TEKSAN DIESEL GENERATOR SETS Operation And Maintenance Manual
  1. Manuals
  2. Brands
  3. TEKSAN Manuals
  4. Portable Generator
  5. DIESEL GENERATOR SETS
  6. Operation and maintenance manual

TEKSAN DIESEL GENERATOR SETS Operation And Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

OPERATION AND MAINTENANCE MANUAL
FOR DIESEL GENERATOR SETS
EVERLASTING
COMPANY
Everlasting Company

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DIESEL GENERATOR SETS and is the answer not in the manual?

Questions and answers

Related Manuals for TEKSAN DIESEL GENERATOR SETS

Summary of Contents for TEKSAN DIESEL GENERATOR SETS

  • Page 1 OPERATION AND MAINTENANCE MANUAL FOR DIESEL GENERATOR SETS EVERLASTING COMPANY Everlasting Company...
  • Page 3 Our documents are being prepared carefully with the help of the academic education we have received and also the knowledge and experience we have obtained from being in this business for the last 25 years. As a standard TEKSAN documentation, the “Operation and Maintenance Manuals” for your “Diesel Engine”, “Alternator” and “Generator Set”...

  • Page 4: Table Of Contents

    EVERLASTING COMPANY TABLE OF CONTENTS 1.SAFETY PRECAUTIONS ..........................6 1.1.General Instructions ........................... 6 1.2.Lifting and Handling ..........................7 1.2.1.Using Slings .........................7 1.2.2.Using Forklift ........................8 1.2.3.Towing Trailer Mounted Generator Sets ................9 1.3.Moving Parts ...........................10 1.4.Hot Surfaces, Sharp Edges and Corners ..................10 1.5.Fire and Explosion ...........................11 1.6.Hazardous and Corrosive Substances ....................12 1.7.
  • Page 5 EVERLASTING COMPANY 5-MAINTENANCE ............................40 5.1.General ............................40 5.2.Maintenance of the Diesel Engine ....................41 5.3.Maintenance of the Alternator .......................41 5.4.Lubrication Oil ..........................42 5.5.Coolant ............................42 5.6.Fuel ..............................43 5.7.Maintenance of Batteries .......................43 5.8.Maintenance of Radiator ........................44 5.9.Low Load Operation ........................45 5.10.Long Term Storage ........................46 5.11.

  • Page 6: Safety Precautions

    This manual and the appendices are integral in total. All safety instructions are clearly stated in the relevant sections of this manual. Also remember that you can always get in contact with TEKSAN and ask for advice about any issue that is not understood clearly.

  • Page 7: Lifting And Handling

    EVERLASTING COMPANY 1.2.Lifting and Handling 1.2.1.Using Slings Use the lifting lugs located on the generator set, while you are trying to lift or move the generator set. Before lifting the generator set, be sure that you have checked all the lifting lugs or any connection points for any welding cracks, breakages, twists or rust that may cause any problem during the lifting process.

  • Page 8: Using Forklift

    EVERLASTING COMPANY 1.2.2.Using Forklift Unauthorized personnel shall not ride on forklifts. Only trained and qualified personnel shall operate forklifts. All forklifts shall be strictly maintained in accordance with the manufacturer’s recommendations. Ensure that forklift has enough capacity to handle the generator set safely and properly. Then firstly lower the forklift forks to minimum/ground level and drive the forklift forks into the forklift pockets under the baseframe of the generator set slowly and carefully.

  • Page 9: Towing Trailer Mounted Generator Sets

    EVERLASTING COMPANY 1.2.3.Towing Trailer Mounted Generator Sets Be sure that there is nothing wrong about the towing system including the towing bar, connection points, hooks, pins, etc... Check the chain, brake or electrical interconnections if there is available. Also check the moving parts, connection or interlock points of the generator set.

