pump and injector R&R
• Fault finding and diagnostic
• Use information in QSOL to build the engine
Cummins Our Training facility in Lebanon

2 Days
KTA19/38/50
13
Installation & Application Kubota & John Deere Powered Genset
Course Overview
the requirements of Diesel generating sets to be installed
properly as per manufacturer recommendations and
stipulations. It will assist the operator to select the proper
consumables as Fuel, lubricants and coolants. It provides
solutions for special applications as installation on roof, or
when ambient temp is very low and others.
Pre-requisite
This course is suitable for anybody that will work or deal with Diesel generating sets, just
needs minimum knowledge about diesel engines.
Course Objectives
The participants at the end of the training will be able to confidently
identify the application requirements of all GHADDAR Kubota and John
Deere powered gensets, including fuel tanks & plumping, ventilations
and induction, exhaust system and other engine systems.

• The suitable mounting system
• Fuel specs, fuel tanks and fuel plumping.
• Coolant selection and recommendations
• Lubricating oil system
• Ventilation requirements
• Exhaust system installation and
• Special installation
• Genset accessories and their installation
Application Course Our Training facility in Lebanon

1 Day
Kubota & John Deere
14
Installation & Application Cummins Powered Genset
Course Overview
the requirements of Diesel generating sets to be installed
properly as per manufacturer recommendations and
stipulations. It will assist the operator to select the
proper consumables as Fuel, lubricants and coolants. It
provides solutions for special applications as installation
on roof, or when ambient temp is very low and others.
Pre-requisite
This course is suitable for anybody that will work or deal with Diesel generating sets, just needs
min knowledge about diesel engines.
Course Objectives
The participants at the end of the training will be able to confidently
identify the application requirements of all GHADDAR Cummins
powered gensets, including fuel tanks & plumping, ventilations and
induction, exhaust system and other engine systems.

• The suitable mounting system
• Fuel specs, fuel tanks and fuel plumping.
• Coolant selection and recommendations
• Lubricating oil system
• Ventilation requirements
• Exhaust system installation and
• Special installation
• Genset accessories and their installation
Application Course Our Training facility in Lebanon

1 Day
Cummins G-Drive
15
NON-ENGINE TRAINING COURSES
16
Engine Related Training Courses
Code Course Name Trainer Language Duration
This course covers all general requirements

TE1 Installation of Diesel 1 Day to install generating sets, this includes
M. Shaat English/Arabic mounting, vibration, Cooling, fuel, Lube
Generating sets
oil, ventilation, noise, exhaust and others.
This course covers the dismantling,
assembly and service Delphi DP fuel
TE2 Delphi DP Fuel O. Ghaddar English/Arabic 1/2 Day injection pump that is fitted to John Deere
Injection pump 3029 & 4045 series and Perkins 1100
Mech engines.
This course delivers the practical experience

PM program
TE3 (customer to specify 1 Day to achieve the routine maintenance of
O. Ghaddar English/Arabic engine as stipulated and recommended
the target engines)
by engine manufacturers.
17
Alternator Training Courses
Code Course Name Trainer Language Duration Description
This course covers all types of Leroy

Leroy Somer Somer excitation systems with related
TA1 Alternator Excitation M. Shaat English/Arabic 1/2 Day AVRs, along with needed routine service.
Systems & AVRs
This course delivers the practical experience

to achieve the routine maintenance of
TA2 Alternator PM M. Shaat English/Arabic 1/2 Day
alternator as stipulated and
recommended by LS.
This course delivers the details of new range,

TA3 TAL Range M. Shaat English/Arabic 1/2 Day types, AVRs, advantages, standard and
optional scope.
This course covers all techniques and

