Users guide and maintenance manual All
Contents
1. 3 3 2 9 Fuel Since the fuel is classed as a dangerous product certain regulations for storage and distribution must be followed It 1s also necessary to consult current laws when carrying out the installation It is usual to fit fixed installations with a daily service tank and storage tank These two tanks can be joined into one if the generating set consumption 1s low WARNING Do not used galvanised receptacles or brass coated receptacles for storing fuel a Manual filling tank Solution for a manual starting generating set that is visually monitored This tank is often part of the frame and has a mechanical gauge filler neck and drain port b Automatic filling tank located in the room Solution for automatic starting generating sets The tank 1s automatically filled by an electric drawing pump in a main storage tank This type of installation 1s subject to regulations Moreover it should be fitted with a retention container capable of collecting leaks with a capacity at least equal to that of the tank There must be an overflow pipe going back to the main tank Its section should be at least twice that of the supply pipes To prevent unpriming the tank is fitted slightly filled in relation to the diesel engine except in covered parking areas This tank must also be fitted with a shut off valve for which the control must be located outside the room 1 Double lined storage tank H H 2 Leak testing cell m i2. rx 7759920 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 7 57 D A4 444 2 Pictoorams and their meanin 2 gs Warning danger Warning risk of electric shock Warning toxic materials Warning pressurised liquids Warning high temperature risk of burns Warning rotating or moving parts risk of getting caught in the machinery Warning corrosive product Web Fax 50H 250 QE e Q 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 707 539 5212 Email sales generatorjoe NET www generatorjoe NET Publications delivered with the generating set must be referred to Protective clothing must be worn Your eyes and ears must be protected Periodic maintenance must be carried out Battery level must be checked Lifting point required Stacking point required GeneratorJoe Naked flames and unprotected lights prohibited No smoking Warning risk of explosion Exctinction by water Entry prohibited to non prohibited authorised persons When on a trailer Power earth the set before starting it Earth Emergency cut out Application of EU Machine Directive 98 37 of 22 June 1998 in relation to generating sets access restricted to authorised personnel only according to the legislation 1n force live installation possible automatic start up 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 53
3. ADD WATER UP TO THE PRESCRIBED LEVEL CHARGE FOR 4 5 HOURS VISUAL AT 1 10 OF THE INSPECTION NOMINAL CAPACITY THEN CHECK THE ELECTROLYTE DENSITY BELOW THE step 2 ELECTROLYTE DEVE CHECK THE PRESCRIBED LEVEL ELECTROLYTE DENSITY STEP 1 OK sten 2 lt 1 22 kg OR VARIATION ABOVE 50 g l BETWEEN CELLS lt 1 22 kg OR VARIATION ABOVE REPLACE THE 50 g l BETWEEN BATTERY CELLS CARRY OUT QUICK 7 122 kg l ELECTRICAL PERFORMANCE p ELECTROLYTE RECHARGE THE DENSITY TEST BATTERY FULLY TESTS step 3 gt 1 22 kg l STEP 2 HE hr THE TESTER GIVES FIT TO OPERATE CHECK THE A POSITIVE RESULT Be TEST OF BATTERY USING A QUICK MIDTRONICS WEGA ELECTRICAL OR SIMILAR TYPE PERFORMANCES OF TESTER THE TESTER GIVES REPLACE THE A NEGATIVE BATTERY RESULT STEP 3 46 57 9 FUEL AND CONSUMABLES All specifications product features are given in the engine and alternator maintenance manuals attached to this manual 9 1 Circuit capacities Volvo engines ENGINES TAD 1232 TWD 1630 TAD 1630 TAD 1631 TAD 1241 TAD 1242 CIRCUIT AND TANK CAPACITY LUBRICATION 1n litres 20 ST 5 a za U2 oo UD 38 164 164 164 135 35C E mene EX II COOLING 1n litres 41 9 36 9 COVER M 413 350 24 EN FUEL M 424 480 1n litres COVER mas EN aso io so o so wiz so sio sto M 426 500 500 500 4016 Quartz Drive Santa Rosa
4. Phone 707 539 9003 C Fax 707 539 5212 Gener atorJoe Email sales generatorjoe NET Web www generatorjoe NET 41 57 6 1 3 Installation positioning The position should first be considered in relation to the electricity distribution centre fuel storage the general environment and type of ground before the equipment can be accommodated The installation area should be flat enough for the frame to rest level on it and strong enough so that the container does not sink down If the container s are being installed definitively a concrete foundation must be constructed for which the calculations and execution must be performed by a specialist ji a NO NNT NN ll 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 42 57 EM Ce a ee I BI LI ERI RI RI RR a IL I I The environmental impact should also be analysed so that the disturbances to be caused by the equipment will not affect those living close by Therefore it is essential to be aware of the regulations in force in order not to be vulnerable to future legal action On this subject the sound level of the set and reverberation effects on buildings must be taken into account 182 HI aa Examples of increases 1n
5. WARNING Before beginning handling procedures you must ensure that the operating personnel has the necessary qualifications All handling procedures must be carried out under the instruction of one co ordinator only It is essential to use an adapted lifting vehicle lifting and travel limit etc fitted with a lifting beam to ensure that the container 1s moved correctly 6 1 Handling transport and positioning of the containers 6 1 1 Handling instructions attach the lifting vehicle slings to the handling rings on the container carefully stretch the slings without lifting the container check that the sling hooks are correctly attached and the equipment 1s solid lift the container carefully and without jerking direct and stabilise the container towards its final position position the container while still lifted in accordance with its final position carefully set down the container without jerking while continuing to position it once the container 1s on the ground and in the correct position release the slings check that the container 1s stable and correct it 1f not detach the slings and remove them from the lifting rings the procedure has been completed when the container 1s in position 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Gener atord OE Email sales generatorjoe NET Web www generatorjoe NET 39 57 Examples of equipment and handling
6. OC MIO SIC OOC OOC 89C Occ Occ OCC OST OST OCC VLI 06C 09 090 09C OLT OII OTT de CS Q HdCCD000cAcCI som ut SIC DNI IOOO oo som ut 06C NOLLVOIDIS UT QN CY C ALDVdV DINVL ANV LINO AID TCDOO0VAY9 I 8DO00VACI L9DOO0VACI CDOO0OVACI C8 000CACT CV 000CACT CV 000C A9 T CC 000C A9 T CC 000C AST C8 000CA9T SHNIDNA T8DO0007A9T T9D0007A9T HC9D000CcAcCI 10 MAINTENANCE OF OPTIONAL EQUIPMENT 10 1 Japy pumps for clear fluids 10 1 1 Technical specifications Base block Zamak piston seat and valves Diesel and petrol Steel shaft against mounting clamps and lugs O ring Base block Hydrocarbons Brass piston seat and valves Max viscosity 300 cst Steel shaft against mounting clamps and lugs O ring Pump body Cover Lever Piston Seat Lever nut O ring Suction or discharge clamp 9 Clamp joint 10 Screw with nut for cover or bracket to be specified 11 Piston valve 12 Seat valve 13 Valve split pin CONN tn BW D 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 G t J Fax 707 539 5212 ener a or oe Email sales generatorjoe NET Web www generatorjoe NET 5157 Suction Suction capacity is completely independent of the size of the pump These pumps can attain 7m to 7 50m of pressure suction with cold water at sea level The suction pipes should
7. The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 34 57 4 INSTALLATION OF MOBILE SITE SETS 4 1 General information Besides the advice and rules given for fixed sets certain arrangements must be made for Site sets 4 2 Specific arrangements An area will be reserved to install the generating set Its should be flat and strong enough so that the generator does not sink into it It could be made of concrete or even large planks fitted together It should be noted that a generating set that does not rest correctly on its base frame or trailer will be subject to vibrations that could cause damage to all the equipment The location of the set on site should be chosen for ease of fuel supply and distribution of current to the users Access to the set s doors should be available at all times for safety and maintenance reasons Ventilation of the generating set should not be affected 1f there are different objects close by It will cause abnormal heating and reduced power Burnt gas evacuation will take place in such a way that there 1s no reaspiration into the air filter or cooling system The generating set s neutral speed must
