background image

User manual 

When

 

change

 

the

 

coolant,

 

cleaning

 

is

 

needed

 

for

 

the

 

cooling

 

system,

 

the

 

cleaning

 

procedures

 

are

 

suggested

 

as

 

follows:

 

Empty

 

the

 

cooling

 

system

 

Use

 

water

 

to

 

rinse

 

cooling

 

system

 

Feed

 

15%~20%

 

condensed

 

coolant

 

to

 

the

 

cooling

 

system,

 

timely

 

run

 

the

 

generator

 

set

 

for

 

one

 

or

 

two

 

times

 

then

 

discharge

 

the

 

coolant

 

Empty

 

the

 

cooling

 

system

 

then

 

use

 

normal

 

mixed

 

liquid

 

to

 

rinse

 

If

 

contaminant

 

still

 

exists,

 

then

 

repeat

 

the

 

cleaning

 

procedure

 

until

 

no

 

contaminant

 

exists

 

in

 

the

 

system

 

After

 

the

 

system

 

has

 

been

 

fully

 

rinsed,

 

feed

 

new

 

coolant

 

which

 

has

 

been

 

mixed

 

according

 

to

 

specified

 

proportion

 

Note:

 

If

 

the

 

cooling

 

system

 

is

 

cleaned

 

periodically,

 

only

 

rinse

 

it

 

with

 

small

 

amount

 

of

 

additives

 

or

 

clean

 

water

 

is

 

enough.

 

2.6.4

 

Feeding

 

of

 

coolant

 

Before

 

adding

 

coolant

 

to

 

the

 

coolant

 

system,

 

please

 

make

 

sure

 

the

 

radiator

 

‘s

 

discharge

 

valve

 

and

 

the

 

engine’s

 

discharge

 

valve

 

are

 

tightly

 

closed.

 

Add

 

the

 

coolant

 

to

 

the

 

system

 

in

 

a

 

proper

 

speed

 

so

 

that

 

to

 

avoid

 

air

 

cock

 

being

 

formed

 

in

 

the

 

system.

 

Air

 

shall

 

be

 

discharged

 

through

 

the

 

adding

 

hole

 

or

 

the

 

discharge

 

valve

 

in

 

the

 

engine

 

body.

 

If

 

the

 

cooling

 

system

 

is

 

furnished

 

with

 

heater,

 

the

 

control

 

valve

 

for

 

the

 

heater

 

shall

 

be

 

opened.

 

Ensure

 

ventilation

 

of

 

the

 

unit

 

when

 

adding

 

the

 

coolant.

 

Note:

 

The

 

air

 

discharge

 

valve

 

in

 

the

 

engine

 

body

 

shall

 

be

 

located

 

in

 

the

 

top

 

point

 

of

 

the

 

water

 

path

 

or

 

near

 

the

 

thermostat

 

or

 

water

 

temperature

 

sensor,

 

or

 

you

 

can

 

slightly

 

loose

 

the

 

water

 

temperature

 

sensor

 

and

 

re

tighten

 

it

 

when

 

you

 

see

 

coolant

 

run

 

out

 

from

 

it

 

so

 

that

 

to

 

discharge

 

the

 

air.

 

When

 

adding

 

the

 

coolant,

 

the

 

surface

 

of

 

liquid

 

shall

 

reach

 

to

 

the

 

level

 

that

 

is

 

5

 

centimeters

 

below

 

the

 

radiator’s

 

welded

 

surface

 

(or

 

shall

 

reach

 

the

 

level

 

indicating

 

Line).

 

Be

 

sure

 

that

 

the

 

generator

 

set

 

has

 

stopped

 

and

 

become

 

fully

 

cooled

 

before

 

adding

 

Coolant.

 

Before

 

the

 

system

 

is

 

capable

 

of

 

ventilation

 

and

 

the

 

liquid

 

is

 

added

 

to

 

the

 

required

 

level,

 

please

 

don’t

 

start

 

the

 

generator

 

set.

 

After

 

the

 

coolant

 

being

 

fed,

 

please

 

start

 

and

 

pre

heat

 

the

 

generator

 

set,

 

and

 

at

 

the

 

same

 

time

 

check

 

the

 

liquid

 

level

 

and

 

add

 

coolant

 

if

 

needed.

