Hyundai DHY22KSEm User manual

SOUNDPROOF TYPE DIESEL GENSET
Diesel generator SOUNDPROOF type, powered by 4 cylinders 4 stroke water cooled
direct injection engine with electric start, for Industrial applications, large fuel tank
providing over 8 hours running, AVR for smooth voltage output, large muffler to reduce
noise harmful effects, Bottom fuel tank, air preheating system for easy start up (we
recommend water heater for cold weather). Two bottom holes for the forklift and two
hooks on the cover top. Digital control panel, Emergency stop button, fuel intake hole
outside the canopy, weather proof canopy.
DHY22KSEm 22kVA 50Hz.
OPTIONAL ACCESSORIESRECOMMENDED SPARE PARTS
DESCRIPTION:
D200/300/400. ELECTRIC STARTER MOTOR
REFERENCE:
7016005
QUANTUTY: 1
REF. SPARE PARTS NAME QTY
AIR FILTER CORE
OIL FILTER ELEMENT
TURBO OIL FILTER ELEMENT
FUEL FILTER ELEMENT
1
1
-
1
REF. ACCESSORIES NAME QTY
ATS BOX & 30m cables: ATS1-100A
WATER HEATER 1000W
INTELLIGENT BATTERY CHARGER 24V
24 HOURS FUEL TANK
1
1
1
1
RATED POWER (kW/kVA)
MAX. POWER (kW/kVA)
FREQUENCY (Hz)
VOLTAGE (V)
CURRENT (A)
CONTROLLER
ATS PORT
BATTERY (Ah)
FUEL TANK CAPACITY (L)
COOLING FLUID VOLUME (L)
FUEL CONSUMPTION (l/h 50/100% loading)
RUNNING TIME UNDER (h 50/100% loading)
NOISE LEVEL BEHIND 7 METERS (dBA)
ENGINE MODEL
POWER OUTPUT (kW/1500rpm)
ROTATE SPEED
SPEED REGULATION
STARTING METHOD
DISPLACEMENT (cc)
OIL CAPACITY (L)
ALTERNATOR
RATED POWER (kW/kVA)
POWER FACTOR (Cosφ)
VOLTAGE REGULATION
LOW OIL PRESSURE
BLOCK ON START UP
LOW BATTERY
HIGH TEMPERATURE ON WATER
LOW OIL LEVEL
LOW RUNNING ON ENGINE
EMERGENCY STOP
N.G. (kg.)
G.W. (kg.)
PRODUCT DIMENSIONS (mm)
CAPACITY (units/container)
20/20
22/22
50
230
87
IL-NT MRS10
INCLUDED
1x12V-54Ah
93
10
4.5/7.7
21/12
68
DG4100
27
1500 RPM
MECHANICAL
ELECTRIC
3.298
15
184G
21/21
1
AVR / BRUSHLESS
YES
YES
YES
YES
YES
YES
YES
880
2220X950X1300
6/20GP;12/40GP;12/HQ
GENERATOR SET
ENGINE
ALTERNATOR
ALARMS
LOGISTICAL DATA
D
Di
e
d
di
r
e
p
pr
o
n
no
i
r
re
c
h
ho
o
o
ou
t
DHY22KSEm
22kVA
50Hz.
RATED P
O
WER
(
kW
/
kV
A)
MA
X
P
OW
ER
(
kW
/k
VA
)
* Product might be different from pictures shown
* specifications might vary as continuous product development
BREAKER
MCB (0~125A)
MCCB (125~1000A)
MEASUREMENTS
POWER OUTPUT AREA
TERMINALS U.V.W.N.PE
3 X SINGLE PHASE SOCKETS
InteliLiteNT
Mode Start
I
Stop
0
Mode
Horn
reset Fault reset
MRS 10
G
Enter
Page
MRS 10
MANUAL AND REMOTE
START CONTROLLER
InteliLiteNT
Mode Start
I
Stop
0
Mode
Horn
reset Fault reset
MRS 16
G
Enter
Page
I/ 0
MRS 16
MANUAL AND REMOTE
START CONTROLLER WITH
SUPPORT FOR EFI ENGINES
GENERATOR VOLTAGE
GENERATOR CURRENT
GENERATOR FREQUENCY
POWER FACTOR
OIL PRESSURE
COOLANT TEMPERATURE
BATTERY VOLTAGE
ENGINE ROTATING SPEED
ENGINE HOURS RUN
PIN PASSWORD
RS232/485 INTERFACE
FAULTS REPORT
MULTI-LANGUAGE FUNCTION
MRS10
YES
OPTIONAL
NO
YES
MRS16
YES
OPTIONAL
YES
YES

DIESEL GENERATOR
Models Hyundai Engine Series
Operation and Maintenance manual

SAFETY.
The operator of the machine;
Is responsible for and has a duty of care in making sure that the machine is operated
safely and in accordance with the instructions in this user manual.
Should never leave it in a condition, which would allow an untrained or unauthorised
person/s to operate this machine.
Take all due care and diligence for the safety of and with regard to those around
whilst using the machine, to include but not limited to;
Elderly, children, pets, livestock and property.
Some or all of the following PPE, warning signs and symbols may appear throughout this
manual and you must adhere to their warning/s. Failure to do so may result in personal
injury.
Warning Signs and Symbols –FOLLOW safety messages to avoid or reduce risk of injury or death.
DANGER - indicates a
hazard, which, if not
avoided, could result in
serious injury or death.
WARNING - indicates a
hazard, which, if not
avoided, could result in
serious injury or death.
CAUTION - indicates a
hazard, which, if not
avoided, might result
in minor or moderate
injury.
NOTE - indicates a
situation that could
easily result in
equipment damage.
READ MANUAL
Personal Protective Equipment (PPE)

Carbon monoxide
Carbon monoxide is a colourless and odourless gas. Breathing it can cause death as
well as serious long-term health problems such as brain damage.
The symptoms of carbon monoxide poisoning can include the following;
Headaches, Dizziness, Nausea, Breathlessness, Collapsing or Loss of
Consciousness.
Carbon monoxide symptoms are similar to flu, food poisoning, viral infections
and simply tiredness. That is why it is quite common for people to mistake this
very dangerous poisoning for something else.
To avoid carbon monoxide poisoning DO NOT use petrol/diesel powered equipment
inside a home or garage even if doors and windows are open.
If you think you or someone around you has been affected by carbon monoxide poisoning;
L eave the affected area and get fresh air immediately.
Open doors and windows and turn the machine off.
See your doctor immediately or go to hospital - let them know that you
suspect carbon monoxide poisoning.
DO NOT use in an enclosed area or a moving vehicle.
General fuel safety.
Contact the Health and Safety Executive for additional fuel safety information.
All fuels are Flammable.
Keep away from all ignition sources i.e. Heaters, Lamps, sparks from Grinding or
Welding.
Hot work on tanks that have contained fuel is extremely dangerous.
Keep work area clean and tidy. Clean up all spills promptly using correct methods i.e.
absorbent granules and a lidded bin.
Dispose of waste fuels correctly.