TA4 Alternator M. Shaat English/Arabic 1 Day methodologies to diagnose alternator
troubleshooting electrical and mechanical faults.
This course covers all requirements to select

alternator for all kind of applications, this
TA5 Alternator Selection M. Shaat English/Arabic 1 Day includes big starting, transformer, pump,
harmonics, UPS, enclosure IP, single/double
bearings, parallel operation and others.
This course covers all requirements to select
and install Medium voltage alternators,
TA6 Medium Voltage M. Shaat English/Arabic 1 Day including coupling type, bearing types,
Alternator cooling, temperature protection, VTs,
CTs and Earthing.
18
Genset Control Training Courses
This course covers overview of all DSE

DEEPSEA Controller
(depending on controllers, with focus on tech specs,
TC1 M. Shaat English/Arabic 1 Day wiring and programming of gensets
customer request)
DSE6xxx, DSE7xxx controlled by a specified DSE controllers
(DSE6xxx or DSE7xxx).
This course covers connection and

DSE configuration programming of DSE controllers using
TC2 M. Shaat English/Arabic 1 Day DSE config suite (customer needs to
suite software
specify DSE6xxx or DSE7xxx).
This course covers the different methods

Remote monitoring
of DSE Controllers to monitor DSE controllers remotely, using
TC3 M. Shaat English/Arabic 1 Day DSE SACAD System through DSE8005,
SCADA+
WEBNET+GSM DSE8003, DSE890/1 or GSM modems.
This course covers basic requirements of synchronizing

Parallel Operation and load sharing gensets, this includes between gen-
TC4 of Diesel Gensets M. Shaat English/Arabic 2 Days sets and also with Mains. The course covers how to
(based on DSE8xxx) implement the rules using DSE8xxx controllers. Some
special applications will be discussed.
This course covers basic requirements of
Parallel Operation synchronizing and load sharing gensets,
TC5 of Diesel Gensets M. Shaat English/Arabic 2 Days this includes between gensets and also with
(based on Woodward Mains. The course covers how to implement
EGCP controller) the rules using Woodward EGPG controller.
This course covers tech specs, wiring and

programming of gensets controlled by
TC6 ComAp GMP203-C M. Shaat English/Arabic 1 Day ComAp controllers
(namely ComAp IL-NT).
This course delivers skills as building

electric circuit, understand wiring diagram,
TC7 Electrical Wiring M. Shaat English/Arabic 1 Day
troubleshooting evaluate wiring quality and troubleshoot
electrical faults.
This course covers selection of power cables

TC8 Power Cable M. Shaat English/Arabic 1/2 Day
selection according to tech specs, installation and
electrical requirements.
19
Hybrid / Solar Training Courses
PV–Diesel– This course covers the basics of solar

TH1 Grid Solution M. Shaat English/Arabic 1 Day PV power for residential and industrial
(On Grid) applications, and needed data to design
profitable solution.
Hybrid DC VSG This course covers the basics and

Solution for Telecom benefits of various types of DC Hybrid
TH2 application M. Shaat English/Arabic 1 Day solution for telecom applications. It
VSG: Variable covers also the expected revenue of
Speed Genset Hybrid solution with Solar power.
20
Sales Training Courses
This course covers basics of gensets,

Prime – Standby – Baseload ratings
TS1 Genset Sizing M. Shaat English/Arabic 1 Day Meaning of KVA-KW-KVAR and PF
Handling special cases: Pump,
transformer, UPS, LE Lighting.
This course covers the huge capability of

TS2 Kubota Range M. Shaat English/Arabic 1/2 Hour Kubota range, for all types of diesel and gas
engines, with different ignition systems. This
besides to engine advantages
GHADDAR This course covers advantages of

“Kubota powered” M. Shaat English/Arabic
TS3 gensets for Telecom 1/2 Hour applying Kubota powered gensets in
application Telecom application.
This course covers the great capability of

TS4 John Deere Range M. Shaat English/Arabic 1/2 Hour John Deere range, for all types of
diesel engines.
This course covers the great capability

