TEKSAN DIESEL GENERATOR SETS Operation And Maintenance Manual Download

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Everlasting Company

EVERLASTING

COMPANY

OPERATION AND MAINTENANCE MANUAL
FOR DIESEL GENERATOR SETS

Summary of Contents for DIESEL GENERATOR SETS

Page 1: ...Everlasting Company EVERLASTING COMPANY OPERATION AND MAINTENANCE MANUAL FOR DIESEL GENERATOR SETS ...

Page 2: ......

Page 3: ...5 years As a standard TEKSAN documentation the Operation and Maintenance Manuals for your Diesel Engine Alternator and Generator Set must have been delivered to you together with your generator set Your duty as our customer is to read understand and remember all information shared in these documents before using your generator set This will help you avoid any possible accidents that may be harmful...

Page 4: ...or Sets 17 2 2 3 Drop Over Canopy Type Generator Sets 18 2 2 4 Mobile Generator Sets 19 2 3 Diesel Engine 20 2 4 Alternator 20 2 5 Fuel Tank 21 2 6 Base Frame 22 2 7 Vibration Isolators 22 2 8 Exhaust System and Silencer 23 2 9 Control Systems 23 3 INSTALLATION 24 3 1 Selecting Room Location 24 3 2 Ground and Platform 25 3 3 Vibration 25 3 4 Cooling and Ventilation 25 3 5 Exhaust System 27 3 6 Fue...

Page 5: ...e Diesel Engine 41 5 3 Maintenance of the Alternator 41 5 4 Lubrication Oil 42 5 5 Coolant 42 5 6 Fuel 43 5 7 Maintenance of Batteries 43 5 8 Maintenance of Radiator 44 5 9 Low Load Operation 45 5 10 Long Term Storage 46 5 11 General Maintenance Schedule 48 6 TROUBLESHOOTING 49 6 1 General 49 7 WARRANTY 52 ...

Page 6: ...es for installation usage and maintenance Any disorder or disobeying about these procedures rules instructions methods or measures in manuals will increase the probability of failure and accidents that may end up with injuries or maybe death Pay attention to all labels and warnings on the generator set Install and operate the generator set fully in conformity with the related standards rules and r...

Page 7: ...ety clips and all of them are connected correctly Be sure to use guide ropes or equivalents in order to prevent any rotation or swing action when the machine is lifted and there is no contact left between the machine and the ground Do not try to lift the generator set if there is a strong blowing wind around Once the generator set is lifted be careful about the people around and keep them at a saf...

Page 8: ...der the baseframe of the generator set slowly and carefully Once the forklift forks are completely inside the pockets then raise the level of forklift forks slowly around 15 20 cm and so the generator set shall be lifted from the ground After being completely sure that the lifted generator set has no contact with the floor then drive the forklift carefully to the place that the generator set will ...

Page 9: ... tire without the confirmation of manufacturer Furthermore make sure that all the bolts nuts and parts are tightened with an appropriate torque If there are any available make sure that all the headlights signal lights brake lights or the fog lights are running properly and their covering lenses or glasses are clean and in good condition Do not let people to stand on the towing bar or travel on th...

Page 10: ...ore starting the generator set be sure that everyone around is at a definite safety distance In order to minimize the risk of accidents due to sliding or falling keep your hands feet or the ground clean of fluids like fuel diesel grease anti freeze or water 1 4 Hot Surfaces Sharp Edges and Corners Avoid anyone from touching the hot grease hot coolant any hot surface sharp edge and corners Keep you...

Page 11: ... battery connections Keep any cables battery terminals or other electrical equipment in a good condition Replace any cracked broken or defective cables terminals isolators or any electrical equipment Provide a proper grounding for all the conductors and electrical equipment that is directly exposed to electricity This will prevent the accidents due to any arc or spark occurrences caused by the ele...

Page 12: ...s exposed part using plenty of soap and water 1 7 Environmental Protection Generator sets have some potential risks for the environment such as lubrication oil fuel exhaust gas battery There may be local set of rules regulations or limitations about the usage of diesel generator sets and also about the disposal of the environment risky materials listed above It is the customer s user s responsibil...

Page 13: ...r any tool Also be sure that you are standing on a dry and insulated ground if you have to touch them electrical installation or equipment for any repair or maintenance purposes Be sure to keep the insulators at the alternator output on their places Put them back to their places right after any connection or disconnection activity Do not run the generator set if these insulators are not mounted on...