8. TN Incorrect exhaust and Ground too uneven or soft Reduced access ventilation Set incorrectly positioned Fuel filling impossible Opening cover doors impossible 3 3 2 Measurements and layout These are governed by two types of requirement 3 3 2 1 Static requirements These are the dimensions of the equipment installed and its surroundings namely daily service fuel tank cabinet silencer batteries etc 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET 24 57 Web www generatorjoe NET GeneratorJoe 3 3 2 2 Dynamic requirements These are the measurements to be adhered to between each piece of equipment to allow for refitting and possible removal About a 1 metre space around the set 1s considered the minimum required for carrying out problem free maintenance This will give enough space to check that the doors of covered sets open fully that equipment can be accessed for maintenance and that integral removal of the set can be carried out Example of room dimensions for a covered version set 3 3 2 3 Construction All sorts of shelters can be designed to house a generating set If noise level and speed of starting are not the main considerations in your choice it can be installed under a basic shelter to protect it from bad weather rain snow storms etc If a low noise level and fast start are important criteria e g emergency set or n
9. Example of container lifting using a lifting Example of grip by Example of grip by a beam fitted with hooks shackles or manually an ordinary hook safety hook coupled locks Example of grip by a Example of shackle manually coupled lock grip Attachment of lifting device Checking the attachment lifting when the container is still on the ground Example of lifting Example of a container lifted by four parts in the bottom corners 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Ge ti J Fax 707 539 5212 ner a or OE Email sales generatorjoe NET Web www generatorjoe NET 40 57 DAX Example of a lifting method not to be used Example of a handling method not to be used 6 1 2 Transport The transport of containers should be in accordance with the highway code for the relevant countries The transport equipment trailer semi trailer container holder etc should be suitable for this use and provide all safety guarantees in terms of its capacity to support the load and the attachment devices Driving should be on vehicular roads of sufficient quality not to damage the equipment stored inside the container WARNING Although they look very like ISO transport containers our equipment does not comply with the different certification tests that these have undergone Therefore our containers cannot carry additional loads no stacking 4016 Quartz Drive Santa Rosa CA 95405 Bd
10. a 3 Filling port JE vn I w E 4 Shut off valve control unit CF f 3 5 Safety valve control unit Ny 3 b 6 600 L retention container FS Re 7 500 L daily service tank em gt ui e 8 Gauge with level switch aH 9 Manual pump 2 A 10 Electric pump cm E 11 generating set ol D 12 Vent 13 Safety valve 14 Shut off valve 15 Earthing Lo 16 Electric fuel level gauge 17 Anti return valve with strainer 18 Concrete floor plate 19 Anchoring belt 1 m Fuel supply 20 Pits Fuel return 21 Pipe passage Electrical wiring Access plug Mechanical cable Drains 24 Min hole 0 70 x 0 70 25 Type and capacity label Example of installation 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 G t Ji Fax 707 539 5212 ener a or oe Email sales generatorjoe NET Web www generatorjoe NET 28 57 3 3 2 10 Burnt gas exhaust studying the evacuation of burnt gases by a generating set should not be seen as a minor detail due to the fact that a pipe can always be installed even in the most inaccessible areas In fact there are a certain number of constraints to be considered such as drops in pressure caused by the exhaust insulation suspension noise level and air pollution It should be noted that the more complicated a circuit the more it causes drops in pressure and consequently its diameter will be large and heavy and its supports and silencers
11. be pumped Fluid leak Check the pipe connections Replace the seals 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 56 57 10 3 REN RAB automatic oil auxiliary adjuster 10 3 1 Description Vent Pressure equalising line for an engine working with pressure in the sump other than atmospheric pressure Oil intake to the regulator A 1 2 pierced inlet port is located on each side of the lower section of the regulator Outlet ports A 1 2 pierced outlet port 1s located on each side of the of the regulator chamber Centre of the regulator and level maintenance line Regulator inlet Regulator outlet 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 n cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 57 57
12. be used to protect people Earthing 1s carried out using a metal post buried deeply in the ground These sets are to be covered or protected from bad weather by a suitable construction see previous sections 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 35 57 ROAD TRAILER 5 1 Trailer linkage Before attaching the trailer check the trailer hook on the tow vehicle it should fit the trailer ring perfectly WARNING DANGER Trying to tow a trailer with a non matching device bar wires cords etc could lead to serious accidents Also check no incipient fractures or excessive wear on the hitching system locking system is operating properly To hitch the trailer proceed as follows lock the wheels to stop the trailer from moving lift up the rear trailer supports and lock them release the parking brake release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook hitch the trailer remove the locks on each side of the wheels then lift up the front wheel fully using its handle connect the electrical circuit of the trailer to that of the tow vehicle hook the handbrake safety wire onto the hook on the tow vehicle CORRECT CORRECT Tow vehicle Tow vehicle INCORRECT JO 4016 Quartz Drive Santa Rosa CA 95405 Phone 707
13. expensive NOTE generating sets with a silencer fitted in the enclosure must be fitted with an exhaust compensator This compensator or hose will be fitted to the exhaust outlet in the cover Main components exhaust pipes 2 elbows 3 expansion bellow 4 condensation bleed 5 bulkhead crossing roof outlet 6 exhaust outlet 7 suspension line 8 needle frame 9 base of column 10 silencer suspension 4 11 heat insulation 12 silencers The installer must check that all the components installed on the exhaust pipe do not cause pressure drops greater than the engine s admissible pressure 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 f rx 775952 Generatordoe Email sales generatorjoe NET Web www generatorjoe NET 29 57 Figure 1 Pipes It is recommended that you use seamless pipes However for weight reasons rolled steel pipes can be used In any event welded bars inside the duct are to be avoided Figure 2 elbows The elbow should have a minimum curve radius of 2D if possible in a single component If the elbow is made of welded steel check that 1t includes at least 3 sectors for 90 elbows Figure 3 expansion bellows and hoses expansion bellow absorbs sideways movements due to expansion approx Imm metre 100 C hose allows for considerable sideways travel but low longitudinal amplitude Figure 4 condensation and rainwater bleed Allo
14. maintenance manual for the engine fitted to the set maintenance manual for the alternator fitted to the set user manual for the control panel if fitted wiring diagrams these diagrams are supplied with the reference material or delivered with the generating set 2 1 2 2 Level B This reference material is additional to the level A reference material In addition it contains the spare parts catalogue for the engine fitted to the set and enables a qualified user to identify a part and order it Composition List index mark description part number etc Illustrations index mark These parts catalogues are only available in English regardless of the engine manufacturer 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Gener atorJoe Email sales generatorjoe NET Web www generatorjoe NET 6 57 2 1 2 3 Level C This reference material 1s additional to the level B reference material It contains the information required for major maintenance of the generating set or power station workshop repair manual This document enables an experienced user to carry out repairs to equipment following deterioration or damage Composition Illustrated text index mark commentary procedure intervention period required level etc Tools list This reference material exists mainly in English regardless of the engine manufacturer 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003