 

The

 

coolant

 

which

 

needs

 

to

 

be

 

added

 

to

 

the

 

radiator

 

shall

 

be

 

of

 

the

 

same

 

specification

 

as

 

that

 

existing

 

in

 

the

 

radiator.

 

 

For

 

some

 

generator

 

sets

 

installed

 

with

 

coolant

 

filter,

 

please

 

open

 

the

 

filter’s

 

valve

 

before

 

put

 

into

 

use.

 

2.7

 

Lubricant

 

system

 

Lubricant

 

system

 

is

 

composed

 

of

 

oil

 

pan,

 

oil

 

pump,

 

strainer,

 

oil

 

pipe,

 

oil

 

cooling

 

unit,

 

oil

 

filter

 

unit,

 

and

 

the

 

oil

 

path

 

inside

 

of

 

the

 

engine

 

and

 

all

 

kinds

 

of

 

lubricant

 

parts

 

which

 

are

 

in

 

relative

 

motion

 

etc.

   

The

 

main

 

purpose

 

of

 

the

 

lubricant

 

system

 

is

 

to

 

provide

 

sustained

 

tempered

 

oil

 

film

 

between

 

the

 

parts

 

which

 

are

 

in

 

motion

 

so

 

that

 

to

 

reduce

 

friction

 

and

 

wear,

 

and

 

draws

 

off

 

part

 

of

 

the

 

heat

 

absorbed

 

by

 

the

 

parts,

 

bath

 

mechanical

 

part,

 

improve

 

sealing

 

effect

 

and

 

prevent

 

rust

 

from

 

each

 

part’s

 

surface.

 

Users

 

can

 

determine

 

the

 

model

 

of

 

lubricant

 

according

 

to

 

the

 

specific

 

working

 

environment

 

and

 

conditions.

 

For

 

the

 

first

 

time

 

lubricant,

 

normally

 

users

 

shall

 

change

 

it

 

within

 

100

 

hours

 

upon

 

and

 

from

 

the

 

time

 

when

 

the

 

generator

 

set

 

first

 

started.

 

(

details

 

refer

 

to

 

engine

 

maintenance

 

manual

)

 

Note:

 

The

 

critical

 

point

 

is

 

to

 

use

 

qualified

 

lubricant

 

oil

 

which

 

is

 

with

 

proper

 

viscosity

 

and

 

conform

 

to

 

the

 

engine’s

 

requirement,

 

and

 

periodically

 

change

 

the

 

lubricant

 

oil

 

and

 

oil

 

filter

 

so

 

that

 

to

 

ensure

 

the

 

generator

 

set’s

 

normal

 

working.

 

The

 

malfunctions

 

caused

 

by

 

wrong

 

model

 

of

 

lubricant

 

oil

 

with

 

low

 

quality

 

or

 

long

 

time

 

no

 

change

 

of

 

lubricant

 

oil,

 

or

 

oil

 

filter

 

do

 

not

 

belong

 

to

 

the

 

scope

 

of

 

warranty.

   

We

 

recommend

 

that

 

high

 

quality

 

multi

 

grade

 

SAE

 

15W/40

 

high

 

service

 

engine

 

oil

 

in

 

diesel

 

engines

 

are

 

used.

 

At

 

ambient

 

temperatures

 

above

  ‐

15

 

degree

 

Celsius

 

is

 

15W40.

 

The

 

minimum

 

API

 

oil

 

quality

 

levels

 

recommended

 

for

 

use

 

is

 

CH

 

/

 

CI

4,

 

CH

 

or

 

CI

4

 

can

 

be

 

used

 

in

 

areas

 

where

 

CF4

 

oil

 

is

 

not

 

yet

 

available,

 

but

 

the

 

oil

 

interval

 

must

 

be

 

reduced

 

API

 

CA,

 

CB,

 

CC,

 

CD,

 

CE,

 

CG4

 

categories

 

not

 

recommended,

 

do

 

not

 

use.

