V. 200610
Operation and Maintenance Manual of Diesel Engine Generator Sets
SHANGHAI YANGKE ENGINE CO., LTD.
Content
Chapter 1
Brief
1
Chapter 2
Main equipments and technique parameters
2
Chapter 3
Control principle of the diesel engine generator set 3
Chapter 4
Mounting and use
4
Chapter 5
Maintenance and trouble shooting
5
SHANGHAI YANGKE ENGINE CO., LTD.
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CHAPTER-1 BRIEF GF、SMS、GFT and other series diesel generator sets are made in YangKe company(called as the units in the brief), which synthesize advanced technique aboutbrushlesssynchronousgenerator,excitationdeviceandgeneralstructureetc., which are equipped with national standards diesel engine such as 95 series, 135 series, 190, S1100 (S 1105, S1110) and domestic well-known diesel engine work suchasWEICHAI,YANGDONG,Shanghaitractorandinternalcombustionengine company, Shanghai New Holland. The quality of theirproductions is superior and their techniques are advanced generators. Our company is able to supply high quality,durableandeconomicgeneratorsforglobalcustomers. TheorderingofSetmodelisexplainedforasfollows:
1 2 3 4 GF —— SMS—— 1.Ratedpowerofthedieselgeneratorset. 2.GFmeansthree-phaseopentypedieselgeneratorset. SMSmeanssilentdieselgeneratorset. 3.Zmeanstheautomation. Tmeansthemobiletrailerdieselgeneratorset. Bmeanssemiautomation. 4.Thefunctionfillsin. Forexample： 10GFmeansthree-phaseopentypedieselgeneratorsetof10KW. 20SMSZmeansa20KWsilentautomaticdieselgeneratorset. 90GFTmeansa90KWmobiletrailerdieselgenerator.
Section-1 Structure of units The diesel engine generator sets in YangKe company are the alternator sets, whicharehighquality,durable,convenientmaintenance,andabletosupplymobile or fixed power source for mine, factory, enterprise, hotel, hospital, village, town, fishingorherding,forest,highwayorbridge,communicationorbroadcastandsoon, andusedasbackuppowersupplyofmansion,workmineral,hospital,square,bus stationandcabaret. SHANGHAI YANGKE ENGINE CO., LTD.
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The control methods of the machine set can be classified as manual control, half-automaticcontrolandfull-automaticcontroletc.Coolingsystemscanbedivided into a open type circulatory system and a close type circulatory system. Starting methodscanbedividedintohandingrecoilorelectricstarter.Thegeneratorcanbe dividedintobrushlessorbrushbyexcitation,CONTROLorNonCONTROL,thrice harmoniouswaveetc. Constitutionsoftheunits: a.Dieselengine. b.Alternator. c.Radiator,jointandpublicchassis. d.Controlpanel. e.Fueltank,battery,spareparts,accessoriesandtoolboxes.
Section-2 Technical performances of the units Thepowerofthedieselgeneratorsetswhichrangesfrom8KWto500KW,and the frequency ranges from 50 Hz to 60 Hz. According to the requirement of customers,thereareenoughspeciestomeetwithdifferentcustomers'requests. Diesel generator set in the land is manufactured according to “GB2820”. Self-startup and emergent diesel generator set is manufactured according to “GB12786”. Export diesel generator set is manufactured according to “JB4122”. Mobile electric station is manufactured according to “GB/T2819” other than the above-mentionedrelevantstandards. Whenthemachinesetiszeroload,itsvoltagerangesfrom95%to105%rated voltage.whenpowerfactoris0.8,steadyadjustratio,instantaneousadjustratio 、 steady time、fluctuant ratio of the voltage and the frequency should not exceed specificationsinthefollowingtable: Voltage
Rated power Type
＞250
Steady Instantaneous Steady adjust
adjustratio
time
ratio(%)
(%)
(s)
Ⅰ
±1
+20/-15
0.5
Ⅱ
±3
+20/-15
Ⅲ
±5
Ⅳ
(KW)
≤250
Frequency Fluctuant
Steady Instantaneous
Steady Fluctuant
adjust
adjustratio
ratio(%)
(%)
0.5
1
±5
3
0.5
1.0
1.0
3
±5
5
1.0
——
3.0
1.5
5
±5
7
1.5
±7
——
——
1.5
6
±5
——
1.5
±2.5
+20/-15
1.5
1.0
（0~5）
±5
7
1.0
ratio(%)
time(s) ratio(%)
The table data are at the environment temperature 298k. The data must be adjusted when the environment temperature. SHANGHAI YANGKE ENGINE CO., LTD.