  • Page 10: Moving Parts

    EVERLASTING COMPANY 1.3.Moving Parts Keep your body (especially hands, arms and hair) and clothes away from gearwheels, pulleys, belts or other moving and rotating parts. Do not attempt to run the generator set, if any protection cover of fans or other moving parts is removed. Be sure that your clothes completely fit on you, if you are working around a generator set that is running.

  • Page 11: Fire And Explosion

    EVERLASTING COMPANY 1.5.Fire and Explosion Be sure that the fuel that will be used is a well-designed combination of appropriate ingredients, according to its purpose of use and all related norms and standards. Keep the floor clean around the generator set in order not to face any accidents due to slippery floor covered with grease, battery electrolyte or coolant.

  • Page 12: Hazardous And Corrosive Substances

    Generator sets have some potential risks for the environment such as lubrication oil, fuel, exhaust gas, battery. There may be local set of rules, regulations or limitations about the usage of diesel generator sets and also about the disposal of the environment-risky materials listed above.

  • Page 13: Electrical Equipment And Connections

    EVERLASTING COMPANY 1.8.Electrical Equipment and Connections Cable classification and connections of a generator set should be made and checked by only trained and qualified electricians. Do not touch the electrical hardware of the generator set directly with you bare hands or with the help of any conducting material.

  • Page 14: First Aid In Case Of Possible Electrical Shock Accidents

    EVERLASTING COMPANY 1.8.1. First Aid In Case Of Possible Electrical Shock Accidents If you witness an electrical accident it is important to respond quickly but with caution at the same time. So do not touch the victim until being sure that the electricity is switched off, otherwise you may receive an electric shock too.

  • Page 15: General Definitions

    2.2.Generator Set TEKSAN produces reliable generator sets at high quality in accordance with ISO8528 standards. Generator set specifications, options, electrical and mechanical drawings are all recorded and followed under the unique serial number of the generator set.

  • Page 16: Canopy Type Generator Sets

    EVERLASTING COMPANY 2.2.1 Canopy Type Generator Sets Teksan manufactures canopies for outdoor installation with the following features and specifications; • Weather and sound proof capability, • High level of noise reduction, • Sheet metal structure painted with electrostatic powder paint , •...

  • Page 17: Container Type Generator Sets

    EVERLASTING COMPANY 2.2.2 Container Type Generator Sets Teksan manufactures containers for outdoor installation with the following specifications; • Interior surface of canopy is covered with non-flammable noise isolation foams. • Improved sound insulation performance with the sound insulation cells and sections at the air inlet and outlet of the container.

  • Page 18: Drop Over Canopy Type Generator Sets

    EVERLASTING COMPANY 2.2.3 Drop Over Canopy Type Generator Sets Teksan manufactures drop over canopies for outdoor installation with the following specifications; • Interior surface of canopy is covered with non-flammable noise isolation foams. • Sound insulation for air inlet and outlet.

  • Page 19: Mobile Generator Sets

    EVERLASTING COMPANY 2.2.4 Mobile Generator Sets Trailer Mounted Generator Sets & Lighting Tower Generator sets can be supplied with trailers for mobile usage. Equipped with tires to provide full mobility services for easy movement to the site where power is required, these generator sets can be utilized as lighting towers, rental power, military, construction etc.

  • Page 20: Diesel Engine

    EVERLASTING COMPANY 2.3 Diesel Engine Teksan uses the diesel engines those are manufactured with latest technology, in accordance with ISO3046 standards and designed for generator sets. The diesel engines used; are designed for low fuel consumption, with 4-stroke type, direct injection, with all needed limiting and level sensors, with diesel electronic or mechanical type governor mounted on fuel pump for sensitive speed adjustment or regulation.

  • Page 21: Fuel Tank

    EVERLASTING COMPANY 2.5 Fuel Tank Teksan can provide base frame fuel tank or free standing fuel tank dependent on model preferences of the customer. Larger sets require free standing fuel tank due to needs of high fuel capacity. Fuel tanks are manufactured of plate steel or other suitable materials.