 

2.8

 

Fuel

 

system

 

Our

 

 

generator

 

 

sets

 

 

requires

 

 

the

 

 

fuel

  ‐ 

 

diesel

 

 

shall

 

 

be

 

 

clean,

 

 

without

 

 

air

 

 

and

 

 

water

 

 

and

 

 

with

 

 

proper

 

pressure,

 

 

of

 

 

which

 

 

all

 

 

kinds

 

 

of

 

 

parameters

 

 

such

 

 

as

 

 

sulphur

 

 

content

 

 

etc.

 

 

shall

 

 

meet

 

 

national

 

 

standards,

 

and

 

 

end

 

 

use

 

 

temperature

 

 

grade

 

 

meet

 

 

the

 

 

requirement

 

 

of

 

 

customer’s

 

 

working

 

 

environment.

 

Generally

 

 

generator

 

 

set’s

 

 

fuel

 

 

system

 

 

includes

 

 

two

 

 

parts,

 

 

that

 

 

is,

 

 

engine’s

 

 

fuel

 

 

system

 

 

and

 

 

external

 

 

fuel

 

system.

 

 

HYUNDAI

 

 

is

 

 

only

 

 

responsible

 

 

for

 

 

installation

 

 

of

 

 

the

 

 int

ernal

 

 

fuel

 

 

system

 

 

which

 

 

includes

 

 

fuel

 

 

tank

 

and

 

connecting

 

fuel

 

pipes

 

etc.

 

2.8.1

 

Fuel

 

Recommendations

 

Содержание DHY34KSE

Страница 1: ... REGULATION STARTING METHOD DISPLACEMENT cc OIL CAPACITY L ALTERNATOR RATED POWER kW kVA POWER FACTOR Cosφ VOLTAGE REGULATION LOW OIL PRESSURE BLOCK ON START UP LOW BATTERY HIGH TEMPERATURE ON WATER LOW OIL LEVEL LOW RUNNING ON ENGINE EMERGENCY STOP N G kg G W kg PRODUCT DIMENSIONS mm CAPACITY units container 25 31 28 34 50 230 400 45 IL NT MRS 10 INCLUDED 1x12v 60Ah 93 10 5 2 9 3 18 10 68 HY4102 ...

Страница 2: ...DIESEL GENERATOR Models Hyundai Engine Series Operation and Maintenance manual ...

Страница 3: ...tock and property Some or all of the following PPE warning signs and symbols may appear throughout this manual and you must adhere to their warning s Failure to do so may result in personal injury Warning Signs and Symbols FOLLOW safety messages to avoid or reduce risk of injury or death DANGER indicates a hazard which if not avoided could result in serious injury or death WARNING indicates a haza...

Страница 4: ...e even if doors and windows are open If you think you or someone around you has been affected by carbon monoxide poisoning Leave the affected area and get fresh air immediately Open doors and windows and turn the machine off See your doctor immediately or go to hospital let them know that you suspect carbon monoxide poisoning DO NOT use in an enclosed area or a moving vehicle General fuel safety C...

Страница 5: ...rior to carrying out any maintenance work Prior to use and with all electrical supplies isolated check all electrical cables plugs and connections for the following Are intact and have no signs of damage to include but not limited to bare wires chaffing cuts and loose wiring If there are any signs of damage you should stop using the equipment The damaged item must repaired by an electrically compe...

Страница 6: ... starting DO NOT pour water directly over the generator nor wash it with water For each use make sure that the generator has been electrically grounded earthed Failure to do so can be fatal DO NOT smoke while charging a battery The battery emits flammable hydrogen gas which can explode if exposed to electric arcing or open flame Keep the area well ventilated and keep open flames sparks away when c...

Страница 7: ...is close to the battery and fuel because the mixture of volatilization from fuel and hydrogen generated by battery charging process will cause explosion when it meets sparkle or naked flame The generator set installation room shall be facilitated with BC and ABC fire extinguisher and operators shall be familiar with the knowledge on how to use it When fan protection cover or other protection cover...

Страница 8: ...t is running do not attempt to reach under or around the guards to do maintenance or for any other reason Keep hands arms long hair loose clothing and jewelers away from pulleys belts and other moving parts SAFEGUARD WARNING Generating sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 105 dB A Prolonged exposure to noise levels above 85 dB A is haza...