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Note: 1. When the machine set is 0~25% rated load, its voltage and frequency fluctuant rate is permitted to exceed 0.5. 2. Don't include the voltage change between cold status or hot status while computing the steady voltage adjust ratio.
Section-3 Working environment of the machine set The machine set can supply the provision power and work credibly under the following conditions: 1. The surrounding environment temperature is 273K~313K; 2. The altitude height is no more than 1000 meters; 3. The air humidity is less than 95% (at temperature 298K); The working environment temperature of the normal set should be more than 273k, otherwise it should be pre-heated. The working environment temperature of the automatic set should be more than 288k; otherwise you should start the set at a warmer temperature. Usually, the altitude height of the set should be less than 1000 meters. The height of 4000 meters is permitted only but with lower output power. High temperature and wet environment will accelerate the generator aging, and decrease the diesel engine output power, and have serious effects on the service life and the credibility of the machine set. Rated power of the machine set means 12 hours continuous power under the standard condition: the atmosphere pressure Pa=100kpas (750mmHg), the relative humidity φ =30%, the environment temperature T=298K. When the machine set has been used continuously for more than 12 hours, its electricity power will be at 10% discount of the engine rated power which cannot exceed the rated power of the set. Under nonstandard working conditions, the customer should modify the diesel engine power in order to prevent the diesel engine from overloading. Modify formula：P=(Pe·K1-Pf)·K2 In the formula ： P: Output power of the machine set (kW). Pe: The diesel rated power under standard condition (kW). Pf: The fan power (kW). K1: Temperature, humidity and atmosphere pressure modify correction efficiency in nonstandard (correction efficiency table). SHANGHAI YANGKE ENGINE CO., LTD.
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K2: the generator efficiency (kW). When the computed power of the machine set is lower than the rated power of the set, it is used according to the computed one. When the computed power of the machine set is bigger than the rated power of the set, it is used according to the rated one. Power correction table:
Powercorrectionefficiencywhenrelativehumidity=30% Altitude (m) 0 200 400 600 800 1000 1500 2000 2500 3000 3500 4000
Atmospheric pressure (KPa) 100 97.63 95.39 93.16 90.92 88.68 83.42 78.42 73.68 69.21 64.87 60.79
Atmospheric temperature (℃) 0 1.10 1.07 1.04 1.01 0.98 0.96 0.89 0.83 0.77 0.70 0.65 0.60
5 1.08 1.05 1.02 0.99 0.96 0.94 0.87 0.81 0.74 0.69 0.63 0.58
10 1.06 1.03 1.00 0.97 0.95 0.92 0.85 0.79 0.73 0.67 0.62 0.57
15 1.04 1.01 0.98 0.96 0.93 0.91 0.84 0.77 0.72 0.66 0.61 0.56
20 1.02 0.99 0.96 0.94 0.91 0.89 0.82 0.76 0.70 0.64 0.59 0.54
25 1.00 0.97 0.94 0.92 0.89 0.87 0.81 0.74 0.68 0.63 0.58 0.53
30 0.98 0.95 0.92 0.90 0.87 0.85 0.79 0.73 0.66 0.61 0.56 0.51
35 0.96 0.93 0.90 0.88 0.85 0.82 0.76 0.70 0.64 0.59 0.54 0.49
40 0.93 0.90 0.88 0.85 0.83 0.80 0.73 0.68 0.62 0.57 0.52 0.47
45 0.90 0.87 0.85 0.83 0.80 0.78 0.71 0.65 0.60 0.55 0.50 0.45