15. may be cut with an axe Take extreme care to avoid the electric arc that results from this Begin emergency procedures Resuscitation If breathing has stopped begin artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 2 3 8 Risks related to moving the set Use lifting units to lift the generating set Always make sure that the lifting equipment is in good condition and has a sufficient lifting capacity In order to work in complete safety and prevent the components fitted to the top of the engine from being damaged the engine should be lifted with an adjustable boom All chains and cables should be parallel to one another and as perpendicular as possible to the top of the set If other equipment fitted to the generating set alters its centre of gravity special lifting devices may be required to maintain the correct balance for working in total safety Never carry out work on a generating set that is suspended on a lifting device only 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 15 57 2 3 9 Recommendation for the operator and environment Operating personnel should be aware of the safety and operating instructions These will be regularly updated Operating should
16. noise level due to reverberation and positioning The equipment should also be installed so that the vents controlling the air intake should be opposite so that there are no difficulties in difficult weather conditions intake of air snow sand etc 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 roe 7075952 Generatordoe Email sales generatorjoe NET Web www generatorjoe NET 43 57 6 2 Maintenance lubricate the hinges and locks regularly ubricate the joints with silicone grease wash and clean the bodywork using products designed for car bodywork check the condition of the bodywork and retouch any scratches straight away to prevent the start of corrosion 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 44 57 7 PREPARATION BEFORE OPERATING THE SET WARNING DANGER The inspections referred to in this section enable the electrical generating set to operate Specific skills are required to carry out these operations They must only be entrusted to personnel with the necessary skills Failure to follow these instructions in any way could lead to incidents or very serious accidents 7 1 Installation checks e check that the general recommendations from the installation section ventilation exhaust fluids etc are followed e check the levels oil water diesel batte
17. then lift it up using jacks to support it remove the pipes and put down the set checking that it 1s in the correct position then remove the jacks 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 G iy t J Fax 707 539 5212 ener or oe Email sales generatorjoe NET Web www generatorjoe NET 21 57 It is recommended to use a fork lift truck with arms that are longer than the width of the frame If you are using a rail or crab once it is in position continue in the same way as described in the slings paragraph 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe NET 22 57 3 3 Installation of fixed sets NOTE If you do not follow the basic principles the installation assembly will suffer damage and abnormal wear The procedure described gives the main requirements for installing a conventional generating set made up of a heat engine a generator and electric panel These requirements are general principles to be observed For any specific applications or if you have any doubts our technical departments will advise you and look at your specific conditions of installation The current regulations provisions and laws in installation locations must be adhered to EVACUATION OF EXHAUST GASES OUTSIDE THE ROOM If the original pipework needs to be extended it must be suspended and fitted with an expansi
18. this procedure This radiator 1s cooled by the fan controlled directly by the engine In all cases the air is blown in the direction from fan radiator Cooling 1s ensured by the circulation of air across the room An expansion vase can compensate for the variations in the volume of coolant fluid according to the temperature b Air recooler The engine cooling circuit is connected to an air recooler located inside or outside the room in order to implement this procedure When located in the room it operates in the same way as a ventilated radiator The fan 1s either attached to the diesel engine or run by an electric motor If the air recooler is moved outside on the roof or in another room the coolant pipes are extended and cooling ventilation is supplied from another room In these installations the degassing conditions should be considered even more carefully than for a radiator In all cases the air cooler 1s cooled by the fan For cooling by radiator or air cooler in the room the increase in temperature due to heat radiation for the sizing of the installation should be taken into account 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx roux GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 33 57 c Lost water exchanger This type of cooling consumes a non negligible degree of water and hence there is an operating cost to be taken into account This the solution when local provis
19. with a foot valve This device 1s necessary for draining the pump If there 1s a threat of frost do not forget to open this tap while checking that the discharge port is free to let air in Draining should take place normally but for increased safety after the water has flowed out pull the lever two or three times to complete the draining If the body or cover is cracked by frost do not try to repair it by autogenous welding as this would distort the part Extended lack of use If the pump is not used for a while it is recommended if frost is not likely to check that the pump chamber 1s always full of pumped fluid if frost 1s likely to drain and if possible pull the lever a few times to prevent the internal components from becoming blocked by oxidation if not drain and add liquid paraffin by spraying if possible to prevent oxidation and the internal components from becoming blocked 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775920 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 9053957 In the event of oxidation and blocking never force the lever as this risks breaking the piston Remove the cover carefully clean the inside of the pump with an oiled cloth but never with abrasive material Lightly oil before refitting The Japy pump does not normally require any lubrication After several years of service or after use for water or fluids that are full of impurities o
20. 37 kW engine made for continuous work JEV 10 658 single phase 50 Hz 220V 2 4 A 240V 2 1 A JEV 10 658 single phase 60 Hz 208V 3 7 A 271V 3 3 A JEV 11 661 three phase 50 Hz 380V 0 8A 415V 1 A JEV 11 661 three phase 50 Hz 200V 1 5 A 240V 1 6 A JEV 11 661 three phase 60 Hz 380V 0 9 A 480V 1 4 A JEV 11 661 three phase 50 Hz 208V 1 8 A 240V 2 A WARNING DANGER The engines are not flame proof Do not use them in locations where there may be flammable vapours 10 2 3 Suitable fluids water fuel diesel amp light oil maximum viscosity of 10 cst at atmospheric temperature 10 2 4 Prohibited fluids Corresponding dangers Flammable fluids with PM below 55 degrees C Supply fluids Pollution of the fluids Corrosive chemical fluids solvents Damage to linings and joints 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 55 57 10 2 5 Maintenance The pumps do not require any specific maintenance Possible checking for leaks at the joints 10 2 6 Faults and repairs The engine does not work Possible causes No electric current Check the connections Blocked rotor Take apart the engine pump Look for a possible foreign body No flow or insufficient pressure Possible causes Actions Suction height too high Move the pump nearer to the fluid to
21. 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 G t J Fax 707 539 5212 ener a or oe Email sales generatorjoe NET Web www generatorjoe NET Users guide and maintenance manual All generating sets General considerations Safety instructions Installation R f constructeur MUE SD std A R f GPAO 33522903401 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 G t Ji Fax 707 539 5212 ener a or oe Email sales generatorjoe NET Web www generatorjoe NET 1 57 1 CONTENTS TONN 2 Premie 5 PM PRI ELIO PELLE TR TEES 5 2 Mel eneral tecomtmendattOfls eon rece s NST 5 2 1 2 Structure of the reference material issues eene nennen nens 6 PINE EN UR TTE 6 PAR BEAR OR LR 6 DAS Era ee c cM ER 7 2 2 Pi tograms and their meanlnD9s iere iei eoo o eer eti ooo ara bere name 8 2 3 Safety instructions and regulations cccccscsssssssccccccsssssssssssccccescsssssssssccesssesssssssees 10 TGI 1 pene ene 10 2 3 2 Risks related to feed gas concerns gas SES insert aires 12 2 3 3 Risks related to exhaust gases and fuels 12 2 29 RISKS related 0 dOXIO Ole ed 13 2 25 Risk ot nre burds and Explosion Lado bere Mo a 13 2 3 6 Risks related to electrical networks sise 14 2 3 7 Dangers presented by electric currents first aid 15 2 9 8 Risks related to MMO VINO he Sets Te 15 2 3 9 Recommendation for the operator and environme