Страница 9: ...nal disconnected prior to attempting to connect or disconnect load connections Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground Make sure connect generator set to earth Replace the generating set terminal box cover as soon as connection or disconnection of the load cables is complete Do not operate the generating set without the cover secur...

Страница 10: ...erator Set Working Room 4 2 5 Installation of Generator Set 5 2 6 Cooling system 7 2 7 Lubricant system 8 2 8 Fuel system 8 2 9 Battery 10 2 10 Electrical Connection 11 2 11 Power distribution system 11 3 Operation 3 1 Inspect Before Operation 12 3 2 Generator set s running 12 3 3 After Running 13 3 4 Record for running 13 3 5 Matters need attention 13 3 6 Operation for control system 14 3 7 ATS c...

Страница 11: ...tandby power supply to provide continue electric power for non invariable loads The generator set is suitable for the area where must ensure continue power supply such as hospitals industrial facilities airports etc Keep the generator set standby state at any time and start to run when the mains supply is abnormal Emergency service Used as auxiliary power supply to solve energy interruptions that ...

Страница 12: ...a pusher fan and thermostat The alternator has its own internal fan to cool the alternator components 1 6 Electrical System The engine electrical system is 12 volt or 24 volts DC negative ground earth This system includes an electric engine starter a battery and a battery charging alternator For DC 12 volts electrical system one battery is given For 24 volt system two lead acid batteries are given...

Страница 13: ...ilitated onnect direc valve is an UNDAI Pow n for the rplus lubrica t by openin ransportatio been designe Standard ca fting hole o enerator set canopy roo me which b o have stati the generato Optional S ed with heat l the pre hea n be started gency cases 3 y with ctly to nother wer It users ant or g the on ed for anopy on the ts we of and better ionary or set Spare ter for ater is under s and al d...

Страница 14: ...nect to other architecture s foundation The width and depth of foundation shall meet requirement Ensure foundation s levelness and smoothness If possible waste discharge sink can be sued so that the waste oil can be discharged in a timely manner Cable channel for generator power output cable need to be reserved Normally concrete foundation is reliable simple and preferable When pouring the concret...

Страница 15: ...set to outside For example corrugated vibration reduction pipe has been used to connect exhaust pipes air exhaust path fuel inlet pipe fuel return pipe and busbar cable etc all of these parts need to use soft connections Only in this way we can reduce the adverse effect caused by the vibration of generator set to the minimum extent 2 5 2 Ventilation When a generator set with a complete set of radi...

Страница 16: ...essure and side stress Reserve some space for hot shrinkage and cold expansion Reserve space for generator set vibration Reduce exhaust noise level Overload of exhaust backpressure will cause following adverse effect Output power loss Fuel efficiency reduce Exhaust gas temperature rise Note When more than one generator set are installed try not to discharge all of the generator sets gas from one e...

Страница 17: ... the liquids in a separate container evenly and then add the mixture into the radiator ensure the anti freeze will not freeze under low temperature In the area when there is low possibility of freezing the coolant can be a mixture of water and anti rust according to the anti rust which recommended by the engine supplier and refer to its operation manual mix the liquids in a separate container even...

Страница 18: ... specification as that existing in the radiator For some generator sets installed with coolant filter please open the filter s valve before put into use 2 7 Lubricant system Lubricant system is composed of oil pan oil pump strainer oil pipe oil cooling unit oil filter unit and the oil path inside of the engine and all kinds of lubricant parts which are in relative motion etc The main purpose of th...

Страница 19: ...tor sets provide base frame style fuel tank for customer The base frame style fuel tank is installed with fuel tank fuel pipes and fuel level indicator This fuel supply system does not need customer to make other installations Customers only need to add fuel to the base frame Users who intend to self manufacture the fuel tank shall use stainless steel or steel plate to make the backup tank do not ...

Страница 20: ...s are required to correctly connect the signal line to this control panel details see the control panel operation manual Automatic transfer panel optional is the automatic transfer switch for transfer between generator set and mains details refer to control panel operation manual 2 9 Battery Our generator set standard configuration provides start battery as accessory parts According to user s diff...

