ArcGen Hilta PowerMaker 15MVK User manual

ISSUE DATE: FEBRUARY 2006
Caution: Do not attempt to operate this machine until
you have read and understood completely
ALL instructions and guidelines contained.
Keep this manual available at all times for
operators and service engineers.
Instruction Manual
& Parts List
Multi-Voltage Generator
Model: PowerMaker
15MVK
1

Contents Page
Page Numbers
1. Preparations 7-8
2. Instrument Names 9-10
3. Operating Procedures 10-22
3.1 Starting and Operations 13-14
3.2 Stopping the engine 14-15
3.3 Operating Precautions 15-16
3.4 Emergency Stop Devices 16
3.5 Engine Stop Switch 16
4. Operating the Generator 17-22
4.1 AC Power 17-19
4.2 Earth Leakage Relay 18-22
5. Lubricating Oil, Coolant and Fuel 23-24
5.1 Engine Oil 23
5.2 Engine Coolant 23-24
5.3 Fuel 24
6. Maintenance 25-27
6.1 Required Maintenance for the Initial 50 Hours 25
6.2 Maintenance Check Every 100 Hours of Operation 25
6.3 Maintenance Check Every 200 Hours of Operation 26
6.4 Maintenance Check Every 300 Hours of Operation 26
6.5 Maintenance Check Every 400 Hours of Operation 26
6.6 Maintenance Check Every 500 Hours of Operation 26
6.7 Maintenance check Every 1000 Hours of Operation 27
6.8 Other Checks and Maintenance 27
6.9 Maintenance Check List 27
7. Troubleshooting 28
8. Storage of Machines 29
2

Contents Page Continued
Page Numbers
9. Major Specifications 30
10. Generator Wiring Diagram 15MVK 31
11. Engine Wiring Diagrams 32
12. Outline Drawings 15MVK 33
Parts List and Diagrams 36-71
3

Please use the machine with the following instructions
• This “INSTRUCTION MANUAL” gives a detailed description of operation, routine,
inspection, maintenance and troubleshooting of the generator, and other items
required for correct operation.
• Please read this manual carefully, especially the contents and caution symbols.
• While the generator is in its required place of operation, please keep the instruction
manual in a place readily available to operators and service engineers
• For detailed operation and maintenance of the ENGINE, please refer to the “Engine
Operation Manual”, supplied by the engine manufacturer.
Your machine: Model No: Powermaker 15MVK
There may be a difference between the
specification detailed in this manual
and the actual performance of the machine
due to modifications to the machine.
Symbol Mark in this Manual
DANGER: Indicates an imminently hazardous situation
which, if not avoided could result in death or
serious injury
CAUTION: Indicates a potentially hazardous situation which,
if not avoided may result in minor or moderate injury
or property-damage.
(Notice): Notice is used to notify people of installation operation,
maintenance information which is important but not
hazard-related.
4

Safety Precautions
DANGER:
ENSURE GOOD VENTILATION
Exhaust from the engine contains substances harmful
to the human body. Sufficient change of air is necessary
when the machine is used in places with poor ventilation,
such as in a tunnel or indoors. Do not direct exhaust to
passers by or houses.
DANGER:
FIRE PREVENTION
Fuel and oil are inflammable. Keep inflammable material
away from the machine, never smoke while refuelling and
never refuel during its operation.
DANGER:
AVOID ELECTRIC SHOCKS
Do not touch the output terminals during operation. This is
extremely dangerous when your hands are wet. Stop the
machine when you touch the terminals for connection and
other purposes.
DANGER:
NO CONNECTION TO DOMESTIC WIRING
Connecting to domestic wiring is illegal and very dangerous
because it may cause electric shocks and damage to the
generator.
DANGER:
CONFIRM CONNECTION
Damaged cables and insufficient tightening of connections
may cause damage to the machines and electric shocks.
Repair damaged cables and ensure connections are tight.
5

Safety Precautions - Continued
CAUTION:
DURING OPERATION
Do not open any of the following items while the generator
is running and immediately after the generator has stopped.
1. Radiator Cap
Only perform these checks when the engine is cold to
avoid injury. Do not at anytime, when the engine is still
hot, remove the radiator cap. Opening the radiator cap
when the engine is hot will result in boiling water gushing
out of the radiator which will scald people nearby.
2. Cooling Water Drain Plug
Opening the cooling water drain plug when the engine is hot will result in boiling water
gushing out of the engine which will scald nearby people.
3. Engine Oil Drain Plug
Opening the engine oil drain plug when the engine is still hot will result in burning oil
gushing out of the engine which will scald nearby people.
4. Do not touch while operating the generating set, the engine cooling fan or any other
places of high temperatures like, the exhaust pipe, engine and radiator. Even when
the machine is stopped, take care that the machine has cooled down enough before
touching the engine and other components.
CAUTION:
Battery
As the battery contains combustible gas, take extreme care in handling the battery. If
you are careless, like dropping the battery, there is a risk that the battery might explode.
In carrying out maintenance or inspection check, recharging and using booster cables,
extreme care should be taken to ensure safety.
CAUTION:
Strictly prohibited
Do not expose the battery to naked flames, sparks, cigarettes, and anything else
flammable, as the battery contains flammable liquid and gas.
CAUTION:
There is a risk of explosion if you do not charge the battery as there will be a build up
of combustible gas. The recharging process and handling of the battery should be done
in an area that is exposed to an air current, to avoid the risk of a dangerous concentration
combustible gas.
CAUTION:
In case the battery liquid is (dilute sulphuric acid) happens to come into contact with clothing
or skin, you must immediately rinse it out by using a lot of water. If the battery liquid comes
into contact with your eyes, wash it out with lots of water and seek medical attention
immediately.
6