22. 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET INCORRECT Tow vehicle Tow vehicle Trailer 36 57 5 2 Check before towing Before towing carry out the following checks wheel torquing lock trailer hook tyre pressure light signals working cover doors closed parking brake off front wheels and rear supports lifted tightening and fixing the draw bar arms locking levers brake test for road type trailers fitting brake safety cable 5 3 Driving On site type trailer These trailers are not fitted with a main brake and so cannot brake when operating the tyres are designed for a speed of 17 mph 27 Km h Therefore it 1s absolutely forbidden to exceed this speed Road type trailer The driving speed should be adapted to road conditions and the trailer handling Driving at sustained speed causes tyres to heat up therefore it 1s important to stop from time to time to check them Excessive heating can lead to a blow out and hence a serious accident When reversing do not forget to lock the overrun brake NOTE Particular attention must be paid to wheel torquing on new vehicles Indeed during the first few miles heat build ups on the wheel hubs and brake drums lead to reduced wheel torquing It 1s therefore essential to check the torquing every 6 miles 10 kilometres until no further loosening 1s noted The torque test should nevertheless be
23. 9 9003 rx or ssosct2 GeneratordJoe Email sales generatorjoe NET Web www generatorjoe NET 9 57 2 3 Safety instructions and regulations THESE SAFETY PRECAUTIONS ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows You should also refer to any local and national regulations that apply in accordance with your own jurisdiction 2 3 1 General advice Read and understand the manuals provided with the generating set in full Do not wear loose clothing and do not go near the machines when operating Note that the fans are not clearly visible when the engine 1s running Warn all people present to keep well back during operation B The generating set should always be controlled by an experienced person Always test the generating set from the control panel Follow the maintenance table and its directions Never let anyone else use the generating set without having first given them the necessary instructions Do not run the engine without having refitted the protective covers Engine with turbocharger never start the engine without fitting the air filter The rotating compressor wheel in the turbocharger can cause severe physical injury Foreign objects in the intake duct can cause mechanical damage Engine with air preheating sta
24. CA 95405 Phone 707 539 9003 Fax 707 539 5212 Gener atord OE Email sales generatorjoe NET Web www generatorjoe NET 47 57 LS 8t 9N TT INL opour 103 OG I son ut 001 001 001 001 Ev Ev Ev TANA tr I8 6v 6v Cr Cr pe L san ur DNITOON 01 S S vs vs L L 9 9 sou ur NOLLVORIGSN T ALIDVdVI DINVL ANV LINO AID SS Saas OS Solas TS sous TS souos TS SOLS TS sores JT souos TT souos HGS CIYS GS clvS HAS CIES QS CIES HASTET AS ET S3UT313 STANS IN S9HISEGES JINDAL TG LS 60 087 ttr N CC gt Ove OVE OVE OVE OVE OVE 9cc W eg NER Oly Olt Ot Olt Olt OIF 9TC IN ee ee JM A3OO JE 3 OOT 001 001 LOT W EE 06T 061 6TI W TANS m M OST OST OST OST OST OST STI IN Drm aeo zc EE sam ut TSE 8ST neris B ST SSc 8S st vec ee se zoz zoz en nr For For TI ONITOOD som ut GITISIT STE SIT SET SETI SETI SET SET S ET SET SET NOLLVORIGNT ALIDVdVI DINVL ANV LINO AID N mm uidi 0081 MAOIT ag 4091 4H8909 en wdi 9061 MA EST 091 4H8909 wdi 0051 MAEST 071 4H8909 OSTALS POP OTTALS OY OSTALS POP OTIALS POP OSTAHS O OTIAHS O OSTAGSHOr O7TIAGSHOr OSTAL6ZOE OTIAL6ZOE OZIAG6ZOE SHNIDNA 0L04H1809 OTTH L8909 di 0081 D MALST m OS 1HH8909 Q LS 0S THO LvtcC LVEC LEC LEC Lvtc LVEC LEC LVET LVEC LV C
25. EUR MANUFACTURER PLATE GROUPE ELECTROGENE GENERATING SET Type Execution GS4000200427 SDMO INDUSTRIES GS40002004277 SDMO INDUSTRIES Engines JOHN DEERE Engine Serial Number CD4045T123456 CD4045TF150 ADS DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE X XX RG7935 UN 13NOV97 FRIEDRICHSHAFEN Type 12V 4000 G60 Motor Nr 526 100 950 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe NET Baujahr 2002 Masse FRIEDRICHSHAFEN 1330 Leistung Drehzal 1500 CEE 54 5360 PUISSANCE ACOUSTIQUE SOUND POWER L wa 18020 1Tv0D1630 400 96 5 Num ro Homologation PRESSION ACOUSTIQUE SOUND PRESSURE dB A m 5 m AVP31650 01G Q C1 32889221 001 7 wem AVP31650 01G Q CI 32889221 0 AVP31650 01G Q C 32889221 0 7 VOLVO PENTA id ENGINE MODEL XXXXXXXX jSPEC NO XXXXXX i SERIAL NO _XXXXXXXXXX RATED NET POWER without fan kW hp XXX XXX with fan kW hp XXX XXX ISPEED AT RATED POWER rpm PRELIFT mm INJ TIMING X X X X XX tX X O MADE IN SWEDEN 3826077 o Dieselmotor MTU Motoren und Turbinen Union Friedrichshafen GmbH Dieselmotor kW GeneratorJoe l min MTU Motoren und Turbinen Union Friedrichshafen GmbH 18 57 Alternator oe ae am IS D D Tu Dn som Cie an ns rz ris 65 v g CJ 6 Made by Leroy Samer E Mg
26. always face on an upwards slope from the fluid suction pump to the pump installation point with no top section and with as few bends as possible with a large radius For any suction over 2 metres a foot valve must be installed suction valve to hold the fluid in the pipes which should have no cracks or leaks The suction manometric height should not be confused with the vertical distance of the expanse of water to the pump Losses of pressure are inevitable and are related to the length and diameter of the pipes used according to the flow the presence of a non return valve or elbows in the pipes A non return valve or elbow causes a loss of pressure equivalent to what 5 metres of straight pipes would give When there is a certain length of pipework or high suction or discharge a larger diameter pipe than usual should be used Discharge The pumps have been tested at a pressure of 1 500 kg to 2 kg and can therefore handle a 15m discharge However the force developed by the person handling the pump will increase according to the flow and elevation height suction discharge Therefore with a low flow the fluid can be raised higher than with a large flow pump Draining A small tap or bolt about 0 70m above the pump is indispensable Fitting The pump should be installed on a strictly vertical plane with Japy marque on the discharge side Check that the mounting has a flat surface and that the nuts are tightened moderat
27. be carried out according to the periods indicated in the attached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all adjustments and repairs are carried out by personnel who have received the appropriate training The dealers are suitably qualified and can answer all of your questions They can also supply you with spare parts and other services The left and right sides can be seen from the back of the electrical generating set the radiator is at the front Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum For all parts replacement contact your nearest dealer representing our company who will have the necessary equipment and properly trained and informed staff to carry out maintenance parts replacement and even total reconditioning of generating sets Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance IMPORTANT Some user manuals and maintenance manuals for the engines fitted to the electrical generator assemblies include information on the control units and detail the engine starting and stopping procedures As the electric generator assemblies are fitted with assembly specific test and