Page 14: ...el down in such a position that your knee is near the patients head and your other foot is close to his her shoulder B 5 Put your hands on the patient s shoulders and place your palms on his her scapula 6 Push your arms forward in a vertical position Slightly apply pressure 10 15 kg on the patient s scapula for 2 5 seconds 7 Release the pressure by sliding your hands over the patient s shoulder to...

Page 15: ...ing any spare parts or while applying for a warranty case about that generator set 2 2 Generator Set TEKSAN produces reliable generator sets at high quality in accordance with ISO8528 standards Generator set specifications options electrical and mechanical drawings are all recorded and followed under the unique serial number of the generator set Main components of the generator set are shown in th...

Page 16: ...y against corrosion and rust Assembly of the parts is carried out with screws with no welding so the replacement of the damaged parts are easier Ease of transportation with lifting lugs Exhaust silencer fitted inside the canopy Emergency stop button fitted outside the canopy Fresh air inlets for adequate ventilation of the generator set Hot air outlet from the top for discharging the hot air and e...

Page 17: ...may be fitted on the canopy due to limited space inside canopy The internal structure of exhaust design is proper for a silent ambient One emergency exit door that is close to the side of the radiator for providing a more easy access to the generator Also a cabinet door is located when transfer switch will be inside container in some systems The fuel tank is put inside a separate section in the co...

Page 18: ...s on both sides for reaching around the generator set easier Transfer panel can be included inside the canopy or it can be put somewhere outside the canopy Generator should not be lifted up using the lifting lugs on the canopy Firstly generator set must be located on the platform and then drop over canopy must be put on it Drop over canopy can be mounted and unmounted easily on a generator set so ...

Page 19: ... sets can be supplied with trailers for mobile usage Equipped with tires to provide full mobility services for easy movement to the site where power is required these generator sets can be utilized as lighting towers rental power military construction etc applications These sets can also be designed as ultra silent upon customer request ...

Page 20: ...rs which are designed for heavy operation conditions which provide the engine a long lifetime with a high performance All the equipment that is needed for the diesel engine for operating safely and reliably is provided along with the generator set 2 4 Alternator Alternators used on TEKSAN generator set are designed in compliance with the standards IEC600341 CEI23 BS4999 BS5000 VDE0530 NF51100 NF51...

Page 21: ...ufactured of plate steel or other suitable materials Teksan ensures that the fuel tanks are all manufactured in accordance with relevant standards Teksan fuel tanks are equipped with Filling cap Tank ventilation Fuel outlet valve Fuel return connections Tank drainage plug Sediment trapping section Level gauge pipe Float switches Optional Automatic filling Optional It is highly recommended to insta...

Page 22: ...with international standards 2 7 Vibration Isolators Vibration insulators are used in order to decrease the negative effects of vibrations caused by the rotational movement of the engine and alternator These insulators which also prevent the vibration to be transferred from base frame to the ground are placed between engine alternator and base frame Specially chosen vibration isolators are mounted...

Page 23: ...rol Systems Various control systems are developed for ensuring the protection of the generator set against failures load transfers and the reliability of the operation for the generator set Control system designs can vary according to the customer requirements and assembling requirements The main types of control systems are Manual Automatic Standby and Parallel working systems All control systems...

Page 24: ...ean dry well illuminated and ventilated free of corrosive or conductive pollutant substances like dust lint smoke oil vapour exhaust smoke etc Be sure to leave enough blank space around the generator set in order to ease future maintenance or repair activities Remember that it can be necessary to disassemble the main parts like engine alternator or the base frame in some cases The base ground that...

Page 25: ...e frame In applications with higher power ratings the insulators may be placed under the base frame for more efficiency in terms of vibration insulation If the generator set is placed on an upper floor this vibration analysis of the generator and the base ground must be done more carefully In these types of applications special insulation system designs may be needed with special insulators The ba...

Page 26: ...ator matrix In order for the protection of air channels stationary or moving shutter systems can be built within these windows For an automatic generator set an automatically moving shutter system which is designed to open automatically when the engine starts is the best solution for this purpose However manually opened moving shutters can be acceptable in some manual mode generator set applicatio...

Page 27: ...ng the muffler at a closest possible location to the engine will help you decrease the sound level in exhaust pipes There may be placed another muffler at the end of the line if the exhaust line is too long Every engine must have its own separate exhaust system No multiple engines shall be connected to a single exhaust line system Because the exhaust gas soot or the condensation inside exhaust lin...