1. Preparations
This machine has undergone stringent factory tests and inspections to ensure the machine
performs in accordance with its specifications, before being shipped to the end user.
As with any piece of motorised machinery, excessive use of brand new machinery may
shorten the life of the machine. Therefore, it is recommended for the initial 50 hours of
machine usage, special care is required for this running in period.
Upon receipt of this machine, please perform a maintenance check of the machine BEFORE
USE, so as to further insure there are no major malfunctions or damage to the machine that
occurred during transit.
We recommend that the machine be placed upon a level surface,
where there is not excessive dust or moisture.
1.1 When using the machine where there is inadequate
ventilation, make sure the following care is taken:
DANGER:
Ensure good ventilation, exhaust from the engine contains
substances harmful to the human body. Sufficient changes of air is necessary when
the machine is used in places with poor ventilation, such as in a tunnel or indoors. Do
not direct exhaust onto passers by or houses.
1.2 Caution in machine transporting.
CAUTION:
In cases where wheels are fixed to the generator, for better mobility, make sure
blocks are used to stop the generator from moving when in operation and
transporting the generator.
CAUTION:
When transporting, loading or unloading the machine you must
use the balanced centre point lifting hook which is situated on
the top panel of the machine.
CAUTION:
Caution should be taken in transporting the machine to and from sites. It is advisable
when using the machine to use the balance centre point lifting hook. Trucks and the
like should be used as a means of transportation. When loaded on a truck be sure to
use the bar on the front and back of the machine, as means to affix the machine
during transportation.
7

1. Preparations - Continued
1.3 Notice for Installation
(Notice)
Make sure the generator is placed on a secure and level
surface. When using the generator on an inclined surface,
the allowable inclination angle is up to 20 degrees.
(Notice)
Avoid using the generator in places of high humidity.
(Notice)
Avoid using the generator in places where surrounding
temperature is likely to rise over 40 degrees Celsius.
(Notice)
Avoid using the generator in places where there is excessive dust, noxious gases and
explosive gases.
(Notice)
Provide adequate space for machine inspection and maintenance.
(Notice)
Do not have obstacles within 1 metre from the machine otherwise the
machine could overheat.
1.4 Caution During Operation
While operating the generator set, you should check the instruments on the control panel
(e.g. frequency meter, voltmeter, ammeter, etc, to make sure the machine is working
correctly), on a regular basis.
1.5 Battery
Correct maintenance of the battery is important to ensure smooth starting and long service
life. Check the specific gravity, level of electrolyte and output voltage every 50 hours or
once every month.
(Notice)
If the specific gravity is 1.28 (at 20°C) the battery
is adequately charged. If the specific gravity is 1.245
or less, recharging is necessary.
(Notice)
The electrolyte must always cover the plates. If the plates are exposed to air for a long
time, damage will result. Apply a thin coat of grease on the terminals, to ensure a good
connection.
8

2. Instrument Names
Reference
Powermaker
15MVK
2.2 Name of Components
01. Alternator
02. Diesel Engine
03. Air Cleaner
04. Fuel Tank
05. Fuel Filter
06. Oil filler
07. Oil Filter
08. Oil dipstick
09. Radiator
10. Radiator Reserve Tank
11. Battery
12. Junction Terminal
13. Fuse
Reference Powermaker 15MVK
01. Control Panel. 06. Bar 11 AC Power output
02. Fuel level gauge. 07. Air intake (415/240V)
03. Fuel tank inlet. 08. Exhaust 13. Radiator inlet.
04. Lifting hook / lug 09. Ventilation 14. Water Drain.
05. Door latch 10. Fuel drain 15. Oil drain.
11. AC Power output
Terminal (110V single
phase)
2.1 Outline Drawing and name of instruments.
9

10
2. Instrument Names - Continued
2.3 Control panel and name of instrument
3. Operating Procedures
The following checks before start up must be undertaken.
1. Oil Check
Be sure to check the oil before start up everyday. The oil level must be maintained
between the two notches on the dipstick. Of the oil level is lower than the lower notch,
immediately replenish the oil, so that the oil level lies between
the two notches on the dipstick. Do not overfill so that the oil
level is greater than the upper notch as this may cause the oil
seals to fail, causing an oil leak. When checking the oil level,
be sure to check if the oil is clean and viscous. If the oil is not
clean, drain the oil by removing the oil drain plug and then re-fit
the oil plug and replenish the oil.
After a specified amount of the engine oil is supplied, run the
engine for several minutes and then stop it to re-check the oil
level again.
(Notice): Use only high quality lubricating oil with classification CC and DC.
1. Circuit breaker (for 415V) 13. AC Power output receptacle
2. Circuit breaker (for 110V) (1-phase 240V 16A )
3. Frequency meter 14. AC Power output receptacle
4. A.C Ammeter (1-phase 110V 16A)
5. A.C Voltmeter 15. AC Power output receptacle
6. Indicator lamp unit (oil pressure 16. Circuit breaker (Miniature
water,battery charging and 240V) circuit 110V or breakers
7. Starter switch
8. Hour meter
9. Earth terminal for earth leakage relay.
10. AC Power output receptacle
(3-phase 415V 16A)
11. AC Power output receptacle
(1-phase 110V 32A )
12. AC Power output receptacle
(1-phase 240V 16A)
15MVK
Engine oil Capacity 5.1L