CHAPTER-2 MAIN EQUIPMENT AND TECHNIQUE PARAMETERS 1. GF series diesel generator set: The GF series diesel generator set (the power scopes 10-500 KW) is the main product of YangKe company. It is top-quality. It is advanced technology. GF series diesel generator set is the alternator set, which is steady, durable and convenient maintenance. The set can supply steady, credible and economic power for global customers. The automatic voltage adjusting rate of the machine set can meet with the common usage under three-phase symmetrical load within 0~100% rated power and 0.8 power factor, which can be adjusted with the scope of 95~105% rated power at zero load. The machine set can startup directly the rat-cage type three-phase asynchronous motor whose rated power within 30~70% rated power of the set. When the machine set is operated during three-phase asymmetrical load, and if phase current is less than rated current and three-phase current is less than 20%, the continuous operation of the set for a long time is admitted. Technique parameters are as follows:
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Model
Rated output (KW)
Rated voltage (V)
Rated Rated Fuel current frequency consumption (A) (Hz) (g/kW*h)
Engine model
Alternator model
8GF
8
400/230
14.4
50
295AD
TFW-8
1800*800*820
10GF
10
400/230
18
50
295AD
TFW-10
1800*800*820
12GF
12
400/230
21.6
50
2100AD
TFW-12
1800*800*820
15GF
15
400/230
27
50
YD485
TFW-15
1900*850*850
20GF
20
400/230
36
50
≤238
YSD490
TFW-20
2000*850*850
24GF
24
400/230
43.3
50
≤258.4
K4100D
TFW-24
2000*850*850
32GF
32
400/230
57.6
50
≤242
R4100
TFW-32
2300*950*900
40GF
40
400/230
72.1
50
50GF
50
400/230
90.2
50
64GF
64
400/230
115.4
50
75GF
75
400/230
135.3
50
100GF
100
400/230
180.4
50
120GF
120
400/230
216.5
50
R6113ZLD TFW-120 3100*1100*1200
150GF
150
400/230
270
50
12V135AZD TFW-150 3100*1100*1200
200GF
250
400/230
361
50
250GF
300
400/230
451
50
300GF
400
400/230
504
50
400GF
500
400/230
722
50
Z12V150ZD TFW-400 5500*1350*1950
500GF
250
400/230
902
50
Z8V190D2
≤250.2
≤247
≤231 ≤224 ≤218
R4105ZD1
TFW-40 2400*1050*1200
R4105ZD1
TFW-50 2400*1050*1200
R6105ZD1
TFW-64 2800*1100*1200
R6105ZLD
TFW-75 2900*1100*1200
R6105AZLD TFW-100 2900*1100*1200
12V135AD ≤250
Dimension （mm）
TFW-200 3100*1300*1650
12V135JZD TFW-250 3500*1300*1700 12V135AZD TFW-300 3500*1300*1700
TFW-500 5270*2040*2778
2. SMS series diesel generator set. SMS(low noise) series diesel generator set can install common control, four protections, YK-2000, DACTS 704C full-automatic controller with ATS, self startup, self protection, self jump in, self shift and self shut down and so on equipments according to the customer's requirements. Rated Rated Rated Rated Fuel Engine Alternator Dimension (mm) output voltage current frequency consumption model model (KW) (V) (A) (Hz) (g/KW*h) 8SMS 8 400/230 14.4 50 YD380 TFW-8 1700*800*720 ≤269.3 10SMS 10 400/230 18 50 YD480 TFW-10 1800*800*820 ≤250.2 12SMS 12 400/230 21.6 50 YD485 TFW-12 1800*800*820 ≤247 15SMS 15 400/230 27 50 YD490 TFW-15 1900*850*850 20SMS 20 400/230 36 50 YD4100 TFW-20 2000*850*850 ≤238 24SMS 24 400/230 43.3 50 K4100D TFW-24 2000*850*850 ≤258.4 32SMS 32 400/230 57.6 50 R4100 TFW-32 2300*950*900 ≤242 40SMS 40 400/230 72.1 50 R4105ZD1 TFW-40 2400*1050*1200 ≤231 50SMS 50 400/230 90.2 50 R4105ZD1 TFW-50 2400*1050*1200 64SMS 64 400/230 115.4 50 R6105ZD1 TFW-64 2800*1100*1200 ≤224 75SMS 75 400/230 135.3 50 R6105ZLD TFW-75 2900*1100*1200 ≤218 100SMS 100 400/230 180.4 50 R6105AZLD TFW-100 2900*1100*1200 120SMS 120 400/230 216.5 50 R6113ZLD TFW-120 3100*1100*1200 Model
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3. GFT series mobile power station. Model
Rated output (KW)
Rated Rated Rated Fuel voltage current frequency consumption (V) (A) (Hz) (g/KW*h)
Engine model
Alternator Dimension (mm) model
10GFT
10
400/230
18
50
295AD
TFW-10 2800*1600*1800
12GFT
12
400/230
21.6
50
295AD
TFW-12 2800*1600*1800
15GFT
15
400/230
27
50
395AD
TFW-15 2800*1600*1800
20GFT
20
400/230
36
50
495AD
TFW-20 2800*1600*1800
24GFT
24
400/230
43.3
50
495AD
