Atlas Copco QEP 3-8 Hd ESF User manual

Instruction Manual
Instruction Manual
for AC Generators
English
QEP 3-8 Hd ESF, QEP 4-7 Yd ESF, QEP W210 Hd ESF
QEP R5-14 Hd ESF, QEP R6-7 Yd ESF, QEP R9-10 Ld ESF
QEP S12-14 Hd ESF, QEP S4-7 Yd ESF, QEP S9-10 Ld ESF
01_00_Front Page AC_EN.fm Page 1 Thursday, September 10, 2015 2:45 PM

ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Printed matter N°
2954 8930 00
10/2015
QEP 3-8, QEP W210
QEP R5-14, QEP S4-14
Instruction Manual for AC Generators
Instruction manual ..................................................................................5
Circuit diagrams ....................................................................................85
Original instructions

- 4 -
Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by
Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising from modifications,
additions or conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major
hazards, including fire risk.
While every effort has been made to ensure that the information in this manual is correct,
Atlas Copco does not assume responsibility for possible errors.
Copyright 2015, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain.
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

- 5 -
Contents
1 Safety precautions for on-
site generator sets......................8
1.1 Introduction........................................8
1.2 General safety precautions ...............9
1.3 Safety during transport and
installation........................................10
1.4 Safety during use and
operation ..........................................11
1.5 Safety during maintenance
and repair..........................................12
1.6 Tool applications safety ..................14
1.7 Battery safety precautions..............14
2 Main parts .................................15
2.1 General description QEP Hd ...........15
2.2 General description QEP Yd............16
2.3 General description QEP R..............17
2.4 General description QEP S..............18
2.5 Markings ...........................................19
2.6 Overview features............................20
2.7 Description of the mechanical
features .............................................22
2.7.1 Engine and alternator ......................22
2.7.2 Cooling system.................................22
2.7.3 Frame and canopy............................22
2.7.4 Control panel ....................................22
2.7.5 Data plate and serial number..........22
2.7.6 Drain plugs and filler caps...............22
2.7.7 Fuel tank............................................22
2.7.8 Welding kit (option)..........................22
2.7.9 Wheel kit (option).............................23
2.8 Description of the electrical
features .............................................26
2.8.1 Sockets..............................................26
2.8.2 Safety devices...................................26
2.8.3 Instrumentation................................26
2.8.4 AVR....................................................26
2.8.5 8 position selector switch for
welding current ................................26
2.8.6 12Vdc output.....................................26
2.8.7 Connector for remote start
and stop ............................................27
2.8.8 Differential circuit breaker
(option)..............................................27
2.8.9 Wireless start/stop module
(option)..............................................27
2.8.10 ATS with AMF panel (option)..........28
3 Installation and
connection ................................ 35
3.1 Lifting and transport........................35
3.2 Towing ..............................................35
3.3 Installation........................................36
3.3.1 Indoor installation ............................36
3.3.2 Outdoor installation .........................36
3.4 Connecting the generator set .........36
3.4.1 Precautions for non-linear and
sensitive loads ..................................36
3.4.2 Quality, minimum section and
maximum length of cables..............37
3.4.3 Connecting the load .........................37
3.4.3.1 Site distribution panel......................37
3.4.3.2 Protection..........................................37
Congratulations on the purchase of your QEP generator set. It is a solid, safe and reliable machine, built according to the latest technology. Follow the instructions
in this booklet and we guarantee you years of trouble free operation. Please read the following instructions carefully before starting to use your machine.
While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco
reserves the right to make changes without prior notice.

