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Summary of Contents for Jakson & Company JakPower Kirloskar Koel Green EA10 G1
- Page 3 POWER KIRLOSKAR We can achieve excellent performance from a Silent DG set, if proper care is taken during its installation. (The following suggestions shall help you to achieve optimum performance from the D.G. Set.) For Assistance Please contact our customer care at C-266-267, Mayapuri Industrial Area, Phase-II, New Delhi-110 064 Mobile No.
- Page 4 INDEX S. NO. DESCRIPTION PAGE NO. SELECTION OF SITE FOUNDATION DETAILS & GUIDELINES Ref. Drawing For Foundation of Gen Set EARTHING SYSTEM EXHAUST PIPING FUEL PIPING CABLING BATTERY CHARGING PROCEDURE SUMP CAPACITY CHECK UP BEFORE STARTING THE DG SET. SUMP CAPACITY (NEPAL) ROUTINE MAINTAINANCE OF SDG SET PRE-COMMISSIONING CHECK ROUTINE CHECK POINTS...
- Page 5 SELECTION OF SITE Ø Proper space should be there for placement and opening of doors of the Silent DG set. Ø There should be atleast 1.5 meter free space around the DG set for proper operation and maintenance. Ø There should be cross ventilation of air to ensure proper cooling of DG set.
- Page 6 FOUNDATION DETAILS AND GUIDELINES Ground base Foundation (RCC/PCC) Ø The foundation should be water leveled and at least 300mm above the ground level to maintain cleanliness and avoid flooding. Ø The length and width of the foundation should be at least 600mm to 800 mm more than that of the DG set size i.e.
- Page 7 JAKSON & CO.
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Page 8: Earthing System
EARTHING SYSTEM Ø An Earthing system is required for the protection of equipment and human being, as per Indian electricity Rules 1956. Ø Separate earth should be used for Genset body and neutral earthing. Ø 2 Nos. earthing pits are required for 1 phase DG set and 3 phase upto 30 kVA 1 each for neutral &... - Page 9 Exhaust Piping The exhaust system must be designed to keep the resistance to hot gases (back pressure) as low as possible and load of the extended exhaust pipe / silencer should not be on the engine manifold The following may please be noted. 1.
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Page 10: Fuel Piping
FUEL PIPING Ø A supply and return fuel pipe is required in each DG set . Ø SDGs upto 750 KVA are provided with fuel tanks inside the acoustic enclosure. Ø Outside fuel tank will be provided as per requirement. Ø... - Page 11 CABLING Ø It has been our experience that most electrical failures are caused by overheating due to loose thimbling or undersize cables. Ø Please use cable of correct size to carry full load current and thimble of correct size for cable termination. Ø...
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Page 12: Battery Charging Procedure
BATTERY CHARGING PROCEDURE a. Battery charging procedure Ø Specific gravity of acid inside the battery should be 1.23 to 1.28 kg/ltr. Note: Ø If dry battery is supplied along with the DG set then initial charging of the battery is required. Ø... -
Page 13: Air Cooled
SUMP CAPACITY (LITRES) AIR COOLED Engine Model EA10 G1 EA16 G1 HA294 G1 HA394 TCI G1/G2 HA494 TCI G1 HA694T CI G1 DV12ETA G2 Lts. 130 Ltrs WATER COOLED Engine Model 2R1040 G1 3R1040T G1 3R1040TA G1 4R810TA G1 4R1040TA G1 Lts. - Page 14 CHECK UP BEFORE STARTING THE DG SET Status S. No. Description Air cleaner mounting Fitted/Not fitted Air cleaner cleanliness Clean/dirty/replaced (Dry or oil type) Air cleaner clamps Hoses Cracked/normal/ not clamped / tightened Grade & specs of oil used 15W40 (K-Oil Premium)as per koel manufacture's recommendation Lub oil level &...
- Page 15 SUMP CAPACITY (LITERS) FOR NEPAL GENSETS AIR COOLED Engine Model HA294 Lts. WATER COOLED Engine Model 2R1040 3R1040 4R1040/4R1040T 4R1040TA 4K1080TA 6R1080TA 6K1080TA Lts. 14.8 13.5 Engine Model SL1500TA SR2 SL8800TA DV8SR1 DV8SR2 DV10 DV12 DV12 SR1 Lts. Note- Recommended Lube Oil (15 W 40) / Filters Change Interval Ø...
- Page 16 JAKSON & COMPANY Routine Maintenance of SDG Set. In Running Hours Every Hour/ Daily 1000 2500 5000 Engine oil level. Coolant level in radiator and compensatory tank. Restriction indicator of dry type air cleaner / radiator. Rubber hose & clips of dry type air cleaner / radiator. Engine oil (Every 500 Hrs.) Lube oil filter cartridge (Every 500 Hrs.) Battery and lead connections (Every 50 Hrs.).