Petrol safety.
Always fuel and defuel in well-ventilated area.
Always wear correct, suitable and fit for purpose Personal Protective
Equipment (PPE), suggested items are as follows, but are not limited to.
Hand protection.
Protective clothing.
Respiratory protective equipment.
When defueling always use a propriety fuel retriever.
Always carry fuel in the correct and clearly marked container.
Electrical Safety.
Electricity can kill - never work on LIVE/ENERGISED equipment.
The generators are fitted with an RCD, which protects against electric shock
hazards. The RCD may not function correctly if the generator is not properly
grounded/earthed. All BE Generators have the neutral internally bonded to the
ground/earth wires.
Identify electrical isolation method and always isolate all electrical supplies,
prior to carrying out any maintenance work.
Prior to use and with all electrical supplies isolated, check all electrical cables,
plugs and connections for the following;
Are intact and have no signs of damage, to include but not limited to
bare wires, chaffing, cuts and loose wiring. If there are any signs of damage,
you should stop using the equipment. The damaged item must repaired by
an electrically competent person.
To avoid any kind of trip hazard, all trailing cables carefully routed.
Never work on or near electricity with wet hands, wet clothing, and wet gloves.
Batteries.
Batteries present a risk if they become damage by the
possible leaking of electrolyte. This electrolyte is an acid and can cause serious
injuries. Take care should when working on or near them.
Should you come into contact with acid you should;
Remove all clothing contaminated with acid.
Get medical assistance as soon as possible.
Use fresh running water to wash off excess acid, continue this
until medical assistance arrives.

If acid gets into your eyes, you should remove it immediately. Make
sure that you do not wash the acid to another part of the face or body.
Gasses from charging batteries are highly flammable. You must
charge in well-ventilated areas.
Additional Safety Instructions.
Do not enclose or cover the generator. It may become overheated if it is
enclosed. If the generator is covered, make sure to remove it and keep it well
away from the area during generator use.
Operate the generator on a level surface. It is not necessary to prepare a
special foundation for the generator. However, the generator will vibrate on an
irregular surface.
f the generator is tilted/moved during operation, fuel may spill and/or the
generator may tip over, causing a hazardous situation.
If used on a steep incline or slope then proper engine lubrication will not
happen. In such a case, piston seizure may occur even if the oil is above the upper
level.
Pay attention to the wiring or extension leads from the generator to the
connected device. If the wire is under the generator or in contact with vibrating
parts it may break and possibly cause a fire, generator burnout, or electric shock
hazard. Replace damaged or worn leads immediately.
DO NOT operate in rain, in wet or damp conditions, or with wet hands. The
operator may suffer severe electric shock if the generator is wet due to rain or
snow. If wet, wipe and dry it well before starting. DO NOT pour water directly
over the generator, nor wash it with water.
For each use, make sure that the generator has been electrically
grounded/earthed. Failure to do so can be fatal.
DO NOT smoke while charging a battery. The battery emits flammable
hydrogen gas, which can explode if exposed to electric arcing or open flame. Keep
the area well ventilated and keep open flames/sparks away when charging a
battery.
The engine becomes extremely hot during use and for some time after
operation. Keep combustible materials well away from generator area. Be very
careful not to touch any parts of the hot engine especially the muffler/exhaust
area or serious burns may result.
Keep children and all bystanders at a safe distance from work area
It is essential that you know the safe and proper use of the power tool or
appliance that you intend to use. All operators must read, understand and follow
the tool/appliance owners’ manual. Users must make themselves aware of the
tool and appliance applications and limitations. Follow all directions given on
labels and warnings.
Use only "LISTED" extension leads. When tools or appliances are
used/operated outside, use only extension leads marked for “Outdoor Use".
Extension leads, when not in use, should be stored in a dry and well-ventilated
area.
Always switch off generator's AC circuit breaker and disconnect tools or
appliances when not in use, before servicing, adjusting, or installing accessories
and attachments.
Stop the engine before starting any maintenance, servicing or repair.
Only allow properly trained personnel to maintain/repair the generator.

SafetyandWarning
Beforeoperationandmaintenanceforthegeneratorsets,pleasereadcarefullyaboutthismanualandmakesurea
goodunderstandingofthisoperationmanualandotherdocumentswhichattachedwiththeengine.
Correctinstallationofthegeneratorsetisthepreconditionofnormaloperation.Qualifiedsparepartsshallbeused
formaintenancetoensuregoodrunningconditionandlonglifeexpectancyofthegeneratorsets.
Thegeneratorsetshallbeoperatedonlybythestaffswhohavereceivedtrainingontheoperationandtherepair
shallbemadebytheauthorizedstaffs.Operatorandmaintenancestaffshallbeclearaboutsafetyandpreventive
actionsandoperationmaintenanceprocedure.
Thegeneratorsetscanonlybestartedundersafetyconditions.Pleasedonotstartthegeneratorsetswhenany
abnormalconditionhasbeenfoundsothattoavoidaccidents.
Whenclean,maintainandrepairthegeneratorsets,pleaseshutdownthegeneratorsetandcutofftheconnection
ofnegativepolarofthebatteryordismantlebatteryconnectingcable,andplacewarninglabelattherelativeplace
sothattoavoidaccident.
Theexhaustairdischargedfromengineisharmfulforpeople’shealth.Allofthegeneratorsetsinstalledindoors
shalldischargetheexhaustgastooutsidedoors.
Duringtheperiodofgeneratorsetrunning,theexhaustpipeandsilencerwillgeneratehightemperature.Therefore
whenthegeneratorsetisinstalled,thesepartsneedtobecoveredwithinsulationmaterialsandbekeptfaraway
frominflammablematerials.
Pleaseensuregoodventilationandorganizedenvironmentforthegeneratorset’sinstallationroom.
Pleasedonotplaceinflammablematerialsandexplosives(liquid)neartheengine.
Smoking,sparkover,andotherfirelightingbehaviorsarenotallowedintheareawhichisclosetothebatteryand
fuelbecausethemixtureofvolatilizationfromfuelandhydrogengeneratedbybatterychargingprocesswillcause
explosionwhenitmeetssparkleornakedflame.
ThegeneratorsetinstallationroomshallbefacilitatedwithBCandABCfireextinguisher,andoperatorsshallbe
familiarwiththeknowledgeonhowtouseit.
Whenfanprotectioncoverorotherprotectioncoverhasbeendetached,pleasedonottrytostartthegenerator
set;andwhenthegeneratorsethastobestarted,pleasedon’tputyourhandintheareawheretheprotection
coverismissingormakerepairaroundtheseareas.
Pleasekeepyourpalm,arm,longhair,jewelryandlooseclothesfarawayfrombeltpulley,beltandotherpower
transmissionparts.
Whenworkinginthegeneratorsetinstallationroom,pleasewareworkingclothes,glovesandhat.
Afterthegeneratorsetbeingstarted,pleasedon’ttrytoopenthecoveroftheradiatorbeforetheanti‐freezefully
cooleddown,sothattoavoidsteam(hotwater)burstforthtohurtpeople.
Pleasedon’tswalloworletyourskincontactwiththeharmfulmaterialssuchasfuel,anti‐freeze,lubricantand
electrolyte.Whenyouskinisspatteredwiththesekindsofliquids,pleaseuseplentyofwatertorinse.
Longtimestayinhighnoiselevelenvironmentwillcauseharmtoyourhearing.Ifyouhavetoworkaroundthe
generatorsetfrequently,you’dbetterwarethedevicetoprotectyourear.
Whenthegeneratorsetneedtomakecableconnectionstooutputpower,theoperationshallconformtothe
condition,specification,standardrelatedtopowerdistribution.Qualifiedcableshallbeusedtomakepower
distribution.
Whentheinstallationofgeneratorsetinvolveswithwelding,pleasedonotconnecttothegroundcircuitormake
groundingthroughgeneratorset(engine)sothattoavoidthebigcurrentgeneratedfromweldingoperationhurt
theelectricappliance,bearingandbearingbushetc.insideofthegeneratorset.
Pleaseensurethesafetyofgeneratorsetandreliablegrounding.