TFW-24 2800*1600*1800
30GFT
30
400/230
54.1
50
495AZD
TFW-30 2800*1600*1800
40GFT
40
400/230
72.1
50
4135D
TFW-40 3100*1600*1800
50GFT
50
400/230
90.2
50
4135AD
TFW-50 3100*1600*1800
75GFT
75
400/230
135.3
50
R6105ZLD
TFW-75 3100*1700*2200
90GFT
90
400/230
162.3
50
6135AD
TFW-90 3100*1700*2200
100GFT
100
400/230
180.4
50
120GFT
120
400/230
216.5
50
150GFT
150
400/230
270
50
200GFT
250
400/230
361
50
250GFT
300
400/230
451
50
300GFT
400
400/230
504
50
≤257
≤252
≤233
≤230 ≤226 ≤230 ≤233
R6105AZLD TFW-100 3100*1700*2200 R6113ZLD TFW-120 3300*1700*2200 12V135AZD TFW-150 3300*1700*2200 12V135AD
TFW-200 3600*2000*2300
12V135JZD TFW-250 4000*2200*2400 12V135AZD TFW-300 4000*2200*2400
4.1 Water-cooling single-cylinder diesel generator sets. Model Alternator model Alternator type Rated frequency (Hz) Rated voltage (V) Rated output power (kW) Power factor cosΦ Phase number Rated rotation speed (rpm) Dimension (L×W×H) (mm) Net weight (kg) Engine model Engine type Bore × Stroke (mm) Displacement (L) Compression ratio Rated power [kW(HP)/rpm] Fuel consumption (g/kW×h) Cooling mode Fuel tank capacity (L) Starting system
SHANGHAI YANGKE ENGINE CO., LTD.
8GF-SF 10GF-SF 12GF-SF STC-8 / TWG-8 STC-10 / TWG-10 STC-12/TWG-12 Three times harmonic with brush or brushless self-excitation with AVR alternator 50 / 60 50Hz: 400/230, 230 or 60Hz: 240/120, 120 8 10 12 Single phase: 1.0 / Three phase: 0.8 Single phase / Three phase 1500 / 1800 1470×800×1220 1600×800×1220 1600×800×1220 350 360 380 S1100 (M) S1105 (M) S1110 (M) Water-cooled, single-cylinder, 4-stroke, diesel engine 100×115 105×115 110×115 0.903 0.996 1.093 17 17 17 11 (15)/2200 12.13 (16.5)/2200 13.24 (18)/2200 ≤238 Hopper or Radiator 11.5 14.5 15.5 Hand cranking (electric starting)
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4.2 Water-cooling single-cylinder low-noise diesel generator sets. Model Alternator model Alternator type Rated frequency (Hz) Rated voltage (V) Rated output power (kW) Power factor cosΦ Phase number Rated rotation speed (rpm) Dimension (L×W×H) (mm) Net weight (kg) Engine model Engine type Bore × Stroke (mm) Displacement (L) Compression ratio Rated power (kW) Fuel consumption (g/kW×h) Cooling mode Fuel tank capacity (L) Starting system
8SMS-1 10SMS-1 TWG-8-4 TWG-10-4 Brushless self-excitation with AVR alternator 50 / 60 50Hz: 400/230, 230 or 60Hz: 240/120, 120 8 10 Single phase: 1.0 / Three phase: 0.8 Single phase / Three phase 1500 / 1800 1600×950×1170 1600×950×1170 550 560 S1110M S1115M Water-cooled, single-cylinder, 4-stroke, diesel engine 110×115 115×115 1.093 1.195 17 17 13.24 (18HP)/2200 14.7 (20) / 2200 ≤238 Radiator 11.5 14.5 Electric starting
CHAPTER-3 CONTROL PANEL OF THE UNITS Section-1 Function and structure The control systems of the machine set are divided into the cabinet type, the electrical engineering integral type and so on. Generally, the control systems are divided into an open type, nature cooling type. The cabinet type is fit for fixed or bigger capacity set. Because of small scale components, the cabinet type is compact, small and light. The indicating light and various diagraph appearances (such as voltage gauge, current gauge, the frequency table etc.) are showed in Figure 1, Figure 2. These gauges show the operation state of the machine set .The user can know about the inner conditions with these gauges. The user can regulate and control the set by various switches, buttons, regulating hand handles and so on in the panel. There is a sensor of an instrument, an automatic voltage modulator and a control device in the control system. The automatic machine set control principle is explained in ‘The Automation Machine Set Usage Manual’.