28. be monitored directly or indirectly by someone designated by the operator who is familiar with the installation and dangers and problems regarding products stored and used in the installation No one from outside the establishment should be able to access the installations freely unless designated by the operator The user should check the service pressures of the different pressure stages making sure that they are 1n accordance with the prescribed operating requirements The user is also responsible for making the apparatus adjustments according to the manufacturer s instructions and should check that the apparatus 1s operating correctly The user should create or obtain a document describing modifications and showing alterations made to the installations in relation to the original document B Manufacturers notes should be available to technical staff on site 1f possible The internal network diagram should be displayed as close as possible to the access points showing all the individual points Internal and external network information can be contained in a single distribution diagram A sign on the door identifies and gives details of the operating company and includes the telephone number for the gas supplier emergency department Personnel should be aware of the layout of the premises and they should be identified on site to simplify procedures In the event of a problem this type of knowledge about installations 1s cruc
29. carried out before towing 5 4 Unhitching the trailer This operation should be carried out on horizontal flat stable ground lock the wheels lower the front wheel disconnect the road signals wire refit the hitch using the wheel to release the hook ring from the tow vehicle release the tow vehicle engage the handbrake 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 37 57 5 5 Implementation for installation Procedures to be carried out check that the ground is strong enough for the assembly not to sink into it using the front wheel position the set as horizontally as possible engage the handbrake lower the rear trailer supports and lock them 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 38 57 6 INSTALLATION OF ELECTRICAL GENERATING SETS IN CONTAINERS WARNING When the generating set is working in automatic start mode the air evacuation doors must be open WARNING When the generating set is working in manual start mode the air evacuation doors must be open before it starts WARNING DANGER When the generating set has been started and the doors have remained closed they are formally prohibited from being opened very severe risk of injury owing to sudden opening of doors
30. control panels only the information in the documentation regarding the panels fitted to the assemblies should be taken into consideration 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Gener atord 0 Email sales generatorjoe NET Web www generatorjoe NET 5 57 2 1 2 Structure of the reference material The reference material delivered with the generating sets 1s divided into 3 levels 2 1 2 1 Level A This basic level gives all the user and maintenance procedures for the generating set or power station This reference material enables you to get to know the equipment operate it and maintain it both on a daily basis and periodically The reference material for the engines and alternators fitted to the sets consists of engine user and maintenance manuals from the manufacturer and alternator user and maintenance manuals from the manufacturer Level A reference material contains the user and maintenance manual containing among other things o general recommendations and safety regulations to be adhered to general recommendations for installing generating sets o general instructions for preparing generating sets before putting them into operation o Tables of capacities lubricants and coolants and fuel tanks of different engines that may be fitted to the sets according to their configurations covered or not o general reference material for maintaining starter batteries user and
31. d be considered a minimum requirement 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe NET 31 57 Figure 12 silencers These reduce noise by absorbing or causing phase differences in the sound wave An exhaust should be effectively suspended the supports should never rest on the set except for original fittings An exhaust compensator will be fitted to the engine outlet The pipes will never have a diameter less than the set refer to us about vermin and be directed so that gas cannot return to the room The pipes should be fixed so that their weight is not supported by the compensator It should be perfectly straight any misalignment could lead to a rupture Adapted silencer The adapted silencer 1s fitted directly to the set or cover It is an absorption type silencer A compensator 1s fitted between the engine and exhaust in the covered version Absorption silencer The gas passes through a sound proof duct made of acoustic high efficiency absorbent material protected by a perforated metal sheet Absorbent reactive silencer The gas enters an expansion chamber lined with absorbent material supported by perforated metal sheets then into an absorbent sound proof duct 3 3 2 11 Electricity a Connections general information In the same way as for low voltage electrical installations running and maintenance are s
32. e event of contact with eyes rinse immediately with plenty of water for at least 15 minutes CALL A DOCTOR IMMEDIATELY KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN The anti rust product is toxic and dangerous if absorbed Avoid any contact with skin or eyes Read the instructions on the packaging Glycol is a toxic product and dangerous if absorbed Avoid any contact with skin or eyes Read the instructions on the packaging Never expose the equipment to liquid splashes or rainfall and do not place it on wet ground Always use the recommended fuels Using low quality fuels risks damaging the engine and altering performance The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 2 3 5 Risk of fire burns and explosion WARNING DANGER The engine should not be operated in areas containing explosive products There is a risk of sparks forming where all electrical and mechanical components are not shielded Beware of creating sparks or flames and do not smoke near batteries as the electrolyte gases are highly flammable especially when the battery is being filled Their acid is also harmful to the skin and particularly the eyes Never clean lubricate or adjust an engine when it 1s in operation unless you are quali
33. eei tee menie nn an 53 10 2 Japy punip KI eio nie eee EE oe eerie oe roi Deco ne Edere e een e eoa Sets e S5 10 2 Tele Se 55 10 22 Feld ve 55 1023 STE Sa 55 10 24 Prohibited dv 55 10 2 5 Malte idle ee 56 10 2 0 Pauls MN HR 56 10 3 REN RAB automatic oil auxiliary adjuster ecce eee e eee ee eee eere nne 27 10 3 AIDES Crip OM NESE 57 Attached documents User manual for the control unit if fitted level A User and maintenance manual for the engine level A User and maintenance manual and spare parts catalogue for the alternator level A Wiring diagrams supplied with the reference material or with the electrical generating set Level A Engine spare parts catalogue level B Workshop manual repair for the engine level C 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 rx 70592 Gemeratordoe Email sales generatorjoe NET Web www generatorjoe NET 4 57 2 PREAMBLE 2 1 Introduction 2 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to help you operate and maintain your electrical generating set correctly Read the safety instructions carefully in order to prevent any accident incident or damage These instructions must always be followed In order to obtain optimum efficiency and the longest possible life for the electrical generating sets maintenance operations must
34. ely and alternately to prevent distortion of the body 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 552 57 10 1 2 Maintenance and repair Faults The pump no longer sucks or discharges there 1s air intake check all the seals and the suction pipes the foot valve suction valve no longer works there is probably dirt or some waste under the valve that 1t stopping it from resting on its seat check it there 1s dirt inside the pump blocking the valves remove the cover clean inside and check that the valves move freely Cable gland leak tighten the two cable gland bracket nuts alternately by one or two turns Otherwise remove this bracket take out the cable gland which is located in its housing Clean this housing and remove the residual lining Replace it with graphite braiding if itis a pump without cable gland model 254 remove the cover replace the O ring checking that the piston axis is not oxidised If it is clean it carefully Also reline the groove with graphite braiding Frost The draining bolt 1s inefficient and the Japy pump has not been supplied by it for a long time except for special requests using the control On the other hand it 1s indispensable if the pump is exposed to frost to use a small draining tap on the suction pipes about 0 75m above the pump In any case the pipes must be fitted