Safetylabelsinformation
TRANSPORTWARNING
!Neverliftthegeneratingsetbyattachingtothe
engineoralternatorliftinglugs,insteadusethe
liftingpointsonthebaseframeorcanopy.
!Ensurethattheliftingriggingandsupporting
structureisingoodconditionandhasacapacity
suitablefortheload.
!Keepallpersonnelawayfromthegeneratingset
whenitissuspended.
MECHANICALWARNING
!Donotattempttooperatethegeneratingsetwith
thesafetyguardsremoved.Whilethegeneratingset
isrunningdonotattempttoreachunderoraround
theguardstodomaintenanceorforanyother
reason.
!Keephands,arms,longhair,looseclothingand
jewelersawayfrompulleys,beltsandothermoving
parts.
SAFEGUARDWARNING
!Generatingsetsthatarenotequippedwithsound
attenuatingenclosurescanproducenoiselevelsin
excessof105dB(A).Prolongedexposuretonoise
levelsabove85dB(A)ishazardoustohearing.
!Wearprotectiveclothingincludingglovesandhat
whenworkingaroundthegeneratingset.
!Ifequippedkeepaccessdoorsonenclosuresclosed
andlockedwhennotrequiredtobeopen.
!Avoidcontactwithhotoil,hotcoolant,hotexhaust
gases,hotsurfacesandsharpedgesandcorners.

CHEMICALWARNING
!Ensurethatthegeneratingsetroomisproperly
ventilated.
!Keeptheroom,thefloorandthegeneratingset
clean.Whenspillsoffuel,oil,batteryelectrolyteor
coolantoccur,theyshouldbecleanedup
immediately.
!Neverstoreflammableliquidsneartheengine.
!Donotsmokeorallowsparks,flamesorother
sourcesofignitionaroundfuelorbatteries.Fuel
vaporsareexplosive.Hydrogengasgeneratedby
chargingbatteriesisalsoexplosive.
!Neverstoreflammableliquidsneartheengine.
!Donotsmokeorallowsparks,flamesorother
sourcesofignitionaroundfuelorbatteries.Fuel
vaporsareexplosive.Hydrogengasgeneratedby
chargingbatteriesisalsoexplosive.
ELECTRICALWARNING
!Thegeneratingsetshouldbeshutdownwiththe
batterynegative(‐)terminaldisconnectedpriorto
attemptingtoconnectordisconnectload
connections.
!Donotattempttoconnectordisconnectload
connectionswhilestandinginwateroronwetor
soggyground.
!Makesureconnectgeneratorsettoearth.
!Replacethegeneratingsetterminalboxcoveras
soonasconnectionordisconnectionoftheload
cablesiscomplete.Donotoperatethegenerating
setwithoutthecoversecurelyinplace.
!Connectthegeneratingsetonlytoloadsand/or
electricalsystemsthatarecompatiblewithits
electricalcharacteristicsandthatarewithinits
ratedcapacity.
!Keepallelectricalequipmentcleananddry.
Replaceanywiringwheretheinsulationiscracked,
cut,abradedorotherwisedegraded.Replace
terminalsthatareworn,discoloredorcorroded.
Keepterminalscleanandtight.
!Donottouchelectricallyenergizedpartsofthe
generatingsetand/orinterconnectingcablesor
conductorswithanypartofthebodyorwithany
noninsulatedconductiveobject.

Table of Contents
1 General Introduction
1.1 Brief Introduction……………………………………1
1.2 Generator Set Main Parts Specifications…………1
1.4 Alternator ……………………………………………1
1.3 Diesel Engine ………………………………………1
1.4 Alternator …………………… …………………… 1
1.5 Cooling System ……………………………………2
1.6 Electrical System …………………………………2
1.7 Coupling ……………………………………………2
1.8 Fuel Tank and Base Frame ………………………2
1.9 Control Panel ………………………………………2
1.10 Optional for Canopy Generator Set ……………2
1.11 Others ……………………………………………3
2 Installation
2.1 General Outline ……………………………………4
2.2 Transportation ……………………………………4
2.3 Design for Foundation ……………………………4
2.4 Design for Generator Set Working Room ………4
2.5 Installation of Generator Set………………………5
2.6 Cooling system ……………………………………7
2.7 Lubricant system …………………………………8
2.8 Fuel system…………………………………………8
2.9 Battery ……………………………………………10
2.10 Electrical Connection……………………………11
2.11 Power distribution system………………………11
3 Operation
3.1 Inspect Before Operation ………………………12
3.2 Generator set’s running …………………………12
3.3 After Running ……………………………………13
3.4 Record for running ………………………………13
3.5 Matters need attention …………………………13
3.6 Operation for control system ……………………14
3.7 ATS control panel ………………………………16
4 Maintenance
4.1 General outline……………………………………18
4.2 Engine ……………………………………………18
4.3 Alternator …………………………………………19
4.4 Control panel ……………………………………19
4.5 Start battery ………………………………………19
4.6 Maintenance record ……………………………19
5 Check for Malfunction
5.1 General outline……………………………………20
5.2 Malfunction checklist ……………………………21
APPENDIX

User manual
1
1GeneralIntroduction
1.1BriefIntroduction
HYUNDAIseriesdieselenginegeneratorsetsisthe
coreproductsofHYUNDAIPowerEquipment
ManufacturingCo.,Ltd.Thankstotheirgood
performance,thegeneratorsetsarewidelyusedin
thefieldsofconstruction,communication,banking
business,mining,leasingindustryandotherspecial
sites.Aswhatyouareexpecting,HYUNDAIgenerator
setsendeavortomeetyourneedsfortheconceptof
individualdesignthroughtheexcellentfeaturesof
moresafe,morereliableandmoreclean.The
generatorsetsprovidedbyHYUNDAIPoweris
reliableandprofessional.Theadvantageoflownoise
level,energyconservation,andstableperformance
hasmadeacredibleassuranceformanyenterprises.
Ourgeneratorsetssupplythefollowingpower
service:
Continuousservice
Usedasmainpowersupplytogenerateelectricityfor
severalpurposes:motionforce,lighting,heatingetc.
Thegeneratorsetscancontinuerunningandallow10%
overloadfor1hourper12hoursundervariableload,
whichisusedforremotearea.
Standbyservice
Usedasstandbypowersupplytoprovidecontinue
electricpowerfornon‐invariableloads.Thegenerator
setissuitablefortheareawheremustensure
continuepowersupply,suchashospitals,industrial
facilities,airportsetc.Keepthegeneratorsetstandby
stateatanytimeandstarttorunwhenthemains
supplyisabnormal.
Emergencyservice
Usedasauxiliarypowersupplytosolveenergy
interruptionsthatmaycauseseriousproblemsto
people,physicaland/orfinancialdamageortoface
consumptionpeaks.Thegeneratorsetcanstartin
shortordertoprovidesteadyelectricpowerforthe
loadswhenthemainssupplyhappenabnormity,and
switchtostopafterthemainssupplybecomes
normal.Generallythegeneratorsetcontinues
workingforseveralhours.
1.2GeneratorSetMainPartsSpecifications
NONAME
1 CONTROLPANEL
2 BUSBARPANEL
3 LIFTINGLUG
4 BASEFRAMEFUELTANK
5 ENGINE
6 BATTERY
7 RADIATOR
8 ALTERNATOR
9 FUELDRAINOUTLET
10 FUEL LEVEL SENSOR\
11 ABSORBER
1.3DieselEngine
Accordingtodifferentoutputpowerofthegenerator
sets,andcombinewiththeadvantageofeachmodel
ofdieselengineinaspecificrangeofpoweroutput,
HYUNDAIPowerchoosestheengineswithfirstclass
performanceandhighreliability.Andfurthermore,
HYUNDAIPowerpayspecialattentiontothe