  • Page 22: Base Frame

    The base frame on which generator set is placed, has been manufactured using proper steel plate or special profiles based on the necessary dynamic, static and vibration calculations in order for providing high resistance. Teksan produces the base frames for all ranges in accordance with international standards. 2.7 Vibration Isolators Vibration insulators are used in order to decrease the negative effects of vibrations caused by the rotational movement of the engine and alternator.

  • Page 23: Exhaust System And Silencer

    EVERLASTING COMPANY 2.8 Exhaust System and Silencer An exhaust system should be designed to decrease the noise coming from exhaust manifold and dispel the exhaust gases to the atmosphere. Exhaust system consists of flexible compensator that absorbs vibration and expansion, steel pipes, bend, silencer and mounting equipment. Further details on exhaust systems can be found in “Installation”...

  • Page 24: 3-Installation

    EVERLASTING COMPANY 3-INSTALLATION 3.1.Selecting Room Location The selection and preparation of the location that the generator set will be placed is the most important step of installation. So please make sure that the generator set is installed at a place that is selected and prepared fully in conformity with the instructions in this manual.

  • Page 25: Ground And Platform

    3.3.Vibration TEKSAN generator sets are designed for the minimum vibration transmission to the ground. For this purpose, rubber vibration insulators are placed between the engine/alternator and the base frame. In applications with higher power ratings, the insulators may be placed under the base frame for more efficiency in terms of vibration insulation.
  • Page 26 EVERLASTING COMPANY Ensure that hot air is being removed from the generator room with a flexible duct connection. The cooling air flow required can be provided by calculating the dimensions of the air inlet and outlet louvers. Windows area of the room should not be less than the area of radiator matrix. If possible, the air inlet and outlet area should be %150 of the radiator matrix.

  • Page 27: Exhaust System

    EVERLASTING COMPANY 3.5.Exhaust System While designing an exhaust system, avoiding back pressure is very important. Excessive exhaust back pressure can contribute to poor engine performance and increasing working temperature. If any twist or curve is needed on the exhaust line, be sure that the radius of the elbow used on the turning point is more than the 150% of the inner radius of exhaust pipes.

  • Page 28: Fuel System

    EVERLASTING COMPANY 3.6.Fuel System Main purpose of the fuel system is to supply clean fuel into the diesel engine continuously. Ensure that the fuel system has been designed correctly and with suitable materials. It is recommended to use a fuel filter and/or a water separator at the fuel tank outlet line. Here are some important points to be considered while designing a fuel system properly;...

  • Page 29: Storage Of Diesel Fuel

    EVERLASTING COMPANY 3.6.1.Storage of Diesel Fuel The most preferred method for providing a continuous fuel supply for the engine is fuel storage in tanks. The fuel tanks can be installed under or above the ground. There must be an air outlet point on the main fuel tank. The air pressure occurring while filling the tank and the vacuum occurring during the fuel usage will be emptied by this air outlet point.

  • Page 30: Electrical Connections

    Electrical connections must be designed, made and repaired by qualified and trained technicians. All electrical connections and wiring must be done in compliance with the diagrams or the drawings provided by TEKSAN. All the connection, wiring and grounding processes must be made fully in compliance with the related international, national and local specifications, standards, rules and regulations.

  • Page 31: Starter Batteries

    EVERLASTING COMPANY 3.7.1.Starter Batteries The electrical resistance on the starting circuit, is a very important parameter for the operation of the diesel engine. Therefore, the batteries must be placed at a closest possible location to the generator set. This way the battery connections will be shorter and the resistance of them will be lower.

  • Page 32: Noise Control

    Exposure to a sound level higher than 85 dB for a long time, may cause hearing problems. So it is recommended to wear ear plugs around a running generator set. Teksan generator sets are met the noise level norms given in EU 2000-14-EC standards which is valid for the generator sets under 500kVA.