Page 28: ...n and longer life time of the engine Auxiliary fuel tanks can be used if fuel pressure value caused by the main fuel tank s location is out of producer s pressure limits Fuel level in the tank should not be at a height 4 meter higher or 3 meter lower than the fuel lift pump Valves check valves or any other equipment must not be installed on the fuel return line between engine and fuel tank Allowed...

Page 29: ...decreasing the fuel pressure on the suction line For all these reasons the locations of the fuel tanks and the piping to be done between them should be calculated and established well and carefully The size of the fuel supply and return lines should never be less than the sizes of the fuel connecting points on the engine and even they may need to be increased to larger sizes in case for long durat...

Page 30: ... on the wall The connections between the generator set and the load distribution panel must be protected against any possible overcurrent and overloading problems by use of fuses or circuit breakers It is important to load the generator set under balanced loading conditions If the load connected to one phase is much more or less than the other two phases and the difference between them is more tha...

Page 31: ...fly explained in the relevant sections below Connecting and disconnecting While connecting battery cables first connect the positive terminal then connect the negative terminal While disconnecting battery cables first remove the negative connection then remove the positive connection Cleaning Keep the batteries clean and dry Any dirt or oxidation left on the battery terminals or connections will c...

Page 32: ...dent on varying environmental conditions So it is strictly recommended to get professional help when designing special sound reduction systems The sound level of a non insulated diesel generator set is around 100 110 dB from 1 meters The lowest possible sound level also by regarding the economic facts in generator set applications is around 65 75 dB Sound level reduction is a really important para...

Page 33: ...e non active ones must be attached to the ground with the help of a conductor or an electrode This principle is called is called earth grounding The parts and the equipment that are directly exposed to electrical voltage must be well insulated in order to ensure the durability and safety of the electrical system and staff around it However there can be some electrical failures due to defection cor...

Page 34: ...and supplies power when the mains power gets off Manual control panels are used in applications in which the generator set is a primary main power source and they start and supply power when it is necessary and when the generator set gets started manually In both scenarios and panels the microprocessor based TJ509 T controller manages all needs to be done like monitoring the mains power starting o...

Page 35: ...ferred back to mains successfully the controller stops the engine after a cooldown timer Once the engine is stopped finally the generator set gets back to its standby rest position for waiting next mains failure If the operation of the generator set is being blocked by a weekly schedule then the AUTO led will flash and the operation of the generator set will be as in the STOP mode TEST This mode i...

Page 36: ...ature resistant ABS PC UL94 V0 case Remote monitoring capability with use of a GPRS modem DKG090 Ethernet port 10 100 Mb USB host port for USB storage devices or GPS Remote monitoring capability by itself via its RS485 or ethernet ports Embedded Web Server Modbus TCP IP SNMP Rainbow Plus and Rainbow Scada features via its ethernet port Long term data history log storage via its USB host port with ...

Page 37: ...ollowing procedures should be followed at every time before running a generator set The staff that is responsible for the operation of the generator set should be fully trained on these procedures 1 Check the generator set manually and visually for a last time before starting it up Do NOT start the generator set if you see any leakage of liquids cracked or broken parts disconnected cables or parts...

Page 38: ...pletely and properly Always ensure that both mobile and stationary generator earthings are correctly done to avoid the possibility of death or injury When removing the battery disconnect the negative lead first and when putting a battery onto service on a generating set connect the negative lead last due to fact that battery system is earthed from the negative The generator set will not start if a...

Page 39: ... shaded place Other than this charger devices there can be used a charger alternator on the engine for charging the batteries Check the pulley and belts installed on the charger alternator Change them with new ones if they are defected 4 6 Engine Jacket Water Heaters There can be used heaters on the engine s cooling water circuit in order to ease starting up and taking load actions for the engine ...

Page 40: ...lso be looked up from the manuals supplied with both the engine and alternator Be sure to perform all maintenance activities according to the recommended schedule All the documentation including service registration forms model and serial number nameplates drawings or diagrams spare part lists maintenance schedules and the manuals supplied with the generator set must be kept in a good condition Re...

Page 41: ...out corrosion on bearings the operating temperature must be measured and checked Check the coupling if the temperature is rising up to 80 C during operation If it is normal but the bearings change colour to blue then the bearings must be replaced with a new one Any dismantled bearing must be replaced with a new and equivalent one it is not recommended to re install and use any dismantled bearing H...