User manual
2
technicaladvantageofenginesintheaspectsof
reducingexhaustgas,decreasefuelconsumption
rateandgoodnoiselevelcontrol.
1.4Alternator
AllofthealternatorschosenbyHYUNDAIPowerare
singlebearingself‐excitationbrushlessalternators
withtheattributesofinternationaltopbrand.By
citingStamfordalternatorasanexample,wecan
illustratethefeaturesofouralternatorsasfollows:
◆Fourpolarbrushlessself‐excitation,singlebearing,
insulationclassisHandprotectionlevelisIP22.
◆Statorsarewoundto2/3pitch,whichcaneffectively
eliminatestripleandcurbswaveformdeformationof
outputvoltage.Wheninparallelwiththemainsor
othergeneratorsets,thistypeofwindingcan
effectivelyavoidexcessiveneutralcurrentsand
reducesinductiveheat.
◆Beforebeingassembled,rotorsneedtopassdynamic
balancetesting.Theimproveddamperreduces
voltagedeviationandheatunderunstableload.
◆Theexciterrotoroutputisfedtothemainrotor
throughathreephasefullwavebridgerectifier,the
rectifierisprotectedbyasurgesuppressoragainst
surgescausedbyshortcircuitorout‐of‐phase
paralleling.
◆Automaticvoltageregulatorhasthefeatureof
automaticloadcurtailmentwhichisusedtoprotect
theengine,andmakeitpossibletoaddfullloadto
thealternatoratonetime.Steadystatevoltage
adjustingratecanreach±1%(undercertain
requirements,steadystatevoltageadjustingratecan
meet±0.5%).IfPMGsystemischosen,themotor
willhavehighstartingcapacityandtheabilityof
interferencerejectionforthedeformedvoltage
waveformfedbythemainstatorgeneratedby
non‐linearload(suchassiliconcontrolDCelectric
motor,UPSetc).
◆TelephoneinfluencefactorTIF<50,telephone
harmonicwavefactorTHF<2%
， thebrushlessstyle
andhighqualityAVRensureslowinterferencewith
Radio.
1.5CoolingSystem
Theenginecoolingsystemiswatercooled.Thewater
cooledsystemiscomprisedofaradiatorapusherfan
andthermostat.Thealternatorhasitsowninternal
fantocoolthealternatorcomponents.
1.6ElectricalSystem
Theengineelectricalsystemis12voltor24voltsDC,
negativeground/earth.Thissystemincludesan
electricenginestarter,abatteryandabattery
chargingalternator.ForDC12voltselectricalsystem
onebatteryisgiven.For24voltsystemtwolead‐acid
batteriesaregiven.Othertypesofbatteriesmaybe
fittediftheywerespecified.
1.7Coupling
Engineandalternatorarefirmlyjoinedbyacoupling
conethatguaranteestheproperassemblycoaxiality
Single‐supportmachinesarealsousedaspecial
flexiblediskisusedinplaceofaflexiblecoupling.
1.8FuelTankandBaseFrame
Theengineandalternatorarecoupledtogetherand
mountedonaheavydutysteelbaseframe.Thisbase
frameincludesafueltankwithcapacityof
approximately8hoursoperationundervariableloads.
Thetankiscompletewithfillingcapandfuellevel
gaugeandisconnectedbyflexiblejointstotheintake
pipingandtotheoverflowpipingcontainingfuel
fromtheinjectordrain.Bigcapacitygenerator'sfuel
tankisseparatefromgeneratorset.
1.9ControlPanel
AllmodelsofHYUNDAIPowergeneratorsetsuse
highgradecontrolpanel.Thecoreofcontrolpanelis
animporteddigitaldieselenginecontrolmodule,
whichhasbeenfacilitatedwithmorecomplex
functionssuchasfurthermonitors,demonstration,
people‐moduledialogue,distancecommunication
andprotectionetc.
HYUNDAIPowergeneratorsetcontrolpaneluse
steelplatestructure,whichensuressecurityand
reliability,andthesurfaceofithasbeentreatedwith
staticpowderpainting.Theoutsideappearanceis
beautiful.Speciallockhasbeenusedtofixit.Ithas
beendesignedforeasymaintenance.
1.10OptionalforCanopyGeneratorSet
1.10.1Externalantifreezeaddinghole
Ourgeneratorsetshasbeenfacilitatedwithexternal
antifreezefillinghole.Whenuserintendstoadd
antifreeze,Heonlyneedstoopentheantifreeze
fillingholeontheroofofcanopyandtheradiator’s
pressurevalvecaptodirectlyaddantifreezetothe
hole,andeasilywatchtheanti‐freezelevel.

1.10.2 Lubr
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User manual
4
2Installation
2.1GeneralOutline
Correctinstallationofgeneratorsetisthe
preconditionwhichensurethenormalworkingstatus
ofthegeneratorset.Theworkingroomforgenerator
setshallbedesignedspecificallytomeetthe
expectedfunctionsandmaintenanceoperations,and
atthesametimethedesignofgeneratorsetworking
roomshallconformtolocalgovernment’slawsand
regulationsonarchitecture,fireprotectionlawsand
otherapplicableregulations.
2.2Transportation
Duringtheperiodofshipment,protectionshallbe
madeforthegeneratorset.Inaddition,the
generatorsetshallbetightlysecuredintheloading
trucksothattoavoidanyvibrationduringshipment
whichwillcausethegeneratorset’scomponents
loosenandevendamaged.Duringtheprocessof
shipmentofgeneratorset,nopeopleorother
materialisallowedtoplaceabovethegeneratorset
sothattoavoiddamagetogeneratorsetcausedby
weight.
Whenloadingorunloadingthegeneratorsettothe
truck,forkliftorhoistingdeviceshallbeusedtoavoid
thegeneratorsetbecometiltedorfelltotheground,
whichcausesdamage.
Liftingholeshavebeendesignedonthecommon
baseframeofourgeneratorsets.Someofthe
specificallydesignedgeneratorsetshasbeen
facilitatedwithliftingholesontheroofandforklift
openingsonthebaseframeetc.Userscantransport
thegeneratorsetaccordingtotheguidancespecified
onthespecificlabelsstickedonthegeneratorset.
Pleasedonotusetheliftinglugsontheengineoron
thealternatortohoistthewholegeneratorset.
2.3DesignforFoundation
Thefoundationwhichusedtoinstallandfixthediesel
generatorsetisveryimportant,itmustconformto
thefollowingrequirement:
◆Haveenoughhardnessandstability,sothattoavoid
deformation,whichwillaffecttheconcentricityof
dieselengineandalternatorandotheraccessory
parts.
◆Tosupporttheweightofthewholegeneratorsetand
toabsorbthedynamicimpactcausedbyunbalanced
forceandvibrationduringengine’srunningperiod.
◆Generatorset’sfoundationisnotallowedtoconnect
tootherarchitecture’sfoundation.
◆Thewidthanddepthoffoundationshallmeet
requirement.
◆Ensurefoundation’slevelnessandsmoothness.
◆Ifpossible,wastedischargesinkcanbesuedsothat
thewasteoilcanbedischargedinatimelymanner.
Cablechannelforgeneratorpoweroutputcableneed
tobereserved.
◆Normally,concretefoundationisreliable,simpleand
preferable.Whenpouringtheconcretefoundation,
pleasemakesurethesurfaceofconcreteisflat,and
noscratchisallowed.Gradienterorsimilar
instrumentsneedtobeusedduringinstallationof
generatorsetanditsexhaustsystem.
Thedesignoffoundationcanrefertofollowing
calculationformula:(belowisthediagramfordiesel
generatorsetfoundation)
1.Generatordimensionlength×width:L1×W1
2.Foundationdimensionlength×width:L2×W2
L2=L1+400(mm)
W2=W1+400(mm)
3.B=2×M/(L2×W2×D)
B:Thicknessoffoundation
M:Generatorsetweight
L2:Lengthoffoundation
W2:Widthoffoundation
D:DensityofConcrete(referto2322kg/m3)
(FoundationdrawingRefertoAPPENDIXA)