TS5 Cummins Range M. Shaat English/Arabic 1/2 Hour of Cummins range, and their application
in different markets
21
Training Logistics
• Number of participants: 4 to 8 trainees.
• Customized collection of courses can be done for at least 5 trainees
(Pre-requisites and durations are fixed)
• Training fee will include besides to training course, issuance of
certificate, training literature, usage of training equipment in addition
to lunch meal & refreshers. It excludes charges for visa, tickets, hotel,
transportation, medications and others.
• CD containing Presentation Material (Optional).
• Payment should be settled upon receipt of invoice
• Our secretarial services can be put at your disposal to help you book
Hotel rooms, however, accommodation and transportation charges
remain at the expense of the participants.
General Conditions for Enrolment

How to Register
Please send your enquiry by mail or by Fax.
Phone: +961 (0) 7 220 000
Fax: + 961(0) 7 223 322
e-mail: [email protected]
Cancellation of registration
Any cancellation must be notified at least 14 days prior to the start of
the course. Ghaddar Machinery Co. Training reserves the right to can-
cel or reschedule the course in case of “Force Majeur” or any reason
that is out of our control.
Practical information
Upon registration, an agreement and a training program will be sent.
Registration will be confirmed upon receipt of the training agreement
signed. An attendance certificate will be attached to the invoice
Training Venue
Training is given at Ghaddar Machinery Co. training facility in Ghaddar
Machinery Co. Head office- Sidon-Lebanon.
22
Registration Form
Company
Training Booked By:
E-mail:
Name:
Title:
Telephone Number*:
Fax No :
Organization Name:
Course Details
Prerequisites must be met prior to enrolment on product specific courses. This enrolment
request will be declined if prerequisites have not been completed.
Course*:
Course Dates (week beginning):
Delegate Information
Delegate 1*:
Delegate 2:
Delegate 3:
Delegate 4:
Budget and Acceptance

Ghaddar Machinery Co. assumes no responsibility for any costs incurred for accommodation
and sustenance. All hotel costs are to be settled by the delegate prior to departure.
Name & Signature
23
Please send your enquiry by mail or by Fax.
Phone: +961 (0) 7 220 000
Fax: + 961(0) 7 223 322
e-mail: [email protected]
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downloaded from http://www.ghaddar.com
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TRAINING MANUAL

ENGINE & NON-ENGINE COURSES

Training Center Overview 6

John Deere Series 10

Installations & Applications 16

Non-Engine Training Courses

Alternator Training Courses 20

Genset Control Training Courses 21

Hybrid / Solar Training Courses 22

Sales Training Courses 23

General Conditions for enrolment 24

Training Center Overview

Title Duration Pre-requisite

KUBOTA 05 & 03 Series 1 day

KUBOTA V3 Series 1 day

JOHN DEERE PowerTech M 1 day

JOHN DEERE PowerTech E 1 day Electronically Controlled Engines

Cummins QSX15 (CM570) 2 days Electronically Controlled Engines

Cummins QSK23 (CM500) 2 days Electronically Controlled Engines

Cummins QST30 (Genset) 2 days Electronically Controlled Engines

Cummins KTA19/38/50 2 days

Installation & Application Kubota & 1 day

1- Welcome Note & Acquaintance

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Mechanical range of Our Training facility in Lebanon

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Mechanical range of Our Training facility in Lebanon

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Mechanical range of Our Training facility in Lebanon

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Electronic range of Our Training facility in Lebanon

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Cummins G-Drive Our Training facility in Lebanon

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Cummins G-Drive Our Training facility in Lebanon

At the end of the course the delegates will be able to:

Target Engines Course Duration Course Location

Cummins G-Drive Our Training facility in Lebanon

At the end of the course the delegates will be able to understand:

Target Engines Course Duration Course Location

Cummins Our Training facility in Lebanon

At the end of the course the delegates will be able to understand:

Target Engines Course Duration Course Location

Application Course Our Training facility in Lebanon

At the end of the course the delegates will be able to understand:

Target Engines Course Duration Course Location

Application Course Our Training facility in Lebanon

Code Course Name Trainer Language Duration

This course covers all general requirements

This course delivers the practical experience

Code Course Name Trainer Language Duration Description

This course covers all types of Leroy

This course delivers the practical experience