35. ensitive areas ceiling and walls covered if necessary with absorbent materials choice of adapted exhaust silencer s soundproofed door for access to the room and if required to the pressure lock for a very low sound level sound traps fitted to the air inlet and outlet sleeves Sound trap silencer Sound trap Soundproofed doors Example of installation 3 3 2 8 Ventilation A heat engine generates a certain amount of heat which must be evacuated outside the room to ensure the set works properly The heat released by the set originate from different sources cylinder cooling radiation from the engine unit and exhaust duct alternator cooling Also the room must be fitted with air inlet and outlet openings suitable for the conditions of use and cooling system As you know insufficient ventilation will cause the atmospheric temperature to rise and lead to problems ranging from at least a loss of engine power to the set stopping altogether Air must flow through the set room from alternator gt engine gt radiator This solution also supplies the quantity of fresh air needed for combustion The openings should be of ample size Air intake and emission will be as direct as possible The cooling system will be connected to a sealed emission sleeve or cover to prevent hot air from being recycled The air inlet and emission openings should not be located close to one another GeneratorJoe 27 57
36. fied to do so in which case extreme care must be taken to avoid accidents Never make adjustments that you are not familiar with Never cover the generating set with any material while it is working or just after it stops wait until the engine has cooled Do not touch hot components such as the exhaust pipe and do not put combustible material on them Keep all flammable or explosive products petrol oil cloth etc well away when the set 1s running 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 rx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 13 57 Good ventilation is required for your generating set to work properly Without ventilation the engine will quickly reach an excessive temperature that could lead to accidents or damage to the equipment and surrounding items Do not take off the radiator cap when the engine is hot and the coolant is pressurised due to risk of burns Depressurise the air oil and coolant circuits before removing or disconnecting any unions ducts or connected components Be aware of any possible pressure that might be present when disconnecting a device from a pressurised system Do not look for pressure leaks manually High pressure oil can cause physical accidents Some preservative oils are flammable Also some are dangerous to inhale Check that ventilation is good Use a protective mask Hot oil causes burns Avoid contact wit
37. h hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine when the oil filling cap 1s off as oil may be ejected Never start or run the engine when the oil filling cap is off as oil may be ejected Never cover the generating set with a fine layer of oil for anti rust protection Never fill up the oil or coolant when the generating set is running or when the engine is hot 2 3 6 Risks related to electrical networks The electrical equipment supplied with the generating set complies with standard NF C15 100 or the standards of the relevant countries Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Never accidentally touch naked wires or disconnected connections Never handle a generating set with wet hands or feet Maintain electrical wires and connections in good condition Using equipment in poor condition can lead to electrocution and damage to equipment p Any procedure on the equipment must be carried out voltage free Electrical connections must be made in accordance with current standards and regulations in the country Do not use faulty poorly insulated or provisionally connected wires Do not invert the positive and negative terminals of batteries when connecting them Such an inversion can lead to severe damage to the electrica
38. ial when poor identification of the premises might make a situation Worse Written operating instructions must be available for operations that involve dangerous handling procedures and driving installations In particular these instructions prescribe o Operating modes o Frequency of testing for safety devices and devices for handling pollution and other harmful substances generated by the installation o Methods for maintenance checking and use of adjustment equipment and safety devices B The operator should make the necessary arrangements to satisfy site aesthetic requirements The whole site must be kept clean and in good condition The premises must be kept clean and cleaned regularly with in order to avoid piles of dangerous or pollutant material or dust that could be susceptible to catching fire or causing an explosion The cleaning equipment must be adapted to accommodate the risks presented by such products and dust 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 16 57 The presence of dangerous or combustible materials on premises where combustion apparatus 1s sheltered 1s limited to what 1s required for the operation The installations must be operated under the constant supervision of a qualified person This person should periodically check that the safety devices are working properly and ensure the correct fuel suppl
39. ions ensure the flow of water and do not allow the ventilation provisions to be made for cooling by a ventilated radiator or air recooler These lost water installations consist essentially of an exchanger with one of its circuits fitted with an expansion receptacle connected to the engine cooling circuit The latter s water pump ensures circulation The second exchanger circuit known as raw water is connected between the building s water supply and the drain A valve fitted upstream of the exchanger can enable and cut off circulation With automatic sets this valve should also come with an electric control solenoid valve This system s heat exchange ensures engine cooling The room needs a ventilations system and this type of installation requires a detailed study d Ventilation of the room Extractor fans and or air blowers can evacuate heat radiation from the engine and supply fresh air to the room and equipment in the case of external air coolers or lost water exchangers If fans are being used more fans rather than one large one can regulate the temperature Ventilation of the premises requires a detailed study and should take into account the atmospheric air temperature and loss of pressure of components located in the air inlet and outlet grilles sound traps etc in particular 3 3 2 13 Special arrangements generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring
40. l equipment Follow the wiring diagram supplied by the manufacturer 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 14 57 The generating set should not be connected to any other power sources such as the public distribution network In specific cases where there is a reserve connection to existing electrical networks 1t must only be carried out by a qualified electrician who should take the operating differences of the equipment into account according to whether the public distribution network or generating set 1s being used Protection against electric shocks 1s ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications Due to strict mechanical specifications you should only use flexible resistant rubber sleeved wires in compliance with CEI 245 4 or equivalent wires 2 3 7 Dangers presented by electric currents first aid First aid In the event of an electric shock cut off the voltage immediately and activate the set s emergency stop If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire
41. me C E I 34 1118941 According ta E C 34 1 19941 NEWAGE INTERNATIONAL LTD BOX 17 BARNACK ROAD TAMFORD LINCOLNSHIRE PES 2NB ENGLAND MADE IN LEEK NO 06 99 BS 5000 PART 3 IEC 34 1 NEMA MG 1 29 ISO 8528 3 Cabinet Designation ARMOIRE DE 400 VA A0217010 Cde AVP31650 01C Reference SOREEL 371562 03 No OF 02280753 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 hin in Email sales generatorjoe NET Web www generatorjoe NET 19 57 3 INSTALLATION WARNING Sections 3 4 and 5 contain only general recommendations It is recommended that you use a professional to ensure correct installation and start up The company cannot be held responsible for breakdowns related to the conditions of installation 3 1 Unloading 3 1 1 Safety during unloading In order to unload generating sets from their transport mountings under optimum conditions of safety and efficiency you should check that the following points are being followed correctly Suitable lifting vehicles or equipment for the work Slings positioned in the rings provided for this procedure or lifting arms resting fully underneath the frame cross beams Suitable ground to accommodate the load of the set and lifting vehicle without strain if not put down sufficiently strong and stable boards Remove the set as close as possible to its place of use or transport in a clear space with free access 3 1 2 Example