- 6 -
4 Operating instructions .............38
4.1 Before starting .................................38
4.2 Starting.............................................39
4.3 During operation..............................39
4.4 Stopping ...........................................39
5 Maintenance..............................40
5.1 Before maintenance.........................40
5.2 Maintenance schedules...................41
5.2.1 Maintenance schedule for
QEP 3, QEP 3.5, QEP (R)5, QEP
(R)6.5, QEP (R)7.5, QEP (R)8,
QEP W210 .........................................41
5.2.2 Maintenance schedule for
QEP R/S12, QEP R/S14 .....................43
5.2.3 Maintenance schedule for
QEP (S)4, QEP 4.5, QEP (R/S)6,
QEP (R/S)7.........................................45
5.2.4 Maintenance schedule for
QEP R/S9, QEP R/S10 .......................47
5.2.5 Use of maintenance schedule.........49
5.3 Alternator maintenance
procedures........................................49
5.3.1 Measuring the alternator
insulation resistance ........................49
5.4 Engine maintenance procedures....49
5.4.1 Engine oil level check ......................49
5.4.2 Fuel level check ................................50
5.5 Adjustments and service
procedures........................................51
5.5.1 Battery care.......................................51
5.5.1.1 Electrolyte .........................................51
5.5.1.2 Activating a dry-charged battery ....51
5.5.1.3 Recharging a battery........................51
5.5.1.4 Make-up distilled water ...................51
5.5.1.5 Periodic battery service ...................51
5.5.2 Service instructions for
Yanmar engines ...............................52
5.5.2.1 Inspect/clean air filter.......................52
5.5.2.2 Clean/inspect engine oil filter..........52
5.5.3 Service instructions for Honda
GX270-390 engine............................54
5.5.3.1 Inspect/clean air filter.......................54
5.5.3.2 Inspect/replace spark plug...............55
5.5.4 Service instructions for Honda
GX690 engines .................................56
5.5.4.1 Inspect/clean air filter.......................56
5.5.4.2 Change oil filter ................................57
5.5.4.3 Inspect/replace spark plug...............58
5.5.5 Service instructions for
Lombardini engines .........................59
5.5.5.1 Inspect/clean air filter.......................59
5.5.5.2 Replace oil filter................................59
5.5.5.3 Replace fuel filter..............................60
5.6 Engine consumable
specifications....................................61
5.6.1 Engine fuel specifications................61
5.6.2 Engine oil specifications..................61
6 Checks and trouble
shooting .................................... 63
6.1 Checks...............................................63
6.1.1 Checking the volt meter...................63
6.2 Alternator troubleshooting .............64
6.3 Engine troubleshooting...................65
6.4 Socket troubleshooting...................67
7 Storage of the generator
set .............................................. 69
7.1 Storage..............................................69
7.2 Preparing for operation after
storage ..............................................69
8 Disposal..................................... 70
8.1 General..............................................70
8.2 Disposal of materials .......................70
9 Technical specifications........... 71
9.1 Technical data ..................................71
9.1.1 Technical data for QEP Petrol
units...................................................71
9.1.2 Technical data for QEP Diesel
units...................................................72
9.1.3 Technical data for QEP R Petrol
units...................................................73
9.1.4 Technical data for QEP R Diesel
units...................................................74
9.1.5 Technical data for QEP S petrol
units...................................................75

- 7 -
9.1.6 Technical data for QEP S Diesel
units...................................................76
9.2 Derating ............................................77
9.2.1 Diesel units .......................................77
9.2.2 Petrol units........................................78
9.2.3 Carburettor modifications for
high altitude operation of
Petrol units........................................80
9.3 Socket configurations
overview ...........................................81
9.4 Overview power outputs ................82
9.5 Conversion list of SI units into
British units ......................................83
9.6 Data plate .........................................83

- 8 -
1 Safety precautions for on-site generator sets
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the generator set.
1.1 Introduction
The policy of Atlas Copco is to provide the users of their
equipment with safe, reliable and efficient products.
Factors taken into account are among others:
- the intended and predictable future use of the
products, and the environments in which they are
expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper
service and maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific information
about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy
accessible to the operating personnel.
See also the safety precautions of the engine and
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of the
unit.
These safety precautions are general and some
statements will therefore not always apply to a particular
unit.
Only people that have the right skills should be allowed
to operate, adjust, perform maintenance or repair on
Atlas Copco equipment. It is the responsibility of
management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit
with the push-buttons, and is trained to know the safety
aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit the
same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on live
electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same
qualifications as both the operator and the mechanical
technician. In addition, the electrical technician may
carry out electrical repairs within the various enclosures
of the unit. This includes work on live electrical
components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or its
agent to perform complex repairs or modifications to the
equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions. Take necessary steps to
keep unauthorized persons away from the unit and
eliminate all possible sources of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following list is
a reminder of special safety directives and precautions
mainly applicable to Atlas Copco equipment.
Neglecting the safety precautions may endanger people
as well as environment and machinery:
- endanger people due to electrical, mechanical or
chemical influences,
- endanger the environment due to leakage of oil,
solvents or other substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting
from neglecting these precautions or by non-observance
of ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by
Atlas Copco.