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Page 17: Pre-Commissioning Check
PRE-COMMISSIONING CHECK Whenever you want to call a Service Engineer for commissioning, kindly ensure that -- Ø Installation work has been completed (i.e. foundation, earthing, exhaust pipe job has been completed with proper supports, if extended beyond the canopy) Ø Fuel pipe line job is completed, if Fuel Tank is outside the canopy. - Page 18 ROUTINE CHECK POINTS Ø Check Fuel Level Ø Drain water from fuel Tank (Especially during winter Season.) Ø Check Coolant level in the Radiator Ø Check for any leakage Ø Check for any loose connections Ø Check Battery condition Ø Check Lube oil level and quality (lube oil should not be very thick with visible carbon and metal particles).
- Page 19 DO`s Check fuel /coolant/lube oil level Ø Ø Check for any leakage Ø Check electrolyte level in Battery, It should be between 1.23-1.28 kg/ltr Ø Check Fan belt tension Ø Check battery charger Ø Drain the water from fuel tank,weekly during winters Check all nuts, Bolts, Engine/Alternator foundation bolts tightness at the time Ø...
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Page 20: Troubleshooting (Engine)
TROUBLE SHOOTING - ENGINE Important Note - Trouble shooting points are given just for reference. Please do contact KOEL service dealer for any check or repair. Description Causes Remedies No fuel in Tank Fill Fuel in tank Air in Fuel line Vent air from fuel line Choked fuel line Clean and clear fuel line... - Page 21 Choked fuel injector holes Contact to KOEL Service Dealer Dirty/Choked fuel filter Contact to KOEL Service Dealer Fuel level setting wrong Contact to KOEL Service Dealer Faulty fuel Pump Contact to KOEL Service Dealer Water mixed with fuel Check the reason and sort out or Contact to manufacturer/ KOEL service dealer Radiator fins choked Clean the radiator fins...
- Page 22 Dust entry in air inlet system Make necessary arrangement to stop dust entry without any modification in air inlet arrangement Dirt/ clogged air cleaner Clean air cleaner Derating due to temp,altitide,humidity Contact to manufacturer Poor quality of fuel Change the fuel and use good quality fuel Choked fuel injector holes Contact to KOEL Service Dealer Damage or dribbling nozzle...
- Page 23 Water mixed with fuel Check the reason and sort out or Contact to Engine give white manufacturer/ KOEL service dealer smoke Dust entry in air inlet system Make necessary arrangement to stop dust entry without any modification in air inlet arrangement Dirt/ clogged air cleaner Clean air cleaner High exhaust back pressure...
- Page 24 Poor quality of fuel Change the fuel and use good quality fuel Diesel knocking Faulty fuel Pump Contact to KOEL Service Dealer Incorret valve & fuel timing Contact to KOEL Service Dealer Loose component Check and ensure all component should be tighten.
- Page 25 TROUBLE SHOOTING - ALTERNATOR Description Causes Remedies Decfective voltmeter Check voltmeter and replace Short circuit between phases Check and ensure no short circuit between phases. Neutral earthing short with Check and rectify body earthing Power cable faulty Cehck and replace Excitation circuit open Check for loose connection Incorrect excitation circuit...
- Page 26 Over loading of generator Check the load and correct. To be in line with name plate rating Check ventilation and clean passage if Blocking of ventilation passage necessary Low speed on load Adjust prime mover speed Over loading of Generator Low load power factor Reduce the load Generator operating at very...
- Page 27 TROUBLE SHOOTING GUIDE FOR MANUAL PANEL Engine does not start by turning the starting key/push botton provided on panel/ KG controller. Ø Check connection of battery. Ø Check Control MCB . It should be in ON position. Ø Check the battery voltage at terminal 1 and 2 inside panel. It should be 12/24 V.
- Page 28 TROUBLE SHOOTING GUIDE FOR AMF PANEL Engine does not start from the AMF panel in any mode. Ø Check the DC supply control MCBs and 3 Phase mains supply. These should be in ON Position. Ø Check the battery voltage at terminal 1 and 2 in the AMF Panel. It should be equal to 12V/24V.
- Page 29 Ø Engine starts but there is no Voltage from the control Panel l Check HRC fuses/MCB below the DG/MAINS contactor. MCB should be in ON position and fuse should be OK. l Check the setting of AVM ( Alternator Voltage Monitor). l Check the overload relay , if it is tripped than press the reset lever.
- Page 30 JAKSON & COMPANY POWER KIRLOSKAR JAKSON & CO.
- Page 31 JAKSON & COMPANY POWER KIRLOSKAR JAKSON & CO.
- Page 32 REVALIDATION POLICY FOR GENSET Revalidation Eligibility: 1. Genset revalidation is applicable for Gensets which are not in operation for 6 months or beyond from the date of GOEM invoice. 2. Revalidation activity will be carried out on Genset at customer’s end before commissioning / PRF. 3.
- Page 33 Situation E3 –Genset revalidation is completed at customer’s end where Genset not commissioned more than 18 months and below 24 months from date of GOEM Invoice. Situation E4 –Genset revalidation is completed at customer’s end where Genset not commissioned more than 24 months from date of GOEM Invoice. After Revalidation Warranty Period are as below: For Situation E1 &...
- Page 34 Warranty Terms and Conditions for Battery : Kirloskar Green Battery warrants that this product is free from defects in materials and workmanship affecting normal use, and is in conformity with the respective specifications of the product for the warranty period subject to the following: 1.