2.4DesignforGeneratorSetWorkingRoom
Theinstallationofgeneratorsetshallbedesigned,so
thattomeetthedemandofplannedoperationand
maintenance.Thecompleteinstallationshallconform
tolocalarchitecturelaws,fireprotectionlawsand
otherapplicableregulations.Excepttheabove
matters,thereareothermattersneedsyour
attentionasfollows:
◆Ensuredieselenginegeneratorsetworkingroomis
furnishedwithrainproof,sunscreen,andwindproof.
◆Ensuredieselenginegeneratorsetworkingroomhas
goodventilationandgoodexhaustsystem,andthe
areaforventilationissufficient,andatthesametime
usepipestoletoutthehotairgeneratedfromthe
radiatorandpreventthehotairfromreturning.
◆Ensurethewastegasgeneratedduringgeneratorset
runningperiodcanbedischargedtooutsidetimely,
andtryyourbesttoreducetheadverseeffectcaused
toenvironment.Thesilencerandexhaustpipeshall
besupportedbytheroof,thesupportershallallow
theexhaustpipetoexpand.Itisnotpermittedto
installtheexhaustsystemdirectlyonthegenerator
set.
◆Enoughspaceshallbereservedforthediesel
generatorsetforconvenienceofcooling,operation
andmaintenanceetc.Generallyspeaking,noforeign
materialisallowedtobeplacedwithintheareaof

User manual
5
1~1.5mofdistancefromthegeneratorsetand
1.5~2mabovethegeneratorset.
◆Thegeneratorsetworkingroomshallbefurnished
withfireextinguishhydrantwhichconformtothe
specifiedstandard.
◆Emergencylightingfacilitiesshallbeinstalledinthe
generatorsetworkingroomfortheconvenienceof
operationandmaintenance.
◆Nocombustibleandexplosivematerialsareallowed
tobeplacedinthegeneratorsetworkingroom.
Belowisthelayoutfortheopensystemgeneratorset
workingroom.
(FoundationdrawingRefertoAPPENDIXB)


Note:
Ourcompanycanmakedrawingsanddesign
installationdimensionsforgeneratorsetworking
roomaccordingtocustomer’sspecialrequirements.

Belowisthelayoutforthecanopysystemgenerator
setworkingroom.
(FoundationdrawingRefertoAPPENDIXC)
Note:
Canopiedgeneratorsetcanworkoutdoordirectly.If
userswantstooperatethegeneratorsetindoor,
abovediagramcanbetakenasreference.wecan
designthelayoutofgeneratorsetworkingroomand
installationdimensionaccordingtocustomer’sspecial
requirements.
2.5InstallationofGeneratorSet
2.5.1Locatethepositionofgeneratorset
Vibrationreductionunitshavebeeninstalledonour
generatorsets(exceptafewgeneratorsetsdon’t
havethiskindoffacility).Userscantakereferenceon
theinstallationdiagram,correctlyinstallthe
generatorsetonaflatandhardfoundation,usethe
expansionboltstotightlyfixthegeneratorsettothe
concretefoundationthroughtheinstallationholeson
thebaseframe.Whennospecialrequirementis
needed,wedon’tsuggestcustomerstoinstall
additionalvibrationreductionunits.
Softconnectionisneededtoconnectthepartsofthe
generatorsettooutside.Forexample:corrugated
vibrationreductionpipehasbeenusedtoconnect
exhaustpipes,airexhaustpath,fuelinletpipe,fuel
returnpipeandbusbarcableetc.,alloftheseparts
needtousesoftconnections.Onlyinthiswaywecan
reducetheadverseeffectcausedbythevibrationof
generatorsettotheminimumextent.
2.5.2Ventilation
Whenageneratorsetwithacompletesetofradiator
assemblyhasbeeninstalledintheworkingroom,the
basicprincipleistodischargethehotairinthe
workingroomtooutsideandletinthelow
temperatureairfromoutside,andtryyoubestto
avoidthehotaircomeinfromoutside.
Thediagramintherightsidedemonstratestheideal
positionofageneratorsetintheworkingroom.
Thepurposeofthisarrangementistogetcoldair
fromthelowestpointasmuchaspossible,andforce
themtopassthroughtheradiatorcore,andthenlead
themout.



Userscanusemetalplateorcanvastomakeawind
guidecover,theconnectionbetweenwindguide
coverandtheradiatorshallbesoftconnection,so
thattocutoffthetransmissionofvibrationfromthe
generatorset,andalsoensurethehotairexhaustto
outsidethoroughly.
Theeffectivecirculationsectionalareainsideofthe
windguidecovershallbebiggerthan1.25timesof
thefrontfaceareaoftheradiatorcore.Andthewind
guidecovershallbesmooth,nosharpangleand
cambersothattoreducetheresistancetothewind.
Atthesametime,theeffectivecirculationsectional
areaintheairinletopeningshallalsobebiggerthan
1.25timesofthefrontfaceareaoftheradiatorcore.
Whentheusershaveinstalledmeshcoverorshutters
intheairinlet/outletopeningorthereistoomany
cambersintheairinlet/outletopening,theeffective
aircirculationsectionalareawillbereducedand
resistancewillincrease,andtherefore,it’snecessary
tofurtherincreaseaircirculationarea.