SHANGHAI YANGKE ENGINE CO., LTD.
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Sketch map of the control panel:
Figure-1
Figure-2 SHANGHAI YANGKE ENGINE CO., LTD.
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Section-2 Circuit diagram The electric circuit diagram is the path of the electric current expressed with the diagram example and sign. The circuit diagram of the machine set is drawn according to the electricity equipments circumstance and the usage request of the machine set, according to the national standard. It is the basis and the instruction data of installation、adjust and maintenance. The operator should master specialized knowledge. The electric system of the machine set can be divided into three parts as main electric circuit, excitation adjusting voltage and assistant electric circuit. The automation machine set is also equipped with automatic control circuit. Such as Figure 3, Figure 4 show. 1. Main electric circuit The main electric circuit includes synchronous generator 、the excitation machine and the electricity switch(include a main switch and the division switch) etc.. For the parallel operation machine set, it is equipped with parallel operation and automatic adjust electric circuit. The general principle of the machine set is as follows: With the force of diesel engine, both the generator and the excitation machine revolve in the rated and steady speed rate. When the exc itation circuit work normally, the excitation machine (three times harmonic excitation generator and phase compound generator) setups self excitation voltage immediately. After excitation voltage is rectified, the voltage of the generator is steady at rated one. During the normal work of the generator, because of a certain reason (for example: load variety, various speed rate, temperature variety of the round group etc.), the generator voltage is up or down .At the time, the automatic voltage modulator A.V.R. (phase compound equipment), reduces or increases the excitation current to maintain voltage by the tiny voltage deviation. The output side of the generator is connected with the input side of the main switch by the line box, and then the output side of the main switch is led towards division switch and load, which is connected with measure gauge and no power loss current mutual sensor in series. While needing outward power supply, the set will output current, after connecting a main switch and then control panel of the division and then button on according to the requirements. 2. The excitation adjust voltage circuit while adjusting automatically and then work of automatic voltage modulator A. V. R , the magnetic field current of the generator SHANGHAI YANGKE ENGINE CO., LTD.
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depends on the pass angle of the control silicon SCR measured by A.V.R. in order to adjust the output voltage of the generator. The electric principle diagram of the control panel of the machine set:
Figure-3Dieselenginecircuitdiagram
Figure4Dieselgeneratorcircuitdiagram
CHAPTER-4 MOUNTING AND USE OF THE UNITS Section-1 Mounting and use of the units Storage, Mounting and location of the diesel engine generator sets should match following conditions: 1. Engine room should be bright, well ventilated, low humidity, where the environment temperature is less than 313k; 2. In the night, work space should have a good lighting equipment. In the outdoor SHANGHAI YANGKE ENGINE CO., LTD.
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usage, you should add the protection cover in order to avoid rain pour and sun; 3. The environment should be clean and be prohibited to place caustic things such as acidity, alkalescency and so on nearby; 4. Exhaust pipe should be unimpeded. You should avoid long pipe or make a sudden turn as far as possible. When the pipe is connected to the outdoor, you'd better tilt outside slightly in order to make coagulant out; 5. If the machine set isn't fixed on the foundation, you can place rubber plate below the set to decease vibration; 6. When the set is above 30KW, you should pay attention to your installations: a. The foundation is concrete, but the foundation can not be together with the building foundation. The distance between the two foundations should be more than 1.5 meters; b. While assembling, you must use horizontal ruler in order to the horizon degree of the machine set fixed; c. For the sake of the safety, the generator and switch screen must be connected to ground, and the ground line cross area isn't smaller than the one of the generator output line. The line can be connected to the underground water pipe or deeply under the underground steel plate in order to reliably ground. The resistance is less than 50 ohm. d. The open cooling machine set must install another water pipe line in order to supply full cooling water; e. In order to reduce the environment noise, you can use muffler; f. After assembling, the eccentricity between the generator shaft and the crankshaft must be smaller than 0.15 millimeter; the flutter of the generator shaft to the flywheel side face should be less than 0.5/400; g. Storage battery should be well connected with the circuit of startup and charge.