- 9 -
The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and for
modifications, additions or conversions made without
the manufacturer’s approval in writing.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
1.2 General safety precautions
1 The owner is responsible for maintaining the unit in
a safe operating condition. Unit parts and
accessories must be replaced if missing or
unsuitable for safe operation.
2 The supervisor, or the responsible person, shall at
all times make sure that all instructions regarding
machinery and equipment operation and
maintenance are strictly followed and that the
machines with all accessories and safety devices, as
well as the consuming devices, are in good repair,
free of abnormal wear or abuse, and are not
tampered with.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers
shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous
ignition of oil vapour when air is admitted.
4 Normal ratings (pressures, temperatures, speeds,
etc.) shall be durably marked.
5 Operate the unit only for the intended purpose and
within its rated limits (pressure, temperature,
speeds, etc.).
6 The machinery and equipment shall be kept clean,
i.e. as free as possible from oil, dust or other
deposits.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly. See the
maintenance schedule.
8 All regulating and safety devices shall be
maintained with due care to ensure that they
function properly. They may not be put out of
action.
9 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable tolerances.
10 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual to
determine that they are in good operating condition.
11 Mind the markings and information labels on the
unit.
12 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure operator
safety.
13 Keep the work area neat. Lack of order will increase
the risk of accidents.
14 When working on the unit, wear safety clothing.
Depending on the kind of activities these are: safety
glasses, ear protection, safety helmet (including
visor), safety gloves, protective clothing, safety
shoes. Do not wear the hair long and loose (protect
long hair with a hairnet), or wear loose clothing or
jewellery.
15 Take precautions against fire. Handle fuel, oil and
anti-freeze with care because they are inflammable
substances. Do not smoke or approach with naked
flame when handling such substances. Keep a fire-
extinguisher in the vicinity.
16a On-site generator sets (with earthing pin):
Earth the generator set as well as the load properly.
16b On-site generator sets IT:
Note: This generator set is built to supply a sheer
alternating current IT network.
Earth the load properly.

- 10 -
1.3 Safety during transport and
installation
To lift a unit, all loose or pivoting parts, e.g. doors and
towbar, shall first be securely fastened.
Do not attach cables, chains or ropes directly to the
lifting eye; apply a crane hook or lifting shackle meeting
local safety regulations. Never allow sharp bends in
lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and deceleration
shall be kept within safe limits.
1 In case of transporting a non-trailer unit on a truck,
fasten it to the truck by attaching straps via fork lift
slots, via the holes in the frame at the front and back
or via the lifting beam. To prevent damage, never
put straps on the roof surface of the unit.
2 Place the unit on level ground and immobilize the
unit by placing chocks in front of and/or behind the
wheels, if applicable.
3 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
4 Lifting hooks, eyes, shackles, etc., shall never be
bent and shall only have stress in line with their
design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an
angle to its load axis.
5 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a
lifting beam shall be applied between hoist and
load.
6 Never leave a load hanging on a hoist.
7 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken to
prevent load-swinging, e.g. by using two hoists,
each at approximately the same angle not exceeding
30° from the vertical.
8 Locate the unit away from walls. Take all
precautions to ensure that hot air exhausted from the
engine and driven machine cooling systems cannot
be recirculated. If such hot air is taken in by the
engine or driven machine cooling fan, this may
cause overheating of the unit; if taken in for
combustion, the engine power will be reduced.
9 Generator sets shall be stalled on an even, solid
floor, in a clean location with sufficient ventilation.
If the floor is not level or can vary in inclination,
consult Atlas Copco.
10 Do not install the generator set outdoors without
proper protection (especially when being exposed to
rain or snow), as this may impose an electric shock
hazard and/or result in faulty operation.
11 The electrical connections shall correspond to local
codes. The machines shall be earthed and protected
against short circuits by fuses or circuit breakers.
12 When using extension cables, take in account the
maximum cable length. Cables of 1.5 mm² diameter
should not exceed 60 m, cables of 2.5 mm² should
not exceed 100 m.
13 Provide adequate lighting at the working spot to
comply with applicable working norms (min. 20
lux).
14 Never connect the generator set outlets to an
installation which is also connected to a public
mains.
15 Before connecting a load, switch off the
corresponding circuit breaker, and check whether
frequency, voltage, current and power factor
comply with the ratings of the generator set.
16 Before transportation of the unit, switch off all the
circuit breakers.