User manual
6
Undernormalconditions,theairvolumegenerated
fromtheradiator’sfanisenoughtomeetthe
requirementoftheworkingroomventilation.
Theairinlettemperatureoftheengineshallbebelow
30degreeCelsius.Iftheairinlettemperaturekeep
risingabove30degreeCelsius,theengine’soutput
powerwillbereduced,andthereforefreshairfrom
outsideshallbeintroducedintothegeneratorset’s
workingroominatimelymanner.
Ifthegeneratorsetisfurnishedwitharemote
radiator,forcedaircirculationforthegeneratorset
workingroomisamust.Theforcedaircirculation
needtwofans,onefanisresponsibleforairintake,
anotherisairexhaust,whichexhaustshotairto
outside.
Whentheengineisfurnishedwithpropelledfan,itis
recommendedthataseparatepipeisneededto
exhaustthegaswhichgeneratedfromthecrankcase
tooutside.Otherwisetheexhaustgasfromthe
crankcasewillaccumulateontheradiator,whichwill
causetheradiatorstuckbydirtymaterial,andasa
result,theheat‐sinkingcapacitywillbereduced.
2.5.3Exhaust
Ourstandardconfigurationdieselgeneratorsets
provideaccessoriessuchasindustryheavysilencer,
softcorrugatedpipeandelbowetc.Userscandesign
theexhaustsystemofgeneratorsetworkingroom
bythemselves.Whendesignandinstalltheexhaust
system,pleaseconsiderthefollowingaspects:
◆Ensurethetotalexhaustbackpressurenohigherthan
themaximumallowedvaluespecifiedbythe
engine(usuallygeneratorset’smaximumexhaust
backpressureisnomorethan5Kpa)Fixtheexhaust
systemtomakesuretheexhaustmanifoldand
turbo‐chargerarenotsubjecttotheverticalpressure
andsidestress.
◆Reservesomespaceforhotshrinkageandcold
expansion.
◆Reservespaceforgeneratorsetvibration.
◆Reduceexhaustnoiselevel.
Overloadofexhaustbackpressurewillcause
followingadverseeffect:
◆Outputpowerloss
◆Fuelefficiencyreduce
◆Exhaustgastemperaturerise
Note:
Whenmorethanonegeneratorsetareinstalled,try
nottodischargeallofthegeneratorsets’gasfrom
oneexhaustpath.Ifnoseparatedexhaustpipeis
allowed,undertheconditionthatthetotal
backpressurewillnotexceedthegeneratorsets’total
backpressureamoveableseparatepanelshallbe
installedinsideofthebranchexhaustpipesothatto
preventthegasfromreturn.
Intheexhaustsystem,softcorrugatedpipeshallbe
usedtoconnecttheexhaustpipewiththe
turbocharger,thispipehasthreefunctionsas
follows:
◆Separatethedieselenginewithvibrationandthe
weightofexhaustpipe.
◆Compensatetheheatexpansionofexhaustpipe.
Ifthedieselgeneratorsetisinstalledonthe
anti‐vibrationbaseframe,thecorrugatedpipecan
compensatesidewaymovementwhenenginestartor
stop.
Note:
1. Seriousdamagewilloccurwhenrainorcondensed
waterenterintoengine’sexhaustsystem.
Therefore,onewaterdischargeopeningshallbe
installedinthelongexhaustpipe,thepositionof
whichshallbeclosetothegeneratorset. 
2. Whenthetopoftheexhaustpipeisabovethe
architecture,lighteningprotectionisneeded
(connecttotheground)
2.5.4Noisereduction
Whendieselgeneratorsetisrunning,normallyitwill
generatenoiselevelof90～110dB,andthemorethe
load,thehigherthenoiselevel.
Inordertomeetthenoiselevelstandardsestablished
bythelocalenvironmentalprotectionbureauandto
preventthenoisepollutioncausedtoambient
environment,whichwillaffectpeople’snormallife,
toreducenoiselevelofdieselgeneratorsetisalso

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veryimportant.
Noisereductionengineeringisacomprehensiveand
professionalengineering.Duringtheprocesswhen
userstrytodesigntheschemefornoisereduction
project,atthesametimepleasefullyconsiderthe
bottomlimitofairinlet/outletvolumeneededby
engine’snormalrunningandthemaximumallowed
valueforexhaustbackpressureetc.Otherwise,the
noisereductionprojectwillseriouslyaffectgenerator
set’soutputpower,andmakegeneratorset’s
temperaturerise,causefrequentmalfunctionofthe
generatorset,andevenitwillshortenthelife
expectancyofgeneratorset.
Note:
HYUNDAIPowercanprovidecustomerswithoverall
soundproofgeneratorset.
2.6Coolingsystem
Ourstandardconfigurationdieselgeneratorsetsare
closedcyclingwaterchillingunitswithfanand
radiatorinstalled.Closedwaterchillingenginedrive
thecoolingpumptogeneratecirculationpower,
whichkeeptheanti‐freezeinthepathsofcylinder
bodyandcovercontinuouscirculationandheat
elimination.Engine’scoolingpump,radiator(orheat
exchanger)formsaclosed,pressurecyclingand
coolingsystem.
Themostcommoncoolingsystemiscoolingfan
directlydrivenbyradiatorandengine,whichcanbe
replacedbyheatexchanger,remoteradiatoror
remotecoolingtoweretc.Iftheinstallationposition
oftheremotecoolingfanisrelativelyhigher,
transmissionradiatorisneededtopreventthe
damageofheatexchangercausedbytoobiginternal
pressure.
Note:
Thedirtymaterialstayintheradiator’scorewill
greatlyaffectradiator’scoolingcapacity.And
thereforeitisnecessarytocleantheradiatoroften.
2.6.1Coolant
Coolingsystemshallusethecoolantwhichcan
protecttheenginefromcontaminationandfreezing.
Coolantshallbeamixtureofpurewaterand
anti‐freezeorpurewaterandanti‐rustfluid.Inthis
mixture,waterPHvalueshallbebetween6～8,
usuallysuggesttousedistilledwater.Thespecific
mixingratioshallbeaccordingtolocalweather,and
thatofthecoolantrecommendedbytheengine
supplier,andreferencetotheoperation(preparation)
manualofthecoolant.Mixtheliquidsinaseparate
containerevenlyandthenaddthemixtureintothe
radiator,ensuretheanti‐freezewillnotfreezeunder
lowtemperature.Intheareawhenthereislow
possibilityoffreezing,thecoolantcanbeamixtureof
waterandanti‐rust,accordingtotheanti‐rustwhich
recommendedbytheenginesupplierandrefertoits
operationmanual,mixtheliquidsinaseparate
containerevenlyandthenaddthemixtureintothe
radiator.Atthefirsttimewhenanti‐rustisadded,the
generatorsetshallbekeptrunninguntilitgettohot
sothattoachievethebesteffectofanti‐corrosion.
Engine’scoolantshallhavethreefunctionslistedas
below:
◆Provideenoughheattransmissioncapacity
◆Preventallmetalmaterialandsealingmaterial
withinthecoolingsystemfromcorrosion(Cave
corrosion)
◆Providesufficientanti‐freezecapacity
Warning:
!Tochoosetheanti‐freezewhichisrecommendedand
approvedbythequalifiedenginesupplieristhe
criticalpointtoensureengine’snormalrunning.
!Donotmixtheanti‐freezeandanti‐rustofanytypes,
thiswillgeneratealargeamountofbubbleand
reducethecoolant’sperformance. 
!Iftheanti‐freezeusedinthegeneratorsetisofbad
qualityandnotapprovedbytheenginesupplier,
whichcausethemalfunctionofthegeneratorset
(waterleakage,contaminationandetc.),this
malfunction(s)doesnotbelongtothescopeof
warranty.
2.6.2Changeofcoolant
Theeffectofanti‐freezeandanti‐rustwilldecreaseby
thetimeperiodofservice.Andthereforeperiodically
changeofanti‐freezeisamust.Themixtureof
anti‐freezeshallbechangedineverytwoyears.The
mixtureofanti‐rustshallbechangedatleastonetime
everyyear.Andiffilterofthecoolantisinstalled,at
leastthisfiltershallbechangedineveryhalfofyear
(pleaserefertotheengineoperationmanualforthe
specificintervalsofthechangesrequired).
Whenitistimetodischargethecoolant,makesure
thegeneratorsethasbeenshutdownandtheengine
hasbeenfullycooleddown,thenopentheradiator’s
liquidaddinghole.Afterthatopenthedischarge
valveinstalledintheradiatorandintheengine
respectivelytodischargethewater.Ifthegenerator
setisfurnishedwithcoolantfilter,itshallbe
detachedfromtheengineandbechanged.
2.6.3Cleaningofcoolingsystem