  • Page 33: Fire Precautions

    EVERLASTING COMPANY 3.9.Fire Precautions Take all the precautions stated in section “1.5” (Fire and Explosion) against any fire and explosion possibility. There must be an emergency escape route and scenario in case of any fire and explosion possibility. A fire alarm system and an extinguisher in accordance with the legal regulations and standards about fire and explosion, must be provided around the generator set.

  • Page 34: 4-Control System

    Manual (TJM), automatic (TJA) and synchronization (TJPS) control panels are manufactured as a standard in TEKSAN. But it is also possible to design customized control panels for different purposes or scenarios of usage.
  • Page 35 EVERLASTING COMPANY AUTO: This mode is used for running the generator automatically and transferring the load between mains & generator set automatically. Once this mode is selected on controller; if at least one of the phase voltages at the mains side gets out of configured limits, then the mains contactor gets opened and the engine starts cranking for pre-configured times and with pre-configured intervals.
  • Page 36 EVERLASTING COMPANY TJ509-T Controller • Improved firmware and software specifications and skills, • Exact same dimensions with TJ507 or TJ509, (This way it can easily be replaced with them directly.) • AMF (Auto Mains Failure), ATS (Auto Transfer Switch), RS (Remote Start) and EC (Engine Controller) modes of operation, •...

  • Page 37: Synchronization Panels

    In order to provide solutions for such synchronization system requests of customers, Teksan has different panel designs as TJPS10, TJPS20 and TJPS60 and the purpose of use of these panels are as follows;...

  • Page 38: Battery Charger

    EVERLASTING COMPANY Switch the generator set circuit breaker to OFF position. Switch all the fuses inside the control panel to OFF position. Make the battery pole connections. Switch all the fuses inside the control panel back to ON position. Check all the emergency stop buttons and be sure that they are all at ON position. Bleed the air out from fuel system and filters by using priming pump.

  • Page 39: Engine Jacket Water Heaters

    EVERLASTING COMPANY Turn off the battery charger device before removing any battery connection, for avoiding any arc or spark possibility. Battery charger devices should be used according to related instructions. They must not overcharge the batteries. If the temperature of batteries rise above 52°C, then it may cause damage on the batteries. This fact must be taken into consideration especially in tropical countries, the charger and the batteries must be located at a cool and shaded place.

  • Page 40: Transfer Panels

    EVERLASTING COMPANY 4.7.Transfer Panels Transfer panels are used for controlling and transferring the output power safely. So the equipment in these panels (circuit breaker, contactor, fuses, etc…) must be at proper ratings depending on the output power and current rating of generator set. The switching equipment must be controlled by the generator set controller in automatic mode applications.

  • Page 41: Maintenance Of The Diesel Engine

    EVERLASTING COMPANY 5.2.Maintenance of the Diesel Engine Please see the detailed instructions in “Diesel Engine Operation and Maintenance Manual” supplied with the diesel engine. 5.3.Maintenance of the Alternator Any maintenance or repair activity to be performed on alternator, must be carried on by trained and qualified technicians.

  • Page 42: Lubrication Oil

    EVERLASTING COMPANY 5.4.Lubrication Oil The lubrication oil must be changed periodically in specified intervals for obtaining the best performance and lifetime for engine. The lubricant and this changing period is specified by the engine manufacturer, so be sure to comply with these standards, specifications and instructions about lubrication, otherwise the engine may be damaged.

  • Page 43: Fuel

    <1,0 5.7.Maintenance of Batteries Different types of batteries can be used in generator sets. Maintenance free batteries are used in TEKSAN products. They are completely enclosed and does not require any pure water addition. Discharge duration is long for batteries on TEKSAN products, because their internal resistance is very low (5 milliohm).

  • Page 44: Maintenance Of Radiator

    EVERLASTING COMPANY Check the density of battery liquid with a hydrometer. The proper readings should be around 1,27 under nominal conditions and temperature (15°C). Pure or distilled water is used in electrolyte solution, so the water to be added into the battery must also be pure water.