Section-2 Usage of the machine set Before using the machine set, you should read ‘Usage Manual of the Maintenance of the Machine Set’ and the manuals of the diesel engine, generator and control panel etc. usage maintenance manual. 1. Preparation of startup ※ Note: The fuel、engine oil and coolant that the machine set uses
should be
referred to ‘Usage manual of the diesel engine’. a. To get rid off dust 、the water vestige and rust etc. from the machine set and oil SHANGHAI YANGKE ENGINE CO., LTD.
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dirt 、ash dirt from the air filter. b. To wholly check the machine set: tightly connecting, manipulating the organization flexibly, revolving crankshaft easily. c. To check whether the coolant is full or not, whether the water pump is full or not, whether the antifreeze is added or not in the winter, whether the pipe is leak or not, whether the pipe is chocked or not. d. To check the fuel in the tank, to open the fuel switch, to loose high pressure oil pump, to expel air in the fuel pipe, to screw bolt tightly; e. To check engine oil indicator between two scales, to check enough engine oil in fuel pump and activator; f. To check the credibility and sensitivity of activator lever and fuel pump gear, to check enough engine oil here; g. To check all electric wire(include charge 、startup circuit) whether connection is true and connection is good; h. To keep water and oil pipe joints of diesel engine 、lubricating system、cooling system etc from leaking; i. To check integrality, cleanness, break, looseness of control panel; j. To cut off rectifier and capacitor etc. and disconnect ground line, and then measure resistance between wire and rotor round wire with 500megohm gauge which must be more than 3megohm, otherwise to dry the circuit. k. To check generator switch line without any error, and load should be connected with control panel by two sides switch , which should be insulated from wire net(Air is cut off; U, V, W of the generator are corresponding to control panel main side); l. To check switch position of the control panel, to check division position of main switch. m. To check fingers (should show zero); 2. Startup of the machine set. a. Pressure adjust switch should be at hand position; b. You should open the fuel switch, and fix the hand lever of fuel control at 700 rpm fuel control position in the meantime. c. You should pump fuel by hand in succession until a pump pressure and ringing squeak. d. You can startup diesel engine by hand and electric button. After the rotate speed reaches a certain one, the engine can startup; e. After the diesel engine startup, the rotate should be at 600 rpm~700 rpm. You should pay attention to the pressure of engine oil which is above 0.3MPa and the SHANGHAI YANGKE ENGINE CO., LTD.
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charge pressure which is above 0.35MPa. If the manometer shows zero, you should shut down immediately. f. If the machine set is low speed operation, you can rise up to 1000 rpm~1200rpm as a preheat operation. When the water temperature is at 323k~333k and the engine oil temperature is at 318k or so, you can rise up to 1530rpm~1560rpm. At the time the frequency meter should show 50HZ and the voltage gauge should show 380V~410V. If the voltage is higher or lower, you can adjust with A.V.R. g. If the work of the machine set is normal, you can open the generator and the air switch output power, and then you can add a load gradually. You mustn't add a load suddenly. Note: a. Each kind of diesel engine startup should be referred to the manual; b. If the machine set is stored for a overlong period, the generator loses magnetic and the voltage can’t be established. At this time, you can use the storage battery to charge magnetism. When the charge, the magnetic field round L1 (+) to be connected with positive node of the storage battery and L2 (-) with the negative node of the storage battery. Wrong connection is forbidden. Brushless motor must disconnect F+ or F- in A.V.R. After charge magnetism, you can connect the nodes. c. If you press button above 10 seconds, you can't startup still. You should wait a minute or so and startup for the second time. If you fail for three times continuously, you should find out the failure reason; 3. The operation of the machine set. The operation of the machine set. After the new machine set is installed carefully, you should wear away at the initial stage for 60 hours. a. After stable operation of the set, the staff should pay attention to pressure 、 temperature、drain water temperature of the engine oil and show of the gauges. b. You should check checks fuel、engine oil and coolant periodically whether the quantity is ample or not; c. New machine set must replace engine oil after 60 hours operation below 60%~80% rated power. Then you can operate the set at above 1500rpm with load, otherwise A.V.R and magnetic round will damage. d. machine set usage environment if outrun XU3 YONG4's condition that the mark settle, output the power should press . e. You should pay the following attentions: When the generator revolves, you should notice the cooling condition and the voltage and electric current shouldn’t SHANGHAI YANGKE ENGINE CO., LTD.