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Whenchangethecoolant,cleaningisneededforthe
coolingsystem,thecleaningproceduresare
suggestedasfollows:
◆Emptythecoolingsystem
◆Usewatertorinsecoolingsystem
◆Feed15%~20%condensedcoolanttothecooling
system,timelyrunthegeneratorsetforoneortwo
timesthendischargethecoolant
◆Emptythecoolingsystemthenusenormalmixed
liquidtorinse
◆Ifcontaminantstillexists,thenrepeatthecleaning
procedureuntilnocontaminantexistsinthesystem
◆Afterthesystemhasbeenfullyrinsed,feednew
coolantwhichhasbeenmixedaccordingtospecified
proportion
Note:
Ifthecoolingsystemiscleanedperiodically,onlyrinse
itwithsmallamountofadditivesorcleanwateris
enough.
2.6.4Feedingofcoolant
◆Beforeaddingcoolanttothecoolantsystem,please
makesuretheradiator‘sdischargevalveandthe
engine’sdischargevalvearetightlyclosed.
◆Addthecoolanttothesysteminaproperspeedso
thattoavoidaircockbeingformedinthesystem.
◆Airshallbedischargedthroughtheaddingholeor
thedischargevalveintheenginebody.Ifthecooling
systemisfurnishedwithheater,thecontrolvalvefor
theheatershallbeopened.Ensureventilationofthe
unitwhenaddingthecoolant.
Note:
Theairdischargevalveintheenginebodyshallbe
locatedinthetoppointofthewaterpathornearthe
thermostatorwatertemperaturesensor,oryoucan
slightlyloosethewatertemperaturesensorand
re‐tightenitwhenyouseecoolantrunoutfromitso
thattodischargetheair.
◆Whenaddingthecoolant,thesurfaceofliquidshall
reachtothelevelthatis5centimetersbelowthe
radiator’sweldedsurface(orshallreachthelevel
indicatingLine).Besurethatthegeneratorsethas
stoppedandbecomefullycooledbeforeadding
Coolant.Beforethesystemiscapableofventilation
andtheliquidisaddedtotherequiredlevel,please
don’tstartthegeneratorset.Afterthecoolantbeing
fed,pleasestartandpre‐heatthegeneratorset,and
atthesametimechecktheliquidlevelandadd
coolantifneeded.Thecoolantwhichneedstobe
addedtotheradiatorshallbeofthesame
specificationasthatexistingintheradiator.
◆Forsomegeneratorsetsinstalledwithcoolantfilter,
pleaseopenthefilter’svalvebeforeputintouse.
2.7Lubricantsystem
Lubricantsystemiscomposedofoilpan,oilpump,
strainer,oilpipe,oilcoolingunit,oilfilterunit,and
theoilpathinsideoftheengineandallkindsof
lubricantpartswhichareinrelativemotionetc.The
mainpurposeofthelubricantsystemistoprovide
sustainedtemperedoilfilmbetweenthepartswhich
areinmotionsothattoreducefrictionandwear,and
drawsoffpartoftheheatabsorbedbytheparts,
bathmechanicalpart,improvesealingeffectand
preventrustfromeachpart’ssurface.
Userscandeterminethemodeloflubricantaccording
tothespecificworkingenvironmentandconditions.
Forthefirsttimelubricant,normallyusersshall
changeitwithin100hoursuponandfromthetime
whenthegeneratorsetfirststarted.(detailsreferto
enginemaintenancemanual)
Note:
Thecriticalpointistousequalifiedlubricantoilwhich
iswithproperviscosityandconformtotheengine’s
requirement,andperiodicallychangethelubricantoil
andoilfiltersothattoensurethegeneratorset’s
normalworking.Themalfunctionscausedbywrong
modeloflubricantoilwithlowqualityorlongtimeno
changeoflubricantoil,oroilfilterdonotbelongto
thescopeofwarranty. 
WerecommendthathighqualitymultigradeSAE
15W/40highserviceengineoilindieselenginesare
used.Atambienttemperaturesabove‐15degree
Celsiusis15W40.TheminimumAPIoilqualitylevels
recommendedforuseisCH/CI‐4,CHorCI‐4canbe
usedinareaswhereCF4oilisnotyetavailable,but
theoilintervalmustbereducedAPICA,CB,CC,CD,
CE,CG4categoriesnotrecommended,donotuse.
2.8Fuelsystem
Our generator sets requires the fuel‐ diesel shall be
clean, without air and water and with proper
pressure, of which all kinds of parameters such as
sulphur content etc. shall meet national standards,
and end use temperature grade meet the
requirement of customer’s working environment.
Generally generator set’s fuel system includes two
parts, that is, engine’s fuel system and external fuel
system. HYUNDAI is only responsible for installation
of the internal fuel system which includes fuel tank
andconnectingfuelpipesetc.
2.8.1FuelRecommendations