  • Page 45: Low Load Operation

    EVERLASTING COMPANY • The radiator must be cleaned properly and periodically for the reason above. Low pressure steam should be used for this cleaning purpose. The radiator can be immersed into an alkaline solution in case of any stronger sediments. The radiator must be washed with hot water after waiting at least 20 minutes inside this solution. 5.9.Low Load Operation Besides overloading, running a generator set under too light loading conditions can also be harmful for the generator set.

  • Page 46: Long Term Storage

    EVERLASTING COMPANY Corrosive Damage If the temperature of the engine body is not at a proper value, then the lubrication inside the engine will not be done properly so this will cause more corrosion on moving components. Deterioration Of Lubrication Oil Due to loss of combustion performance, unburned fuel mixing with oil in the cylinder makes the oil deteriorated.
  • Page 47 EVERLASTING COMPANY Storage More Than 6 Months (Up To 2 Years) • Drain the engine oil. • Fill with diesel engine protective oil up to maximum level of the oil dipstick. • Immerse the fuel intake and return canals to a pot which contains 1/3 protective oil (JIS K2246 NP9) and to a pot that contains 2/3 diesel oil mixture.

  • Page 48: General Maintenance Schedule

    EVERLASTING COMPANY 5.11. General Maintenance Schedule Periodically (Engine Running Hours) At Least DIESEL GENERATOR SET GENERAL MAINTENANCE SCHEDULE ENGINE LUBRICATION SYSTEM Check the Oil Level Change Oil Change Oil Filters ENGINE COOLING SYSTEM Check the water heater blocks Check whole Cooling System for any Coolant Leakage Check the Coolant Level Check the Cleanliness of Radiator Change the Coolant...

  • Page 49: 6-Troubleshooting

    • You can find any further details in the troubleshooting sections of “Operation and Maintenance Manuals” supplied with the engine, alternator and any other equipment used on generator set. • If you cannot get a solution by using the table below, feel free to contact TEKSAN or its authorized dealers any time.
  • Page 50 EVERLASTING COMPANY BBK-V.122018_ENG People First...
  • Page 51 EVERLASTING COMPANY BBK-V.122018_ENG People First...

  • Page 52: 7-Warranty

    • Provide for the cost of oil and filters which are made unusable by the defect Teksan either will dispatch parts to the Buyer/Owner free or to repair at the factory or on site. If the repair is decided to perform at the factory by Teksan, the Buyer/Owner is responsible to disconnect the product from and reconnect the product to its attached equipment, mounting and supporting systems as well as transporting the product from the site to the factory and from factory to the site.
  • Page 53 • Any failures resulted from act of god, earthquake, snowstorm, avalanche, fire, flood or mains electricity are not under warranty coverage. • In no event will Teksan be liable for loss of use, loss of profits, loss of or damage to other property, inconvenience, commercial loss or other special, incidental or consequential damages whatsoever.
  • Page 54 Additionally, sufficient pictures of the failure should be sent. • Any required operations in purpose of correcting the failure should be done after the approval of Teksan in writing. Warranty claims must be done in 5 working days from date of failure.
  • Page 55 EVERLASTING COMPANY BBK-V.122018_ENG People First...
  • Page 56 NOTES:...
  • Page 57 NOTES:...
  • Page 58 NOTES:...
  • Page 60 HEADQUARTERS & ISTANBUL FACTORY Yenidogan Mah. Edebali Cad. No:12 34791 Sancaktep e / ISTANBUL / TURKEY KOCAELI FACTORY Sepetlipinar Serbest Bolge Mah. 107.Cad. No:18 41090 Basiskele / KOCAELI / TURKE Y www.teksan.com info@teksan.com TECHNICAL SERVICES CENTER Yenidogan Mah. Edebali Cad. No:12 34791 Sancaktep e / ISTANBUL / TURKEY...

Table of Contents

Save PDF