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exceed rated values; if sound is abnormal, you should shut down immediately and check. You should notice water temperature 、oil temperature、oil pressure at any time. If there is a abnormal thing, you should shut down and check. Abnormal things are as follows: Oil leaking、water leaking、air leaking and so on; The color of exhaust gas (Normal condition is caesious; Abnormal condition are blue-black or dark-black); Other things such as oil, water, metal are in the generator; Asymmetry current exceeds 25% or each phase load current exceeds rated one. f. You should record in detail during operation, including environment parameter 、 machine operation parameter 、open machine time、shut down time、break down reason、debug methods and the name and quantity of the replace components etc.; 4. Shut down of the machine set. Take the big machine set as an example to describe as follows: 4.1 Shut down normally; a. You should unload gradually and then close the load s witch. b. After the set descends to 600-800 rpm at zero load and operates for several minutes, then you can push again the oil pump hand handle to stop oil supply. After you stop the set, you should put the hand handle at the lowest position. c. When the environment temperature is less than 278k, the cooling water of the diesel engine and the water pump should be empty in order that the body of the machine set is frozen to crack. If you add antifreeze liquid, you don't need to empty cooling water. When it's necessary, the machine set room should be equipped with constant temperature devices, where the temperature is above 278k and you can startup the set easily. d. During a short term operation, you should keep air from entering fuel pump. During a long term operation, you should close the fuel switch after shutting down. e. Over a long period shutting down, you should empty engine oil. 4.2 Shut down in a hurry. When there are the following troubles with the machine set, you must shut down the set in a hurry. At the time, you should unload at first, and then switch the fuel pump handle to cut off the fuel in order that the engine stops immediately. a. The data of the manometer descends below 1KPa (while working with load normally) b. The set makes a voice of quick knocks, some components damage or the set sends out abnormal voice; c. Cylinder, piston, actiyator and so on choke; d. The voltage of the generator exceeds the maximum value; SHANGHAI YANGKE ENGINE CO., LTD.
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e. It take places a fire disaster or other natural ones; f. When water temperature exceeds 363k, you should turn off the air switch at first, and then you slow down the rate of the set to 700rpm.After water temperature falls a little, you can stop the machine and check it.
CHAPTER-5 MAINTENANCE AND TROUBLE SHOOTING Section-1 Maintenance and maintain of the machine set The machine set is composed of the diesel engine, the generator control panel and so on. Each main component has different maintain way. Because each machine set needs a careful maintain, it should be based on different manual. The machine set often works or stops for a short period and then should be maintained once every week as follows: 1. Each part of the set should be clean. You should wipe each part off dust 、grease stain; 2. You should check the connections of the electric components and leads in order to get rid of ill connect or short circuit. 3. You should check the connections of all parts of the machine set and lubrication status. The general maintenance of the generator is as follows: 1. The generator should be kept from damp and be put in dry room; 2. No matter while storing or operating the set, you should keep miscellaneous things such as drops of water, metals etc from entering the set; 3. While running, you shouldn't see more than 1.5 millimeters of sparks on the collectors, and temperature of the collectors is not more than 353k; 4. Don't let the generator in the steam. Don't use it in the dusty situation; 5. After the bearing has been working for 3000 hours, you should add lubricant grease that is the 3rd calcium fat. The amount of grease should be half of the oil room capacity. The grease should be clean and the bearing temperature shouldn't be more than 368k; 6. Check whether each component of the excitation part disconnects or loosens or not. ※
The debug of the machine set: The operation of the diesel engine refers to
‘Operation and maintenance manual of diesel engine’ (‘Usage manual of diesel SHANGHAI YANGKE ENGINE CO., LTD.
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engine’ in a detail). The operation of the generator refers to ‘Operation and maintenance manual of the generator’ (‘Maintenance maintenance manual’ in a detail). Declare: Because the structure and performance will improve continuously in the following manufacture, the content of the manual may have a little discrepancy with the real product. YangKe company will make a continuous improvement in order to satisfy with customers' requests.
SHANGHAI YANGKE ENGINE CO., LTD. ADD.: No.20 Ronghui Road, Rongbei, Songjiang Zone, Shanghai, China TEL: +86-21-57784118, 57784265 FAX: +86-21-57784183 Http://www.yang-ke.com E-mail:
[email protected]
SHANGHAI YANGKE ENGINE CO., LTD.
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