Страница 21: ...must be connected to an earth ground Since the set is mounted on vibration isolators the ground connection must be flexible to avoid possible breakage due to vibration Ground connection cables or straps should have at least full load current carrying capacity and meet applicable regulations 2 10 3 Insulation Test Before starting the generating set after installation test the insulation resistance ...

Страница 22: ...Start Part of the generator set control panel has been furnished with idle speed full speed transfer switch users can choose if the engine need to be started in idle speed or in one time full speed Usually the time period for idle speed shall not exceed five minutes Do not run the generator set in idle speed in a long time period Press on the start button the duration shall not exceed 30 seconds e...

Страница 23: ...ning situation and if there is any malfunction warning generator set shut down etc Only when the correct and complete record for running maintenance has been kept very well the user can get correct and excellent after sales warranty service 3 5 Matters need attention Warning When engine s temperature is very low the time period for idle speed shall be properly extended However when the generator s...

Страница 24: ...s number 3 times the Alarm LCD would flash If you need to restart wait at least 30 seconds before the retry 8 Check the reading of Voltage Meter and Frequency Meter by operating the Voltmeter Change Over Switch Once the generator set is running at the correct voltage and frequency Turn the Generator set main circuit breaker to ON 9 Turn on every switch or circuit breaker of loads from heavy to lig...

Страница 25: ...light means AMF controller is active then user can select operation type OFF MAN AUTO MEASUREMENT A OFF mode Start stop mains power on off generator set power on off is inactive in this mode B MAN mode 1 Press start pushbutton to start engine 2 When output voltage is in the set range a Press mains power on off pushbutton to turn on the switch b Press mains power on off pushbutton the switch will b...

Страница 26: ... if generator set is used for self start standby power In order to achieve full automatic transfer between mains power and generator set power to guarantee all load present our ATS panel select the best ATS for all generator set And to the most possibility to serve our customers demand we prepare two types of ATS MRS and AMF Besides MRS and AMF can be jointed to a double standby ATS after a little...

Страница 27: ...TO that is OK detail operate step refer module control system ATS PANEL introduction No MODEL 1 ATS switch 2 panel lock 3 mains power output hole 4 generator power output hole 5 communicate with generator module port 6 load power cable output 7 panel on ground leg Maintenance inspect or exchange parts attention Attention All operator must be professional electrician Turn switch on OFF position mak...

Страница 28: ... battery For each 50 600 hours of running or at least each 12 months Change lubricant and lubricant filter Because the quality of lubricant oil sulfur content of the fuel and lubricant consumption rate of each engine is different the interval for lubricant oil change for each generator set will be different When change the lubricant oil at the same time oil filter needs to be changed otherwise the...

Страница 29: ... refer to Control Panel Operation Manual for details 4 5 Start battery Batteries which have been stored in a long time shall be properly charged before being used so that to ensure normal capacitance of the battery Densimeter can be used to check the actual capacitance of the battery Normal operation and battery charging will cause some water inside of the battery being vaporized And therefore con...

Страница 30: ...liminate the malfunction s Especially important for new generator set s customer One thing must to be emphasized most of the malfunctions are caused by user s improper installation operation and maintenance Users are entitled to doubt that the malfunction s is caused by the generator set s manufacture failure but this conclusion shall be based on correct installation operation and periodically mai...

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Страница 39: ...APPENDIX E 1 ...

Страница 40: ...2 ...

Страница 41: ...3 ...

Страница 42: ...t running record TIME ENGINE PARAMETER GENERATOR PARAMETER IF RECORD FOR MALFUNCTION IS AVAILABLE OPERATOR REMARK Start stop generator set time Accumulated running time Oil pressure Temperature Voltage Current Frequency Power ...

Страница 43: ...t serial No Engine serial No Alternator serial No Accumulated running hours Maintenance cycle Reasons for maintenance periodic maintenance or malfunction maintenance Inspection and repair Inspection and adjustment Change of parts Clean and maintenance Others Conclusion for maintenance Maintenance staff signature ...

Страница 44: ...APPENDIX H ...

Страница 45: ......

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