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Thefollowingfueloilspecificationistypical.Fora
specificenginerefertomanufacturers’datasheets
forfueloildetails.
FuelRecommendedPhysicalPropertiesFeature
Viscosity
1.3to5.8centistrokes(1.3to5.8mmpersecond)at40°C(104°F)
(ASTMD445)
CetaneNumber
40Minimumabove0°C(32°F)~45Minimumbelow0°C(32°F)
(ASTMD613)
SulphurContent
Nottoexceed0.5masspercent*(ASTMD129or1552)
ActiveSulfurCopperStripCorrosion
NottoexceedNo.2ratingafterthreehoursat50°C(122°F)
(ASTMD130)
WaterandSediment
Nottoexceed.05volumepercent(ASTMD1796)
CarbonResidue
Nottoexceed0.35masspercenton10volumepercent
residuum(ASTMD524orD189)
Density
42to30°APIgravityat60°F(0.816to0.876g/ccat15°C).
(ASTMD287)
CloudPoint
6°C(10°F)belowlowestambienttemperatureatwhichthefuel
isexpectedtooperate(ASTMD97)
Ash
Nottoexceed0.02masspercent(0.05masspercentwith
lubricatingoilblending)(ASTMD482)
Distillation
Thedistillationcurvemustbesmoothandcontinuous(ASTM
D86)
AcidNumber
Nottoexceed0.1MgKOHper100ML(ASTMD664)
Lubricity
3100gramsorgreaterscuffingBOCLEtestorWearScar
Diameter(WSD)lessthan.45mmat60°C(WSDlessthan.38mm
at25°C)asmeasuredwiththeHFRRmethod.
DieselFuelPropertyDefinition
Ash‐Mineralresidueinfuel.Highashcontentleads
toexcessiveoxidebuildupinthecylinderand/or
injector.
CetaneNumber‐Ignitabilityoffuel.Thelowerthe
cetannumber,theharderitistostartandrunthe
engine.Lowcetanefuelsignitelaterandburnslower.
Thiscouldleadtoexplosivedetonationbyhaving
excessivefuelinthechamberatthetimeofignition.
Incoldweatherorwithprolongedlowloads,ahigher
cetanenumberisdesirable.
Sulphur‐Amountofsulphurresidueinthefuel.The
sulphurcombineswiththemoistureformedduring
combustiontoformsulphuricacid.
Viscosity‐Influencesthesizeoftheatomized
dropletsduringinjection.Improperviscositywilllead
todetonation,powerlossandexcessivesmoke.Fuels
thatmeettherequirementsofASTMor2.0diesel
fuelsaresatisfactorywithfuelsystems.
2.8.2Fueltank
Ourgeneratorsetsprovidebaseframestylefueltank
forcustomer.Thebaseframestylefueltankis
installedwithfueltank,fuelpipesandfuellevel
indicator.Thisfuelsupplysystemdoesnotneed
customertomakeotherinstallations.Customersonly
needtoaddfueltothebaseframe.
Userswhointendtoselfmanufacturethefueltank
shallusestainlesssteelorsteelplatetomakethe
backuptank,donotmakepaintingorgalvanization
insideofthefueltanksothattoavoidthepossible
chemicalreactionbetweenthesekindofmaterials
anddiesel,whichmaygeneratethematerialharmful
tothegeneratorsetanddecreasethequality,Merit
Ratingandcombustionefficiencyofdiesel.In
addition,theconfigurationoffueltankassemblyshall
beasfollows:
◆Airventilationpipeabovefueltanksurface
◆Manholeonthetopsurfaceoffueltank
◆Watchwindowforfuellevel
◆Dischargevalveatthebottomoffueltank
◆Groundcablebetweenfueladdingholeandfueltank
◆Separatepanelwithholesbetweenfuelsupplyarea
andfuelreturnarea,sothattoreduceheatexchange
◆Theendoffuelsupplypipeshallbe50mmabovethe
bottomofbaseframesothattoavoidthedeposit
andwateratthebottomoffueltankbeingsucked
intofuelsupplypipe.
◆Partofthegeneratorsets’fuellevelshallbehigher
thanthepositionoffuelinjector,sothattoavoidfuel
returnfromfuelinjector,whichcausestartdifficulty.
2.7.2Installationoffueltank
◆Thepositionofthefueltankshallensurethe
maximumsuctionfuelheadisnolessthan2meters.
Suctionfuelheadofthefueltransferpumpshallbe
calculatedfromthebottomofthefueltank.
◆Thepositionofthefueltankshallensuremaximum
returnfuelheadnolessthan1.5meters.Returnfuel
headshallbecalculatedfromthetopofthebase
frame.
◆Thearrangementofthefuelpipeshallavoidthefuel
beingaffectedfromtheheateliminationfrom
generatorsettoomuch.
◆Themaximumtemperatureofthefuelbeforefuel
pumpshallbelowerthan60degreeCelsius.
◆Noleakageoffuelandairisallowedinthefuelinlet
andfuelreturnpipe.Thisisveryimportant.
◆Hoseneedtobeusedtoconnectgeneratorsetwith
fueltransferpipe.Ifthegeneratorsetusesoft
connection(throughvibrationreductionunit),hose
shallbeused.
◆Whenengine’sfuelinletpipeisabove6metersand

User manual
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below10meters,thisfuelinletpipe’sinsidediameter
shallbeatleast20%biggerthanthatofthehose
installedinthisengine.Fuelreturnpipeshallbe
connectedtothetopoffueltank.Don’tdirectly
connectittofuelinletpipe.
2.7.3Fuelconsumption
Thecontentofdieselplaysaverycriticalroleindiesel
engine’sperformance,lifeexpectancyandthe
contentofdischargedmaterial.Inordertoachieve
theratedpower,fueleconomyandspecified
emissionstandard,onlythefuelwhichreferto
internationalstandardornationalstandardcanbe
used.
Theparametersofdieselfuelincludelow
temperaturefeature,sulphurcontent,specificgravity,
watercontentandforeignmaterialcontentshallbe
thefirstprioritywhenuserneedtochoosethequality
ofthefuel.Differentqualityoffuelwilldirectlyaffect
dieselgeneratorset’sstart,lubricating,outputpower,
discharge,andfuelfilterchangecycleetc.
Specificrequirementforfuelpleaserefertoengine
operationmanualwhichattachedwiththegenerator
set.
Warning:
!Whenyouintendtoaddfuelintothefueltank,
pleasemakesurethegeneratorsethasbeenstopped.
Onlyaftertheaddedfuelbecomestaticforsome
time,thisgeneratorsetcanbestartedagain.This
waytoavoidtheforeignmaterialinthedieselfuel
beingsuckedtofuelsupplyhose,whichwillcause
fuelfilterstuckandfailtosupplyenginewith
sufficientfuel,andinturndecreasetheoutput
power.
!Themalfunctioncausedbybadqualityoffueldoes
notbelongtothescopeofwarranty.
2.8Controlsystem
Ourdieselgeneratorsetshasbeenfurnishedwith
controlpanel.Allofthecontrolpanelschoose
importeddigitalmeterasthecoreofcontrolsystem
forthegeneratorsets.
◆Digitalcontrolpanel:thegeneratorsetcanbe
controlledlocallybymanual,andalsocanbestarted
orstoppedbyremotecontrol(controlledbyexternal
signalline)usersarerequiredtocorrectlyconnectthe
signallinetothiscontrolpanel.(detailsseethe
controlpaneloperationmanual)
◆Automatictransferpanel(optional):istheautomatic
transferswitchfortransferbetweengeneratorset
andmains.(detailsrefertocontrolpaneloperation
manual)
2.9Battery
Ourgeneratorsetstandardconfigurationprovides
startbatteryasaccessoryparts.Accordingtouser’s
differentrequirements,ourcompanycanprovide
twotypesofbatteries,thatishighefficientplumbous
acidbatteryandmaintenancefreebattery.
Ifmaintenancefreebatteryisused,usersonlyneed
toconnectcablesforthebattery.
Ifplumbousacidbatteryisused,beforebeingused,
usersneedtousestandardbatterytoelectrolyze
primaryliquid.Untightenthebatterycover,slowly
pourelectrolyteintothebatteryuntiltheelectrolyte
levelreachtheindicatinglineintheinternalpolar
plates(notallowtoexceedthisline),thentakeoffthe
lablefromthebatterycover’sairholeandclosethe
cover.Aftertheelectrolytebeingadded,pleasedon’t
useitimmediately,keepthebatteryinstaticstatus
forthirtytosixtyminutes.Inlowtemperature
environment,thistimeperiodneedtobeextended
(usebatterychargertochargebatterywhen
necessary)
Userscanusethestandardconnectingcable
attachedwiththegeneratorset,theredcolorshall
beconnectedtopositivepolar,black(orblue)to
negativepolar,correctlyconnecttothegenerator
set’sstartmotor.Mostofthedieselgeneratorsets’
cableshavebeenconnectedtotheenginesbefore
shipment.
Theenergystoragecapacityofthestartbatterywill
determineifthedieselenginegeneratorsetcan
smoothlystartinaspecifiedperiod.Duringthe
processofgeneratorsetsrunning,thecharging
alternatorinstalledintheenginewillcontinuously
chargebatterytostartbattery.
Warning:
!Pleaseensuretheconnectionforpositiveand
negativepolariscorrect.Wrongconnectionwill
causemalfunction!(Wrongconnectionwillsurely
causedamagetothechargingalternator)
!Whengeneratorsetisrunning,batterycablesarenot
allowedtobecutdown!