42. ng a procedure Only fit original spare parts Use tools that correspond to the work being carried out Clean all traces of oil or coolant with a clean cloth Never use petrol or other flammable substances to clean parts Use only approved cleaning solvents Do not use a high pressure cleaner for cleaning the engine and fittings The radiator hoses electrical components etc could be damaged Avoid accidental contact with parts that reach high temperatures exhaust manifold exhaust Engage the parking brake when the generating set on its trailer 1s installed on the operating site When setting on a slope check that no one is behind the trailer Protective eyewear must be worn when handing during maintenance operations Operators should remove watches chains etc 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 11 57 2 3 2 Risks related to feed gas concerns gas sets WARNING DANGER The gas is explosive It is forbidden to smoke go near or create sparks when the tank is being filled and near to the generating set Request the user technical notes and LPG or NG safety data sheets from your gas supplier B Gas installations must be installed maintained and repaired by recognised specialists Do not attempt to open unseal or intervene in gas supply pressure relief valves and on the gas line in general B Gas su
43. nt 16 2 4 IdGHUIVIHO Seas 18 SANTINO 20 TA de 20 SN durne NGT n cui ione t ui vd epe geld unie b dtu lun iei toe RRUE 20 541 2 Example OL MAUR ea eoruni ne vedi esa tte Ce xe EU deed 20 LS Instructions or Ude 20 SABES D 20 LS Fok Ne 21 5 2 MAAN GING instructions siasio en Rs nn tue 21 3 3 Installation of fixed Sets oue min sh ch die 23 SS M S STL 01 REESE EEE mUS 24 2 2 2 Measurements and Ay OU SG 24 De Di Dl State Se quit eie DES osa ere etm d tps tm tbi tha Cb uu tube tm SUR ne uet 24 ST D rer UNN aia ee bcd o eee tnb din tante 25 355 2 3C ONS CULO EE EE ti nat e 25 3 2 2 4 BASS TENNES 25 RI OPS nee E do a dd on dite 26 DROP UE UU t NEU T T TU 26 ST SOP SJ 26 3 9 208 NV AO 27 NTL 28 TB NNN 29 GE Og RE UU T 32 OM 2 12 CO um Rendre Ga ordi 33 9 92 19 Spectral a AS SR NE ue 34 2 57 4 Installation of mobile site Sets es cete eee Ea ehe o s ELE rune R ERR RR EROR Ka eee e E HR FOE O este 35 Al General informano ee O e CE DE 35 4 2 Specific arranee mellis oed oiii eoo eee ode ie e eoo Sor base eoe o eren eds 35 RO IV QUEL NEED M 36 m Mucium c S 36 2 Check Delore towing as 37 59 DEVINO NR 37 5 4 Umit Chine the traile me eiai 37 5 5 Implementation for installation sososssseccccccsssscecccccossssceccccssssceeccocssesescesssssssseesessso 38 6 Installation of electrical generating sets in container
44. of material crane slings lifting beam safety hook shackles fork lift truck 3 1 3 Instructions for unloading 3 1 3 1 Slings attach the lifting vehicle slings to the rings on the generating set designed for this procedure hang the slings carefully check that the slings are correctly attached and the equipment 1s solid lift the generating set carefully direct and stabilise the set towards the chosen position carefully set down the equipment while continuing to position it release the slings then detach and remove the lifting rings Warning The slings must be perpendicular to the frame in order not to interfere with the set no rubbing 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 rx vor ose GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 20 57 3 1 3 2 Fork lift truck position the arms of the fork lift under the frame making sure that only the cross beams are resting on the arms lift and handle the equipment carefully set down the generating set in its unloading position 3 2 Handling instructions carefully lift the edge on the engine side with 2 jacks then slide 3 pipes under the frame leave the frame under the pipes then move the set by pushing manually while the set 1s being moved use the freed pipes by sliding them one after another under the frame when it has reached the desired location position the set
45. oise sensitive area particular attention will be given and the room will be built of framing concrete or solid concrete blocks 20 cm minimum covered in absorbent fireproof and insulating material NOTE The fire test should comply with current legislation according to the type of building 3 3 2 4 Base of the set An operating generating set generates a certain amount of vibratory energy This vibratory energy makes its way to the floor plate via the frame As a rule our generating sets do not require a specific floor plate as they are fitted to elastic mountings However the floor plate will be sufficiently strong and detached from the rest of the construction It will also be level smoothed by the flow and unshackled If there 1s a risk of vibrations being transmitted the set can be mounted on a vibration mounted floor plate insulated 1f necessary by a resilient material This solution 1s mainly used with very powerful generating sets 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 rx 775920 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 25 57 3 3 2 5 Openings The room should include a certain number of openings which are required for it to operate a door giving access to the generating set and its accessories preferably in line with the set s floor plate ventilation openings fresh air inlet and hot air outlet located so that scavenging takes place in the directi
46. on AIR EMISSIONS joint inserted between the pipes and the silencer Air is evacuated by the radiator or engine In any case it must not rest on the through the wall The opening in the wall or silencer The exhaust pipework must be FIREPROOF DOOR wall should correspond to the size of free of any movement through the walls or the radiator and should be fitted with a partition rain grille HH FUEL STORAGE Storage should comply with current regulations The retention container can be made of steel or masonry AIR INLET Air inlet grille on the door or on the masonry ELECTRIC WIRES The path of wires may be installed in ducts or aerially In this case the wires must be installed in a cable tray FUEL PIPES SECURING EARTH 4016 Quartz Drive Fuel supply and THE UNIT TO Santa Rosa CA 95405 return in a duct THE FLOOR PLATE Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe NET GeneratorJoe 23 57 3 3 1 Position It should be determined on the basis of use There are no specific rules governing the choice of location other than proximity to the electric distribution panel and disturbances caused by the noise However fuel supply burnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered
47. on from the alternator towards the engine Their surfaces depend on the power of the generating set being installed general atmospheric conditions the cooling system selected and the soundproofing procedure 3 3 2 6 Lifting The lifting system should usually be an integral part of the construction It is made up of an H or I steel rail embedded in the walls and ceiling and a crab It should be easy to handle and 1s generally used on top along the longitudinal axis of the set and directed towards the exit 3 3 2 7 Soundproofing The room is soundproofed using two procedures Insulation This prevents the noise from crossing the walls and in this case it 1s the weight then thickness of the wall that 1s important Absorption These are materials that absorb sound energy and this procedure will be used on ventilation openings As a result of this the air inlet and outlet sections are increased The internal lining of the room can also be covered with absorbent material designed to lower the sound level in the room and consequently through the walls ventilation openings and door 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 26 57 General arrangements building structure made from framing concrete or solid concrete blocks 20 cm thick minimum anti vibrating floor plate under the generating set when adjoining s