Page 42: ...ures of water antifreeze and any other chemicals for several purposes The main purpose of using this mixture is cooling the engine But with addition of antifreeze and other chemicals this mixture prevents the cooling water from freezing and protects the cooling system against corrosion Use 50 antifreeze glycol and 50 pure water as coolant mixture if there is any risk of freezing By using this mixt...

Page 43: ...t require any pure water addition Discharge duration is long for batteries on TEKSAN products because their internal resistance is very low 5 milliohm Since the batteries are completely based on oxygen recombination principle no waste gas is formed and there is no gas release on these batteries They are also equipped with special low pressure safety valves for this same reason Operating temperatur...

Page 44: ...led on your generator set is designed and manufactured for functioning properly for long years if the necessary and recommended maintenance activities are performed properly and periodically Here are some recommendations about the operation and maintenance of your radiator The coolant liquid inside the radiator is at high pressure and temperature so be careful when opening the cap or any draining ...

Page 45: ...d level must be increased gradually If the sufficient loading rate cannot be provided for the generator set then a dummy load can be connected to it Maintenance intervals must be more frequent for the generator sets running under low loading conditions For example the air filter must be replaced every year the oil filters must be changed every 6 months if a generator set is running in standby mode...

Page 46: ...otective packing material and store it in a dry and clean place It also should be operated at least once in every 15 days In order not to face any problems on re commissioning after this storage duration the generator set must be operated for a while until it reaches to its nominal operating temperature 75 C and checked for any failures before storage The procedures to be followed by an authorized...

Page 47: ...ove sealing from air inlet and exhaust outlet Inspect all sections of the engine Pay attention that the installation made basis on the rules and the commissioning procedures are completed before running the generator Refresh the engine oil and filter Clean the fuel tank and fill with new fuel Replace fuel filter Clean the air filter if necessary replace it Control and tighten the V belt and pulley...

Page 48: ...Hose Check the Tensions of V belts Check any Screws or Bolts used for Assembling Purposes Check the Compression Pressure if necessary FUEL SYSTEM Check the Cleanliness of Radiator Change the Coolant AIR INLET AND EXHAUST SYSTEM Check whole Air System for any Leakage hoses clamps etc Periodically Engine Running Hours At Least Check the Turbocharger Clean or Change Air Filters Check whole Exhaust Sy...

Page 49: ...priate equipment Do not change any settings or replace any part without a full knowledge on related issues You can find any further details in the troubleshooting sections of Operation and Maintenance Manuals supplied with the engine alternator and any other equipment used on generator set If you cannot get a solution by using the table below feel free to contact TEKSAN or its authorized dealers a...

Page 50: ...50 BBK V 122018_ENG People First EVERLASTING COMPANY ...

Page 51: ...51 BBK V 122018_ENG People First EVERLASTING COMPANY ...

Page 52: ...arriage paid by Buyer Owner Any parts repaired or replaced shall be under warranty until the original warranty period for the diesel generator set expires Buyer Owner Responsibilities Buyer Owner should install operate and maintain the generator set in accordance with the maintenance and operation diesel engine and alternator handbooks supplied with the genset If these books are lost Buyer Owner i...

Page 53: ...being notified of a potential product problem Normal wear the spare parts that should be changed and consumable items such as lubricating oil filters coolant V belt injector nozzles etc Any failures in batteries or failures resulted from batteries Any failures resulted from using biodiesel jet fuels JP sub kerosene fuel fuel oil benzene etc and additionally dirty water mixed with chemical additive...

Page 54: ...failure should be sent Any required operations in purpose of correcting the failure should be done after the approval of Teksan in writing Warranty claims must be done in 5 working days from date of failure If requested Buyer Owner is responsible to present all kind of documents to prove the validity of the warranty period DIESEL GENERATOR SET GENSET MODEL GENSET S NO ENGINE MODEL ENGINE S NO ALTE...

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Page 56: ...NOTES ...

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Page 58: ...NOTES ...

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Page 60: ...debali Cad No 12 34791 Sancaktep e ISTANBUL TURKEY KOCAELI FACTORY Sepetlipinar Serbest Bolge Mah 107 Cad No 18 41090 Basiskele KOCAELI TURKE Y TECHNICAL SERVICES CENTER Yenidogan Mah Edebali Cad No 12 34791 Sancaktep e ISTANBUL TURKEY www teksan com info teksan com ...

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