48. pply procedures must be carried out in fresh air outside in accordance with local regulations in an area well away from fire people or animals 2 3 3 Risks related to exhaust gases and fuels WARNING DANGER generating sets should not be operated in unventilated areas Always follow the local regulations in force regarding generating sets and use of fuel petrol diesel and gas before using your generating set Fuel filling should be carried out when the engine 1s stopped except for sets with an automatic filling system Engine exhaust gases are toxic Do not operate the generating set in non ventilated areas When installed in a ventilated area the additional requirements for protection against fire and explosions must be observed Ifa burnt gas exhaust leaks the generating set may become more noisy In order to be sure of its efficiency you should periodically examine the burnt gas exhaust Pipes must be replaced as soon as their condition requires it 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 12 57 2 3 4 Risks related to toxic products WARNING DANGER The corrosion inhibitor contains alkali This substance should not come into contact with the eyes Avoid any prolonged or repeated contact with skin It should not be swallowed In the event of skin contact wash thoroughly with water and soap In th
49. r slightly acidic it becomes necessary to replace the main internal components This procedure must be carried out by a mechanic In general when pistons and seats need to be replaced we recommend a standard replacement pump To remove the lid and to check inside begin by unscrewing the 6 bolts that attach the lid to the chamber Then to undo the lid hit it preferably with a piece of wood alternately on the discharge and suction manifolds while keeping the other hand on the piston rod and the valve gland clamp Do not carry out these removal procedures often Before refitting carefully clean the whole of the inside with a cloth lightly lubricate the internal parts of the chamber with liquid paraffin put the piston back in place by pushing down slowly with a semicircular motion Check that the suction seat 1s held in place and that the felt pad is properly positioned Put the bolts back in position retighten the blocks moderately and alternately until the cover is locked down 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 54 57 10 2 Japy pump kit 10 2 1 Technical data max flow 37 L man max pressure 2 2 bars with water rotation speed 2800 rpm max suction height 6 m fitted with a by pass operation with discharge cut off 2 to 3 1ns Mx PI 55 protection 10 2 2 Electrical data power 0
50. rter components never use starter aerosol or similar product as starter assistance When it comes into contact with the starter component an explosion may occur in the inlet manifold and lead to physical injury Never let a child touch the generating set even when not in use Avoid using the generating set in the presence of animals can distress the animal Never start the engine without an air filter or exhaust Always follow current local regulations regarding generating sets and use of fuel petrol and gas before using your generating set Never use sea water or any other electrolitic or corrosive product in the coolant circuit 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 rx vor secre Generatordoe Email sales generatorjoe NET Web www generatorjoe NET 10 57 Ri Disconnect the battery and pneumatic starter 1f there 1s one before carrying out any repair to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt at starting Do not modify the engine Only use the correct techniques for turning the crankshaft to rotate the crankshaft manually Do not try to rotate the crankshaft by pulling or exerting force on the lever on the fan This method can cause serious physical or material harm or damage the fan blade s leading to premature breakdown of the fan Always use tools in good condition Check that you have understood how to use them before starti
51. ry 7 2 Connection checks e check the remote controls by section and number sector accessories low voltage central control panels etc e apply voltage to the accessories to check the following components non comprehensive list fuel pump consumption and direction of rotation water preheating intensity and voltage battery charger etc 7 3 Starting the generating set e carry out the mechanical checks oil pressure water temperature absence of noise etc e carry out the electrical checks voltage and frequency e carry out the safety checks emergency stop oil pressure water temperature etc 7 4 Load test on installation e check the rotary field e check the voltage frequency and intensity e check normal emergency switching or coupling 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 rx 775922 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 45 57 8 BATTERY MAINTENANCE WARNING DANGER install the battery so that 1t has the correct ventilation never place the battery close to a flame or fire use only insulated tools never use sulphuric acid or acid water to top up the electrolyte level PROCEDURE FOR TESTING STARTER BATTERIES TEST TYPE PROCEDURE RESULT ACTION CHECK THAT THE TRAY IS NOT DAMAGE NOTED Re BROKEN THAT THERE IS NO CHECK THE TRAY AND LEAK AND CHECK NO DAMAGE ELECTROLYTE THE TERMINALS ELECTROLYTE DAMAGED BLACK
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53. ubject to NF C 15 100 standard rules or the standards of the relevant country They also comply with NF C 15 401 standard rules or the standards of the relevant country 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 G c t J Fax 707 539 5212 eneratorJoec Email sales generatorjoe NET Web www generatorjoe NET 32 57 b Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose c Battery cables Install the battery or batteries immediately beside the electric starter motor The wires will be connected directly from the battery terminals to the starter motor terminals The first instruction to follow 1s to check that the polarities of battery and starter motor correspond The minimum section of the wires is 70 mm It varies according to the power of the starter motor but also the distance between the batteries and the set voltage drops on the line 3 3 2 12 Cooling Three types of heat production must be dissipated heat from the engine cooling circuit s heat radiating from the engine and exhaust ventilation air from the room exhaust gases The systems described below evacuate and pipe the heat produced by the engine cooling circuit a Ventilated radiator The engine cooling circuit 1s connected to a tubular ribbed radiator at the end of the frame in order to implement
54. wed for in the lower section of the installation to protect the silencer and engine or for any changes in horizontal vertical travel Figure 5 bulkhead crossing roof outlet For each bulkhead passage and roof outlet Figure 6 exhaust outlet The exhaust outlets disperse the gases in the atmosphere and protect the inner section of the pipes from bad weather 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe NET _ 39 57 Figure 7 suspension line Generally made up of a flat iron ring attached to the ceiling The suspension line enables the pipes to expand freely Figure 8 needle frame Used for vertical sections the needle frame allows the pipes to expand while holding them laterally Figure 9 column base The column base is designed to hold the weight of the vertical pipes Figure 10 silencer suspension line The silencer suspension lines are designed to hold the weight of the silencers they can be vertical or horizontal Figure 11 heat insulation Depending on the type of installation you may have to insulate the heat released in the room Once it has been insulated the surface temperature should not exceed 70 C The recommended material is rock wool excluding asbestos and eventually it can be recovered with aluminium sheets to improve the look of the installation and the thermal insulation 50 mm thick glass wool shoul
55. y to the combustion apparatus Apart from combustion apparatus flames 1n any form are prohibited This should be displayed in bold on a sign Residual water mud and waste spray 1s prohibited The fuels to be used should correspond to the ones in the declaration file and the specifications prescribed by the combustion apparatus manufacturer The fuel 1s considered as being in the physical state that is introduced into the combustion chamber Burning waste in the open air 1s prohibited Except for where a specific agreement has been made once the gas supply main unit has been closed it can only be reopened by the gas distributor However the user may conditionally have access to it Check for each site Always protect your hands when detecting leaks Pressurised fluids can enter body tissues and cause severe harm Risk of blood poisoning Drain and discard engine oil in a designated container the fuel distributors can collect your used oil 4016 Quartz Drive Santa Rosa CA 95405 Phone 707 539 9003 cx 7759202 GeneratorJoe Email sales generatorjoe NET Web www generatorjoe NET 17 57 2 4 Identifving sets generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documents contained in this manual Examples of identification plates generating set PLAQUE CONSTRUCT
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